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HomeMy WebLinkAboutSS20202020 Standard Specifications M 41-10 Page 1 Standard Specifications for Road, Bridge, and Municipal Construction2020 M 41-10 Page 2 2020 Standard Specifications M 41-10 Ordering Information The 2020 Standard Specifications can be purchased from the Washington State Department of Printing website at myprint.wa.gov. Note: This publication is not for resale. The 2020 Standard Specifications can be also downloaded, free of charge, from the following web page at www.wsdot.wa.gov/publications/manuals/m41-10.htm. Americans with Disabilities Act (ADA) Information Title VI Notice to Public It is the Washington State Department of Transportation’s (WSDOT) policy to assure that no person shall, on the grounds of race, color, national origin or sex, as provided by Title VI of the Civil Rights Act of 1964, be excluded from participation in, be denied the benefits of, or be otherwise discriminated against under any of its federally funded programs and activities. Any person who believes his/her Title VI protection has been violated, may file a complaint with WSDOT’s Office of Equal Opportunity (OEO). For additional information regarding Title VI complaint procedures and/or information regarding our non-discrimination obligations, please contact OEO’s Title VI Coordinator at 360-705-7090. 2020 Standard Specifications M 41-10 Page 3 Foreword These Standard Specifications for Road, Bridge, and Municipal Construction have been developed to serve as a baseline for the work delivered to the public by the Washington State Department of Transportation (WSDOT). The Standard Specifications are incorporated into the written agreement (Contract) between WSDOT as Contracting Agency and the Contractor, except where the Contract indicates that a particular specification has been amended or replaced with a special provision to resolve project- specific issues. The decision to amend or replace any standard specification with a special provision is made during the design process and is based upon the sound engineering judgment of the project designer. These Standard Specifications reflect years of refinement through the literally hundreds of projects the Department delivers each year. In addition, the standards are the result of countless hours of development and review by both our internal WSDOT staff as well as our industry partners through the joint WSDOT/Associated General Contractors’ Standing Committees. Finally, these standards reflect the contracting philosophy and balance of risk-allocation that the Department has adopted through the years. We believe that this balance of risks provides us the lowest final cost solution to our transportation needs. For example, shifting risk to the Contractor can provide more certainty on final cost, but may result in higher initial cost. On the other hand, accepting more risk by the owner can result in lower initial costs, but less certainty on the final cost. We at the Department of Transportation believe that we have reached the optimum point of balance for risk, and we will continue to consider this balance on all future specification revisions. The language above indicates that these specifications are to be used only as a guideline during the design process, and that is true. Once they have been incorporated into a Contract, however, they become the legal and enforceable language of that Contract. The Standard Specifications, and the Project Special Provisions, along with any attachments in the Contract documents, define a Contract and are no longer seen as guidelines. Rather, they are the written agreement, subject to revision only through the change order process. This preface is for informational purposes only and is not to be used to interpret or affect the terms. Robert E. Christopher, P.E. State Construction Engineer Page 4 2020 Standard Specifications M 41-10 Contents Division 1 General Requirements Division 2 Earthwork Division 3 Aggregate Production and Acceptance Division 4 Bases Division 5 Surface Treatments and Pavements Division 6 Structures Division 7 Drainage Structures, Storm Sewers, Sanitary Sewers, Water Mains, and Conduits Division 8 Miscellaneous Construction Division 9 Materials 2020 Standard Specifications M 41-10 Page 5 Contents Division 1 General Requirements ............................................1-1 1-01 Definitions and Terms ...............................................................1-1 1-01.1 General ..................................................................1-1 1-01.2 Abbreviations .............................................................1-1 1-01.2(1) Associations and Miscellaneous ................................1-1 1-01.2(2) Items of Work and Units of Measurement .......................1-3 1-01.3 Definitions ...............................................................1-4 1-02 Bid Procedures and Conditions ......................................................1-10 1-02.1 Prequalification of Bidders ................................................1-10 1-02.2 Plans and Specifications ...................................................1-11 1-02.3 Estimated Quantities .....................................................1-12 1-02.4 Examination of Plans, Specifications, and Site of Work ........................1-12 1-02.4(1) General ....................................................1-12 1-02.4(2) Subsurface Information ......................................1-14 1-02.5 Proposal Forms ..........................................................1-15 1-02.6 Preparation of Proposal ...................................................1-15 1-02.7 Bid Deposit .............................................................1-16 1-02.8 Noncollusion Declaration and Lobbying Certification .........................1-17 1-02.8(1) Noncollusion Declaration ....................................1-17 1-02.8(2) Lobbying Certification .......................................1-17 1-02.9 Delivery of Proposal ......................................................1-18 1-02.10 Withdrawing, Revising, or Supplementing Proposal ...........................1-19 1-02.11 Combination and Multiple Proposals ........................................1-19 1-02.12 Public Opening of Proposals ...............................................1-20 1-02.13 Irregular Proposals .......................................................1-20 1-02.14 Disqualification of Bidders ................................................1-21 1-02.15 Pre-Award Information ...................................................1-22 1-03 Award and Execution of Contract ....................................................1-23 1-03.1 Consideration of Bids .....................................................1-23 1-03.1(1) Identical Bid Totals ..........................................1-23 1-03.2 Award of Contract ........................................................1-24 1-03.3 Execution of Contract ....................................................1-24 1-03.4 Contract Bond ...........................................................1-24 1-03.5 Failure to Execute Contract ................................................1-25 1-03.6 Return of Bid Deposit .....................................................1-25 1-03.7 Judicial Review ..........................................................1-25 Page 6 2020 Standard Specifications M 41-10 Contents 1-04 Scope of the Work .................................................................1-26 1-04.1 Intent of the Contract ....................................................1-26 1-04.1(1) Bid Items Included in the Proposal ............................1-26 1-04.1(2) Bid Items Not Included in the Proposal ........................1-26 1-04.2 Coordination of Contract Documents, Plans, Special Provisions, Specifications, and Addenda ...............................................1-26 1-04.3 Reference Information ....................................................1-27 1-04.4 Changes ................................................................1-27 1-04.4(1) Minor Changes .............................................1-29 1-04.4(2) Value Engineering Change Proposal (VECP) ....................1-29 1-04.5 Procedure and Protest by the Contractor ....................................1-33 1-04.6 Variation in Estimated Quantities ...........................................1-34 1-04.7 Differing Site Conditions (Changed Conditions) ..............................1-35 1-04.8 Progress Estimates and Payments ..........................................1-36 1-04.9 Use of Buildings or Structures ..............................................1-36 1-04.10 Use of Materials Found on the Project ......................................1-36 1-04.11 Final Cleanup ............................................................1-37 1-05 Control of Work ...................................................................1-38 1-05.1 Authority of the Engineer .................................................1-38 1-05.2 Authority of Assistants and Inspectors ......................................1-39 1-05.3 Working Drawings .......................................................1-39 1-05.4 Conformity With and Deviations From Plans and Stakes .......................1-40 1-05.5 Tolerances ..............................................................1-41 1-05.6 Inspection of Work and Materials ..........................................1-42 1-05.7 Removal of Defective and Unauthorized Work ...............................1-43 1-05.8 Vacant ..................................................................1-43 1-05.9 Equipment ..............................................................1-43 1-05.10 Guarantees ..............................................................1-44 1-05.11 Final Inspection ..........................................................1-44 1-05.12 Final Acceptance .........................................................1-44 1-05.13 Superintendents, Labor, and Equipment of Contractor ........................1-45 1-05.13(1) Emergency Contact List ......................................1-46 1-05.14 Cooperation With Other Contractors .......................................1-46 1-05.15 Method of Serving Notices ................................................1-46 2020 Standard Specifications M 41-10 Page 7 Contents 1-06 Control of Material .................................................................1-47 1-06.1 Approval of Materials Prior to Use ..........................................1-47 1-06.1(1) Qualified Products List (QPL) .................................1-47 1-06.1(2) Request for Approval of Material (RAM). . . . . . . . . . . . . . . . . . . . . . . .1-48 1-06.1(3) Aggregate Source Approval (ASA) Database ....................1-48 1-06.1(4) Fabrication Inspection Expense ...............................1-49 1-06.2 Acceptance of Materials ..................................................1-50 1-06.2(1) Samples and Tests for Acceptance .............................1-50 1-06.2(2) Statistical Evaluation of Materials for Acceptance ...............1-51 1-06.3 Manufacturer’s Certificate of Compliance ...................................1-57 1-06.4 Handling and Storing Materials ............................................1-58 1-06.5 Owners Manuals and Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-58 1-06.6 Recycled Materials .......................................................1-58 1-07 Legal Relations and Responsibilities to the Public ......................................1-60 1-07.1 Laws to be Observed .....................................................1-60 1-07.2 State Taxes ..............................................................1-61 1-07.2(1) State Sales Tax: WAC 458-20-171 – Use Tax ...................1-61 1-07.2(2) State Sales Tax: WAC 458-20-170 – Retail Sales Tax .............1-62 1-07.2(3) Services ...................................................1-62 1-07.3 Fire Prevention and Merchantable Timber Requirements ......................1-62 1-07.3(1) Fire Prevention Control and Countermeasures Plan .............1-62 1-07.3(2) Merchantable Timber Requirements ...........................1-63 1-07.4 Sanitation ...............................................................1-64 1-07.4(1) General ....................................................1-64 1-07.4(2) Health Hazards .............................................1-64 1-07.5 Environmental Regulations ................................................1-64 1-07.5(1) General ....................................................1-64 1-07.5(2) State Department of Fish and Wildlife .........................1-64 1-07.5(3) State Department of Ecology .................................1-65 1-07.5(4) Air Quality .................................................1-66 1-07.5(5) U.S. Army Corps of Engineers .................................1-66 1-07.5(6) U.S. Fish/Wildlife Services and National Marine Fisheries Service .1-66 1-07.6 Permits and Licenses .....................................................1-66 1-07.7 Load Limits ..............................................................1-67 1-07.7(1) General ....................................................1-67 1-07.7(2) Load-Limit Restrictions ......................................1-68 Page 8 2020 Standard Specifications M 41-10 Contents 1-07.8 High-Visibility Apparel ....................................................1-70 1-07.8(1) Traffic Control Personnel ....................................1-70 1-07.8(2) Non-Traffic Control Personnel ................................1-71 1-07.9 Wages ..................................................................1-71 1-07.9(1) General ....................................................1-71 1-07.9(2) Posting Notices .............................................1-73 1-07.9(3) Apprentices ................................................1-74 1-07.9(4) Disputes ...................................................1-74 1-07.9(5) Required Documents ........................................1-74 1-07.9(6) Audits .....................................................1-75 1-07.10 Worker’s Benefits ........................................................1-75 1-07.11 Requirements for Nondiscrimination ........................................1-76 1-07.11(1) General Application .........................................1-76 1-07.11(2) Contractual Requirements ...................................1-76 1-07.11(3) Equal Employment Opportunity Officer ........................1-79 1-07.11(4) Dissemination of Policy ......................................1-79 1-07.11(5) Sanctions ..................................................1-80 1-07.11(6) Incorporation of Provisions ...................................1-80 1-07.11(7) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-81 1-07.11(8) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-81 1-07.11(9) Subcontracting, Procurement of Materials, and Leasing of Equipment .................................................1-81 1-07.11(10) Records and Reports ........................................1-81 1-07.12 Federal Agency Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-82 1-07.13 Contractor’s Responsibility for Work ........................................1-82 1-07.13(1) General ....................................................1-82 1-07.13(2) Relief of Responsibility for Completed Work ....................1-83 1-07.13(3) Relief of Responsibility for Damage by Public Traffic .............1-83 1-07.13(4) Repair of Damage ...........................................1-84 1-07.14 Responsibility for Damage .................................................1-84 1-07.15 Temporary Water Pollution Prevention ......................................1-86 1-07.15(1) Spill Prevention, Control, and Countermeasures Plan ............1-86 1-07.16 Protection and Restoration of Property .....................................1-90 1-07.16(1) Private/Public Property ......................................1-90 1-07.16(2) Vegetation Protection and Restoration .........................1-91 1-07.16(3) Fences, Mailboxes, Incidentals ................................1-92 1-07.16(4) Archaeological and Historical Objects .........................1-92 1-07.16(5) Payment ...................................................1-93 2020 Standard Specifications M 41-10 Page 9 Contents 1-07.17 Utilities and Similar Facilities ...............................................1-93 1-07.17(1) Utility Construction, Removal, or Relocation by the Contractor ....1-93 1-07.17(2) Utility Construction, Removal, or Relocation by Others ..........1-94 1-07.18 Public Liability and Property Damage Insurance ..............................1-94 1-07.19 Gratuities ...............................................................1-97 1-07.20 Patented Devices, Materials, and Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-98 1-07.21 Rock Drilling Safety Requirements ..........................................1-98 1-07.22 Use of Explosives ........................................................1-98 1-07.23 Public Convenience and Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-98 1-07.23(1) Construction Under Traffic ...................................1-99 1-07.23(2) Construction and Maintenance of Detours ....................1-101 1-07.24 Rights of Way ...........................................................1-102 1-07.25 Opening of Sections to Traffic ............................................1-102 1-07.26 Personal Liability of Public Officers ........................................1-102 1-07.27 No Waiver of State’s Legal Rights ..........................................1-103 1-08 Prosecution and Progress ..........................................................1-104 1-08.1 Subcontracting .........................................................1-104 1-08.1(1) Prompt Payment, Subcontract Completion and Return of Retainage Withheld ........................................1-106 1-08.2 Assignment ............................................................1-108 1-08.3 Progress Schedule .......................................................1-108 1-08.3(1) General Requirements ......................................1-108 1-08.3(2) Progress Schedule Types ....................................1-109 1-08.3(3) Schedule Updates ..........................................1-110 1-08.3(4) Measurement .............................................1-111 1-08.3(5) Payment ..................................................1-111 1-08.4 Prosecution of Work .....................................................1-111 1-08.5 Time for Completion .....................................................1-112 1-08.6 Suspension of Work .....................................................1-113 1-08.7 Maintenance During Suspension ..........................................1-115 1-08.8 Extensions of Time ......................................................1-115 1-08.9 Liquidated Damages .....................................................1-118 1-08.10 Termination of Contract ..................................................1-119 1-08.10(1) Termination for Default .....................................1-119 1-08.10(2) Termination for Public Convenience ..........................1-121 1-08.10(3) Termination for Public Convenience Payment Request ..........1-121 1-08.10(4) Payment for Termination for Public Convenience ...............1-121 1-08.10(5) Responsibility of the Contractor and Surety ...................1-121 Page 10 2020 Standard Specifications M 41-10 Contents 1-09 Measurement and Payment ........................................................1-122 1-09.1 Measurement of Quantities ..............................................1-122 1-09.2 Weighing Equipment ....................................................1-124 1-09.2(1) General Requirements for Weighing Equipment ................1-124 1-09.2(2) Specific Requirements for Batching Scales ....................1-125 1-09.2(3) Specific Requirements for Platform Scales .....................1-126 1-09.2(4) Specific Requirements for Belt Conveyor Scales ................1-126 1-09.2(5) Measurement .............................................1-126 1-09.2(6) Payment ..................................................1-127 1-09.3 Scope of Payment .......................................................1-128 1-09.4 Equitable Adjustment ....................................................1-129 1-09.5 Deleted or Terminated Work ..............................................1-129 1-09.6 Force Account ..........................................................1-130 1-09.7 Mobilization ............................................................1-135 1-09.8 Payment for Material on Hand ............................................1-135 1-09.9 Payments ..............................................................1-136 1-09.9(1) Retainage .................................................1-137 1-09.10 Payment for Surplus Processed Materials ...................................1-138 1-09.11 Disputes and Claims .....................................................1-139 1-09.11(1) Disputes Review Board .....................................1-139 1-09.11(2) Claims ....................................................1-142 1-09.11(3) Time Limitation and Jurisdiction .............................1-145 1-09.12 Audits .................................................................1-145 1-09.12(1) General ...................................................1-145 1-09.12(2) Claims ....................................................1-146 1-09.12(3) Required Documents for Audits ..............................1-146 1-09.13 Claims Resolution .......................................................1-147 1-09.13(1) General ...................................................1-147 1-09.13(2) Nonbinding Alternative Disputes Resolution (ADR) .............1-147 1-09.13(3) Claims $250,000 or Less ....................................1-148 1-09.13(4) Claims in Excess of $250,000 ................................1-150 2020 Standard Specifications M 41-10 Page 11 Contents 1-10 Temporary Traffic Control ..........................................................1-151 1-10.1 General ................................................................1-151 1-10.1(1) Materials .................................................1-151 1-10.1(2) Description ...............................................1-151 1-10.2 Traffic Control Management ..............................................1-153 1-10.2(1) General ...................................................1-153 1-10.2(2) Traffic Control Plans ........................................1-155 1-10.2(3) Conformance to Established Standards .......................1-156 1-10.3 Traffic Control Labor, Procedures, and Devices ..............................1-157 1-10.3(1) Traffic Control Labor .......................................1-157 1-10.3(2) Traffic Control Procedures ..................................1-158 1-10.3(3) Traffic Control Devices .....................................1-161 1-10.4 Measurement ...........................................................1-165 1-10.4(1) Lump Sum Bid for Project (No Unit Items) .....................1-165 1-10.4(2) Item Bids With Lump Sum for Incidentals .....................1-165 1-10.4(3) Reinstating Unit Items With Lump Sum Traffic Control ..........1-166 1-10.4(4) Owner-Provided Resources .................................1-166 1-10.5 Payment ...............................................................1-167 1-10.5(1) Lump Sum Bid for Project (No Unit Items) .....................1-167 1-10.5(2) Item Bids With Lump Sum for Incidentals .....................1-167 1-10.5(3) Reinstating Unit Items With Lump Sum Traffic Control ..........1-168 Page 12 2020 Standard Specifications M 41-10 Contents Division 2 Earthwork .......................................................2-1 2-01 Clearing, Grubbing, and Roadside Cleanup .............................................2-1 2-01.1 Description ...............................................................2-1 2-01.2 Disposal of Usable Material and Debris ......................................2-1 2-01.2(1) Disposal Method No. 1 – Open Burning ........................2-1 2-01.2(2) Disposal Method No. 2 – Waste Site ...........................2-1 2-01.2(3) Disposal Method No. 3 – Chipping .............................2-2 2-01.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-01.3(1) Clearing ....................................................2-2 2-01.3(2) Grubbing ...................................................2-2 2-01.3(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2-01.3(4) Roadside Cleanup ............................................2-3 2-01.4 Measurement .............................................................2-3 2-01.5 Payment .................................................................2-4 2-02 Removal of Structures and Obstructions ...............................................2-5 2-02.1 Description ...............................................................2-5 2-02.2 Vacant ...................................................................2-5 2-02.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2-02.3(1) Removal of Foundations ......................................2-5 2-02.3(2) Removal of Bridges, Box Culverts, and Other Drainage Structures ..2-5 2-02.3(3) Removal of Pavement, Sidewalks, Curbs, and Gutters .............2-7 2-02.4 Vacant ...................................................................2-7 2-02.5 Payment .................................................................2-7 2-03 Roadway Excavation and Embankment ................................................2-8 2-03.1 Description ...............................................................2-8 2-03.2 Vacant ...................................................................2-8 2-03.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-03.3(1) Widening of Cuts ............................................2-8 2-03.3(2) Rock Cuts ...................................................2-9 2-03.3(3) Excavation Below Subgrade ..................................2-12 2-03.3(4) Sluicing ....................................................2-12 2-03.3(5) Slope Treatment ............................................2-12 2-03.3(6) Deposit of Rock for the Contracting Agency’s Use ...............2-13 2-03.3(7) Disposal of Surplus Material ..................................2-13 2-03.3(8) Wasting Material ...........................................2-14 2-03.3(9) Roadway Ditches ...........................................2-14 2020 Standard Specifications M 41-10 Page 13 Contents 2-03.3(10) Selected Material ...........................................2-14 2-03.3(11) Slides .....................................................2-15 2-03.3(12) Overbreak .................................................2-15 2-03.3(13) Borrow ....................................................2-15 2-03.3(14) Embankment Construction ...................................2-16 2-03.3(15) Aeration ...................................................2-23 2-03.3(16) End Slopes .................................................2-24 2-03.3(17) Snow Removal ..............................................2-24 2-03.3(18) Stepped Slope Construction ..................................2-25 2-03.3(19) Removal of Pavement, Sidewalks, Curbs, and Gutters ............2-25 2-03.4 Measurement ............................................................2-25 2-03.5 Payment ................................................................2-26 2-04 Haul ..............................................................................2-29 2-04.1 Description ..............................................................2-29 2-04.2 Vacant ..................................................................2-29 2-04.3 Vacant ..................................................................2-29 2-04.4 Measurement ............................................................2-29 2-04.5 Payment ................................................................2-30 2-05 Vacant ............................................................................2-31 2-06 Subgrade Preparation ..............................................................2-32 2-06.1 Description ..............................................................2-32 2-06.2 Vacant ..................................................................2-32 2-06.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32 2-06.3(1) Subgrade for Surfacing ......................................2-32 2-06.3(2) Subgrade for Pavement ......................................2-33 2-06.4 Vacant ..................................................................2-33 2-06.5 Measurement and Payment ...............................................2-33 2-06.5(1) Subgrade Constructed Under Same Contract ...................2-33 2-06.5(2) Subgrade Not Constructed Under Same Contract ...............2-33 2-07 Watering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 2-07.1 Description ..............................................................2-35 2-07.2 Vacant ..................................................................2-35 2-07.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 2-07.4 Measurement ............................................................2-35 2-07.5 Payment ................................................................2-35 2-08 Vacant ............................................................................2-36 Page 14 2020 Standard Specifications M 41-10 Contents 2-09 Structure Excavation ...............................................................2-37 2-09.1 Description ..............................................................2-37 2-09.2 Materials ................................................................2-37 2-09.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37 2-09.3(1) General Requirements .......................................2-37 2-09.3(2) Classification of Structure Excavation ..........................2-40 2-09.3(3) Construction Requirements, Structure Excavation, Class A .......2-41 2-09.3(4) Construction Requirements, Structure Excavation, Class B .......2-47 2-09.4 Measurement ............................................................2-47 2-09.5 Payment ................................................................2-49 2-10 Vacant ............................................................................2-51 2-11 Trimming and Cleanup ..............................................................2-52 2-11.1 Description ..............................................................2-52 2-11.2 Vacant ..................................................................2-52 2-11.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52 2-11.4 Vacant ..................................................................2-52 2-11.5 Payment ................................................................2-52 2-12 Construction Geosynthetic ..........................................................2-53 2-12.1 Description ..............................................................2-53 2-12.2 Materials ................................................................2-53 2-12.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53 2-12.3(1) Underground Drainage ......................................2-54 2-12.3(2) Separation .................................................2-54 2-12.3(3) Soil Stabilization ............................................2-55 2-12.3(4) Permanent Erosion Control and Ditch Lining ...................2-55 2-12.4 Measurement ............................................................2-56 2-12.5 Payment ................................................................2-56 2020 Standard Specifications M 41-10 Page 15 Contents Division 3 Aggregate Production and Acceptance .............................3-1 3-01 Production From Quarry and Pit Sites .................................................3-1 3-01.1 Description ...............................................................3-1 3-01.2 Material Sources, General Requirements .....................................3-1 3-01.2(1) Approval of Source ...........................................3-1 3-01.2(2) Preparation of Site ...........................................3-1 3-01.2(3) Stripping Quarries and Pits ....................................3-2 3-01.2(4) Production Requirements .....................................3-2 3-01.2(5) Final Cleanup ...............................................3-3 3-01.3 State Furnished Material Sources ............................................3-3 3-01.3(1) Quality and Extent of Material .................................3-3 3-01.3(2) When More Than One Site is Provided .........................3-3 3-01.3(3) Reject Materials .............................................3-4 3-01.3(4) Surplus Screenings ...........................................3-4 3-01.3(5) Moving Plant ................................................3-4 3-01.4 Contractor Furnished Material Sources .......................................3-5 3-01.4(1) Acquisition and Development .................................3-5 3-01.4(2) Surplus Screenings ...........................................3-6 3-01.4(3) Substitution of Gravel Deposit in Lieu of Ledge Rock or Talus Source Provided by the Contracting Agency .....................3-6 3-01.4(4) Gravel Base .................................................3-6 3-01.5 Measurement .............................................................3-7 3-01.6 Payment .................................................................3-7 3-02 Stockpiling Aggregates ..............................................................3-8 3-02.1 Description ...............................................................3-8 3-02.2 General Requirements .....................................................3-8 3-02.2(1) Stockpile Sites Provided by the Contracting Agency ..............3-8 3-02.2(2) Stockpile Site Provided by the Contractor .......................3-8 3-02.2(3) Stockpiling Aggregates for Future Use ..........................3-8 3-02.2(4) Stockpiling Aggregates for Immediate Use .......................3-9 3-02.2(5) Preparation of Site ...........................................3-9 3-02.2(6) Construction of Stockpiles ....................................3-9 3-02.2(7) Removing Aggregates From Stockpiles .........................3-10 3-02.3 Additional Requirements for Specific Aggregates .............................3-10 3-02.3(1) Washed Aggregates .........................................3-10 3-02.4 Measurement ............................................................3-11 3-02.5 Payment ................................................................3-11 Page 16 2020 Standard Specifications M 41-10 Contents 3-03 Site Reclamation ...................................................................3-12 3-03.1 Description ..............................................................3-12 3-03.2 General Requirements ....................................................3-12 3-03.2(1) Contracting Agency-Provided Sites ............................3-12 3-03.2(2) Contractor-Provided Sites ....................................3-12 3-03.2(3) Out-of-State Sites ..........................................3-13 3-03.3 Reclamation Plans ........................................................3-13 3-03.3(1) Contracting Agency-Provided Sites ............................3-13 3-03.3(2) Contractor-Provided Sites ....................................3-13 3-03.4 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 3-03.4(1) Erosion Control ............................................3-13 3-03.4(2) Deviations From Approved Reclamation Plans ..................3-13 3-03.5 Payment ................................................................3-14 3-03.5(1) Contracting Agency-Provided Sites ............................3-14 3-03.5(2) Contractor-Provided Sites ....................................3-14 3-04 Acceptance of Aggregate ...........................................................3-15 3-04.1 Description ..............................................................3-15 3-04.2 Materials ................................................................3-15 3-04.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 3-04.3(1) General ....................................................3-15 3-04.3(2) Point of Acceptance .........................................3-15 3-04.3(3) Sampling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 3-04.3(4) Testing Results .............................................3-16 3-04.3(5) Nonstatistical Evaluation .....................................3-16 3-04.3(6) Statistical Evaluation ........................................3-16 3-04.3(7) Rejected Work .............................................3-17 3-04.3(8) Price Adjustments for Quality of Aggregate .....................3-18 3-04.4 Vacant ..................................................................3-18 3-04.5 Payment ................................................................3-19 2020 Standard Specifications M 41-10 Page 17 Contents Division 4 Bases ...........................................................4-1 4-01 Vacant .............................................................................4-1 4-02 Gravel Base ........................................................................4-2 4-02.1 Description ...............................................................4-2 4-02.2 Materials .................................................................4-2 4-02.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-02.4 Measurement .............................................................4-2 4-02.5 Payment .................................................................4-2 4-03 Vacant .............................................................................4-3 4-04 Ballast and Crushed Surfacing ........................................................4-4 4-04.1 Description ...............................................................4-4 4-04.2 Materials .................................................................4-4 4-04.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4-04.3(1) Equipment ..................................................4-4 4-04.3(2) Subgrade ...................................................4-5 4-04.3(3) Mixing ......................................................4-5 4-04.3(4) Placing and Spreading ........................................4-5 4-04.3(5) Shaping and Compaction .....................................4-6 4-04.3(6) Keystone ...................................................4-6 4-04.3(7) Miscellaneous Requirements ..................................4-6 4-04.3(8) Weather Limitations ..........................................4-7 4-04.3(9) Hauling .....................................................4-7 4-04.3(10) Hours of Work ..............................................4-7 4-04.3(11) Permeable Ballast ............................................4-7 4-04.4 Measurement .............................................................4-8 4-04.5 Payment .................................................................4-8 Page 18 2020 Standard Specifications M 41-10 Contents Division 5 Surface Treatments and Pavements .................................5-1 5-01 Cement Concrete Pavement Rehabilitation ............................................5-1 5-01.1 Description ...............................................................5-1 5-01.2 Materials .................................................................5-1 5-01.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-01.3(1) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-01.3(2) Material Acceptance .........................................5-3 5-01.3(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5-01.3(4) Replace Cement Concrete Panel ...............................5-4 5-01.3(5) Partial Depth Spall Repair .....................................5-6 5-01.3(6) Dowel Bar Retrofit ...........................................5-7 5-01.3(7) Sealing Existing Concrete Random Cracks .......................5-9 5-01.3(8) Sealing Existing Longitudinal and Transverse Joint ................5-9 5-01.3(9) Cement Concrete Pavement Grinding ..........................5-9 5-01.3(10) Pavement Smoothness ......................................5-10 5-01.3(11) Concrete Slurry and Grinding Residue .........................5-12 5-01.4 Measurement ............................................................5-12 5-01.5 Payment ................................................................5-13 5-02 Bituminous Surface Treatment .......................................................5-15 5-02.1 Description ..............................................................5-15 5-02.1(1) New Construction ..........................................5-15 5-02.1(2) Seal Coats .................................................5-15 5-02.1(3) Pavement Sealers – Fog Seal .................................5-15 5-02.2 Materials ................................................................5-15 5-02.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 5-02.3(1) Equipment .................................................5-15 5-02.3(2) Preparation of Roadway Surface ..............................5-16 5-02.3(3) Application of Emulsified Asphalt and Aggregate ................5-18 5-02.3(4) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 5-02.3(5) Application of Aggregates ....................................5-20 5-02.3(6) Additional Emulsified Asphalt and Aggregate ...................5-21 5-02.3(7) Patching and Correction of Defects ...........................5-21 5-02.3(8) Progress of Work ...........................................5-22 5-02.3(9) Protection of Structures .....................................5-22 5-02.3(10) Unfavorable Weather ........................................5-22 5-02.3(11) Temporary Pavement Markings ...............................5-22 5-02.4 Measurement ............................................................5-23 5-02.5 Payment ................................................................5-23 2020 Standard Specifications M 41-10 Page 19 Contents 5-03 Vacant ............................................................................5-25 5-04 Hot Mix Asphalt ...................................................................5-26 5-04.1 Description ..............................................................5-26 5-04.2 Materials ................................................................5-26 5-04.2(1) How to Get an HMA Mix Design on the QPL ...................5-26 5-04.2(2) Mix Design – Obtaining Project Approval ......................5-31 5-04.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32 5-04.3(1) Weather Limitations .........................................5-32 5-04.3(2) Paving Under Traffic .........................................5-32 5-04.3(3) Equipment .................................................5-32 5-04.3(4) Preparation of Existing Paved Surfaces ........................5-36 5-04.3(5) Producing/Stockpiling Aggregates, RAP, & RAS .................5-38 5-04.3(6) Mixing .....................................................5-39 5-04.3(7) Spreading and Finishing .....................................5-40 5-04.3(8) Aggregate Acceptance Prior to Incorporation in HMA. . . . . . . . . . . .5-40 5-04.3(9) HMA Mixture Acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41 5-04.3(10) HMA Compaction Acceptance ................................5-47 5-04.3(11) Reject Work ................................................5-53 5-04.3(12) Joints .....................................................5-55 5-04.3(13) Surface Smoothness ........................................5-56 5-04.3(14) Planing Bituminous Pavement ................................5-57 5-04.3(15) Sealing Pavement Surfaces ...................................5-57 5-04.3(16) HMA Road Approaches ......................................5-57 5-04.4 Measurement ............................................................5-58 5-04.5 Payment ................................................................5-58 5-05 Cement Concrete Pavement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-61 5-05.1 Description ..............................................................5-61 5-05.2 Materials ................................................................5-61 5-05.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-61 5-05.3(1) Concrete Mix Design for Paving ..............................5-61 5-05.3(2) Consistency ................................................5-63 5-05.3(3) Equipment .................................................5-63 5-05.3(4) Measuring and Batching Materials ............................5-65 5-05.3(5) Mixing Concrete ............................................5-68 5-05.3(6) Surface Preparation .........................................5-69 5-05.3(7) Placing, Spreading, and Compacting Concrete ..................5-70 5-05.3(8) Joints .....................................................5-72 5-05.3(9) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73 5-05.3(10) Tie Bars and Corrosion Resistant Dowel Bars ...................5-73 Page 20 2020 Standard Specifications M 41-10 Contents 5-05.3(11) Finishing ...................................................5-75 5-05.3(12) Surface Smoothness ........................................5-76 5-05.3(13) Curing .....................................................5-78 5-05.3(14) Cold Weather Work .........................................5-80 5-05.3(15) Concrete Pavement Construction in Adjacent Lanes .............5-81 5-05.3(16) Protection of Pavement ......................................5-81 5-05.3(17) Opening to Traffic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-81 5-05.3(18) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 5-05.3(19) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 5-05.3(20) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 5-05.3(21) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 5-05.3(22) Repair of Defective Pavement Slabs ...........................5-82 5-05.4 Measurement ............................................................5-83 5-05.5 Payment ................................................................5-84 5-05.5(1) Pavement Thickness ........................................5-87 2020 Standard Specifications M 41-10 Page 21 Contents Division 6 Structures .......................................................6-1 6-01 General Requirements for Structures ..................................................6-1 6-01.1 Description ...............................................................6-1 6-01.2 Foundation Data ..........................................................6-1 6-01.3 Clearing the Site ..........................................................6-1 6-01.4 Appearance of Structures ..................................................6-1 6-01.5 Vacant ...................................................................6-1 6-01.6 Load Restrictions on Bridges Under Construction ..............................6-1 6-01.7 Navigable Streams ........................................................6-2 6-01.8 Approaches to Movable Spans ..............................................6-2 6-01.9 Working Drawings ........................................................6-2 6-01.10 Utilities Supported by or Attached to Bridges .................................6-2 6-01.11 Name Plates ..............................................................6-3 6-01.12 Final Cleanup .............................................................6-3 6-01.13 Vacant ...................................................................6-4 6-01.14 Premolded Joint Filler ......................................................6-4 6-01.15 Normal Temperature .......................................................6-4 6-01.16 Repair of Defective Work ..................................................6-4 6-01.16(1) General .....................................................6-4 6-01.16(2) Pre-Approved Repair Procedures ..............................6-5 6-02 Concrete Structures .................................................................6-7 6-02.1 Description ...............................................................6-7 6-02.2 Materials .................................................................6-7 6-02.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-02.3(1) Classification of Structural Concrete ............................6-7 6-02.3(2) Proportioning Materials .......................................6-8 6-02.3(3) Admixtures ................................................6-13 6-02.3(4) Ready-Mix Concrete ........................................6-14 6-02.3(5) Acceptance of Concrete .....................................6-17 6-02.3(6) Placing Concrete ............................................6-24 6-02.3(7) Tolerances .................................................6-30 6-02.3(8) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 6-02.3(9) Vibration of Concrete .......................................6-31 6-02.3(10) Bridge Decks and Bridge Approach Slabs .......................6-32 6-02.3(11) Curing Concrete ............................................6-37 6-02.3(12) Construction Joints .........................................6-41 6-02.3(13) Expansion Joints ............................................6-43 6-02.3(14) Finishing Concrete Surfaces ..................................6-44 Page 22 2020 Standard Specifications M 41-10 Contents 6-02.3(15) Date Numerals .............................................6-51 6-02.3(16) Plans for Falsework and Formwork ............................6-51 6-02.3(17) Falsework and Formwork ....................................6-53 6-02.3(18) Placing Anchor Bolts ........................................6-84 6-02.3(19) Bridge Bearings .............................................6-84 6-02.3(20) Grout for Anchor Bolts and Bridge Bearings ....................6-85 6-02.3(21) Drainage of Box Girder Cells .................................6-86 6-02.3(22) Drainage of Substructure ....................................6-86 6-02.3(23) Opening to Traffic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-86 6-02.3(24) Reinforcement ..............................................6-87 6-02.3(25) Prestressed Concrete Girders .................................6-96 6-02.3(26) Cast-In-Place Prestressed Concrete ..........................6-112 6-02.3(27) Concrete for Precast Units ..................................6-128 6-02.3(28) Precast Concrete Panels ....................................6-130 6-02.4 Measurement ...........................................................6-134 6-02.5 Payment ...............................................................6-136 6-03 Steel Structures ...................................................................6-138 6-03.1 Description .............................................................6-138 6-03.2 Materials ...............................................................6-138 6-03.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-139 6-03.3(1) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-139 6-03.3(2) Facilities for Inspection .....................................6-139 6-03.3(3) Inspector’s Authority .......................................6-139 6-03.3(4) Rejections ................................................6-139 6-03.3(5) Mill Orders and Shipping Statements .........................6-139 6-03.3(6) Weighing .................................................6-139 6-03.3(7) Shop Plans ................................................6-140 6-03.3(8) Substitutions ..............................................6-141 6-03.3(9) Handling, Storing, and Shipping of Materials ...................6-141 6-03.3(10) Straightening Bent Material .................................6-142 6-03.3(11) Workmanship and Finish ....................................6-142 6-03.3(12) Falsework .................................................6-142 6-03.3(13) Fabricating Tension Members ................................6-142 6-03.3(14) Edge Finishing .............................................6-142 6-03.3(15) Planing of Bearing Surfaces .................................6-143 6-03.3(16) Abutting Joints ............................................6-144 6-03.3(17) End Connection Angles .....................................6-144 6-03.3(18) Built Members. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-144 6-03.3(19) Hand Holes ...............................................6-144 6-03.3(20) Lacing Bars ...............................................6-144 2020 Standard Specifications M 41-10 Page 23 Contents 6-03.3(21) Plate Girders ..............................................6-144 6-03.3(22) Eyebars ...................................................6-145 6-03.3(23) Annealing .................................................6-145 6-03.3(24) Pins and Rollers ............................................6-145 6-03.3(25) Welding and Repair Welding ................................6-146 6-03.3(26) Screw Threads .............................................6-149 6-03.3(27) High-Strength Bolt Holes ...................................6-149 6-03.3(28) Shop Assembly ............................................6-151 6-03.3(29) Welded Shear Connectors ..................................6-153 6-03.3(30) Painting ..................................................6-153 6-03.3(31) Alignment and Camber .....................................6-153 6-03.3(32) Assembling and Bolting .....................................6-154 6-03.3(33) Bolted Connections ........................................6-155 6-03.3(34) Adjusting Pin Nuts .........................................6-162 6-03.3(35) Setting Anchor Bolts .......................................6-162 6-03.3(36) Setting and Grouting Masonry Plates .........................6-163 6-03.3(37) Setting Steel Bridge Bearings ................................6-163 6-03.3(38) Placing Superstructure .....................................6-163 6-03.3(39) Swinging the Span .........................................6-163 6-03.3(40) Draining Pockets ...........................................6-164 6-03.3(41) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-164 6-03.3(42) Surface Condition ..........................................6-164 6-03.3(43) Castings, Steel Forgings, and Miscellaneous Metals .............6-164 6-03.4 Measurement ...........................................................6-165 6-03.5 Payment ...............................................................6-165 6-04 Timber Structures .................................................................6-167 6-04.1 Description .............................................................6-167 6-04.2 Materials ...............................................................6-167 6-04.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-167 6-04.3(1) Storing and Handling Material ...............................6-167 6-04.3(2) Workmanship .............................................6-167 6-04.3(3) Shop Details ..............................................6-168 6-04.3(4) Field Treatment of Cut Surfaces, Bolt Holes, and Contact Surfaces ..................................................6-168 6-04.3(5) Holes for Bolts, Dowels, Rods, and Lag Screws .................6-168 6-04.3(6) Bolts, Washers, and Other Hardware .........................6-168 6-04.3(7) Countersinking ............................................6-168 6-04.3(8) Framing ..................................................6-169 6-04.3(9) Framed Bents .............................................6-169 6-04.3(10) Caps .....................................................6-169 Page 24 2020 Standard Specifications M 41-10 Contents 6-04.3(11) Bracing ...................................................6-169 6-04.3(12) Stringers ..................................................6-169 6-04.3(13) Wheel Guards and Railings ..................................6-170 6-04.3(14) Single-Plank Floors .........................................6-170 6-04.3(15) Laminated Floors ..........................................6-170 6-04.3(16) Plank Subfloors for Concrete Decks ..........................6-171 6-04.3(17) Trusses ...................................................6-171 6-04.3(18) Painting ..................................................6-171 6-04.4 Measurement ...........................................................6-171 6-04.5 Payment ...............................................................6-171 6-05 Piling ............................................................................6-172 6-05.1 Description .............................................................6-172 6-05.2 Materials ...............................................................6-172 6-05.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-172 6-05.3(1) Piling Terms ...............................................6-172 6-05.3(2) Ordering Piling ............................................6-174 6-05.3(3) Manufacture of Precast Concrete Piling .......................6-175 6-05.3(4) Manufacture of Steel Casings for Cast-In-Place Concrete Piles ...6-177 6-05.3(5) Manufacture of Steel Piles ..................................6-177 6-05.3(6) Splicing Steel Casings and Steel Piles .........................6-178 6-05.3(7) Storage and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-178 6-05.3(8) Pile Tips and Shoes .........................................6-179 6-05.3(9) Pile Driving Equipment .....................................6-180 6-05.3(10) Test Piles .................................................6-183 6-05.3(11) Driving Piles ..............................................6-184 6-05.3(12) Determination of Bearing Values .............................6-188 6-05.3(13) Treatment of Timber Pile Heads ..............................6-189 6-05.3(14) Extensions and Buildups of Precast Concrete Piles .............6-189 6-05.3(15) Completion of Cast-In-Place Concrete Piles ...................6-190 6-05.4 Measurement ...........................................................6-190 6-05.5 Payment ...............................................................6-191 6-06 Bridge Railings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-193 6-06.1 Description .............................................................6-193 6-06.2 Materials ...............................................................6-193 6-06.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-193 6-06.3(1) Timber Railings ............................................6-193 6-06.3(2) Metal Railings .............................................6-193 6-06.4 Measurement ...........................................................6-194 6-06.5 Payment ...............................................................6-194 2020 Standard Specifications M 41-10 Page 25 Contents 6-07 Painting .........................................................................6-195 6-07.1 Description .............................................................6-195 6-07.2 Materials ...............................................................6-195 6-07.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-195 6-07.3(1) Work Force Qualifications ..................................6-195 6-07.3(2) Submittals ................................................6-196 6-07.3(3) Quality Control and Quality Assurance ........................6-199 6-07.3(4) Paint System Manufacturer’s Technical Representative ..........6-200 6-07.3(5) Pre-Painting Conference ....................................6-200 6-07.3(6) Paint Containers, Storage, and Handling ......................6-201 6-07.3(7) Paint Sampling and Testing ..................................6-201 6-07.3(8) Equipment ................................................6-202 6-07.3(9) Painting New Steel Structures ...............................6-202 6-07.3(10) Painting Existing Steel Structures ............................6-207 6-07.3(11) Painting or Powder Coating of Galvanized Surfaces .............6-215 6-07.3(12) Painting Ferry Terminal Structures ............................6-219 6-07.3(13) Painting Timber Structures ..................................6-223 6-07.3(14) Metallic Coatings ..........................................6-223 6-07.4 Measurement ...........................................................6-226 6-07.5 Payment ...............................................................6-226 6-08 Bituminous Surfacing on Structure Decks ............................................6-228 6-08.1 Description .............................................................6-228 6-08.2 Materials ...............................................................6-228 6-08.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-228 6-08.3(1) Definitions ................................................6-228 6-08.3(2) Contractor Survey for Grade Controlled Structure Decks ........6-229 6-08.3(3) General Bituminous Pavement Removal Requirements ..........6-230 6-08.3(4) Partial Depth Removal of Bituminous Pavement from Structure Decks ....................................................6-230 6-08.3(5) Full Depth Removal of Bituminous Pavement from Structure Decks ....................................................6-230 6-08.3(6) Repair of Damage due to Bituminous Pavement Removal Operations ................................................6-231 6-08.3(7) Concrete Deck Repair ......................................6-232 6-08.3(8) Waterproof Membrane for Structure Decks ...................6-233 6-08.3(9) Placing Bituminous Pavement on Structure Decks ..............6-234 6-08.3(10) HMA Compaction on Structure Decks ........................6-235 6-08.3(11) Paved Panel Joint Seals and HMA Sawcut and Seals ............6-235 6-08.4 Measurement ...........................................................6-235 6-08.5 Payment ...............................................................6-236 Page 26 2020 Standard Specifications M 41-10 Contents 6-09 Modified Concrete Overlays .......................................................6-237 6-09.1 Description .............................................................6-237 6-09.2 Materials ...............................................................6-237 6-09.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-239 6-09.3(1) Equipment ................................................6-239 6-09.3(2) Submittals ................................................6-243 6-09.3(3) Concrete Overlay Mixes ....................................6-244 6-09.3(4) Storing and Handling .......................................6-246 6-09.3(5) Scarifying Concrete Surface .................................6-246 6-09.3(6) Further Deck Preparation ...................................6-248 6-09.3(7) Surface Preparation for Concrete Overlay .....................6-250 6-09.3(8) Quality Assurance ..........................................6-251 6-09.3(9) Mixing Concrete For Concrete Overlay .......................6-252 6-09.3(10) Overlay Profile and Screed Rails .............................6-252 6-09.3(11) Placing Concrete Overlay ...................................6-254 6-09.3(12) Finishing Concrete Overlay ..................................6-256 6-09.3(13) Curing Concrete Overlay ....................................6-256 6-09.3(14) Checking for Bond .........................................6-256 6-09.3(15) Sealing and Texturing Concrete Overlay .......................6-257 6-09.4 Measurement ...........................................................6-257 6-09.5 Payment ...............................................................6-258 6-10 Concrete Barrier ..................................................................6-259 6-10.1 Description .............................................................6-259 6-10.2 Materials ...............................................................6-259 6-10.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-259 6-10.3(1) Precast Concrete Barrier ....................................6-260 6-10.3(2) Cast-In-Place Concrete Barrier ..............................6-261 6-10.3(3) Removing and Resetting Permanent Concrete Barrier ...........6-262 6-10.3(4) Joining Precast Concrete Barrier to Cast-In-Place Barrier ........6-262 6-10.3(5) Temporary Barrier ..........................................6-262 6-10.3(6) Placing Concrete Barrier ....................................6-263 6-10.4 Measurement ...........................................................6-263 6-10.5 Payment ...............................................................6-264 2020 Standard Specifications M 41-10 Page 27 Contents 6-11 Reinforced Concrete Walls .........................................................6-265 6-11.1 Description .............................................................6-265 6-11.2 Materials ...............................................................6-265 6-11.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-265 6-11.3(1) Submittals ................................................6-265 6-11.3(2) Excavation and Foundation Preparation .......................6-266 6-11.3(3) Precast Concrete Wall Stem Panels ...........................6-266 6-11.3(4) Cast-In-Place Concrete Construction .........................6-267 6-11.3(5) Backfill, Weepholes, and Gutters .............................6-268 6-11.3(6) Traffic Barrier and Pedestrian Barrier .........................6-268 6-11.4 Measurement ...........................................................6-268 6-11.5 Payment ...............................................................6-268 6-12 Noise Barrier Walls ................................................................6-269 6-12.1 Description .............................................................6-269 6-12.2 Materials ...............................................................6-269 6-12.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-269 6-12.3(1) Submittals ................................................6-269 6-12.3(2) Work Access and Site Preparation ............................6-270 6-12.3(3) Shaft Construction .........................................6-270 6-12.3(4) Trench, Grade Beam, or Spread Footing Construction ...........6-272 6-12.3(5) Cast-In-Place Concrete Panel Construction ...................6-272 6-12.3(6) Precast Concrete Panel Fabrication and Erection ...............6-272 6-12.3(7) Masonry Wall Construction .................................6-274 6-12.3(8) Fabricating and Erecting Timber Noise Barrier Wall Panels .......6-274 6-12.3(9) Access Doors and Concrete Landing Pads .....................6-274 6-12.3(10) Finish Ground Line Dressing .................................6-274 6-12.4 Measurement ...........................................................6-275 6-12.5 Payment ...............................................................6-275 6-13 Structural Earth Walls .............................................................6-277 6-13.1 Description .............................................................6-277 6-13.2 Materials ...............................................................6-277 6-13.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-277 6-13.3(1) Quality Assurance ..........................................6-277 6-13.3(2) Submittals ................................................6-278 6-13.3(3) Excavation and Foundation Preparation .......................6-281 6-13.3(4) Precast Concrete Facing Panel and Concrete Block Fabrication ..6-282 6-13.3(5) Precast Concrete Facing Panel and Concrete Block Erection .....6-284 6-13.3(6) Welded Wire Faced Structural Earth Wall Erection .............6-285 Page 28 2020 Standard Specifications M 41-10 Contents 6-13.3(7) Backfill ...................................................6-285 6-13.3(8) Guardrail Placement ........................................6-286 6-13.3(9) SEW Traffic Barrier and SEW Pedestrian Barrier ...............6-286 6-13.4 Measurement ...........................................................6-287 6-13.5 Payment ...............................................................6-287 6-14 Geosynthetic Retaining Walls ......................................................6-289 6-14.1 Description .............................................................6-289 6-14.2 Materials ...............................................................6-289 6-14.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-289 6-14.3(1) Quality Assurance ..........................................6-289 6-14.3(2) Submittals ................................................6-290 6-14.3(3) Excavation and Foundation Preparation .......................6-290 6-14.3(4) Erection and Backfill .......................................6-291 6-14.3(5) Guardrail Placement ........................................6-292 6-14.3(6) Permanent Facing ..........................................6-292 6-14.3(7) Geosynthetic Retaining Wall Traffic Barrier and Geosynthetic Retaining Wall Pedestrian Barrier ............................6-293 6-14.4 Measurement ...........................................................6-293 6-14.5 Payment ...............................................................6-293 6-15 Soil Nail Walls ....................................................................6-295 6-15.1 Description .............................................................6-295 6-15.2 Materials ...............................................................6-295 6-15.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-295 6-15.3(1) General Description ........................................6-295 6-15.3(2) Contractor’s Experience Requirements .......................6-295 6-15.3(3) Submittals ................................................6-296 6-15.3(4) Preconstruction Conference .................................6-297 6-15.3(5) Earthwork ................................................6-297 6-15.3(6) Soil Nailing ................................................6-298 6-15.3(7) Shotcrete Facing ...........................................6-299 6-15.3(8) Soil Nail Testing and Acceptance .............................6-300 6-15.3(9) Concrete Fascia Panels .....................................6-304 6-15.4 Measurement ...........................................................6-304 6-15.5 Payment ...............................................................6-305 2020 Standard Specifications M 41-10 Page 29 Contents 6-16 Soldier Pile and Soldier Pile Tieback Walls ...........................................6-306 6-16.1 Description .............................................................6-306 6-16.2 Materials ...............................................................6-306 6-16.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-306 6-16.3(1) Quality Assurance ..........................................6-306 6-16.3(2) Submittals ................................................6-306 6-16.3(3) Shaft Excavation ...........................................6-308 6-16.3(4) Installing Soldier Piles ......................................6-309 6-16.3(5) Backfilling Shaft ...........................................6-309 6-16.3(6) Designing and Installing Lagging and Installing Permanent Ground Anchors ...........................................6-310 6-16.3(7) Prefabricated Drainage Mat .................................6-313 6-16.3(8) Concrete Fascia Panel ......................................6-314 6-16.4 Measurement ...........................................................6-314 6-16.5 Payment ...............................................................6-314 6-17 Permanent Ground Anchors ........................................................6-317 6-17.1 Description .............................................................6-317 6-17.2 Materials ...............................................................6-317 6-17.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-317 6-17.3(1) Definitions ................................................6-317 6-17.3(2) Contractor Experience Requirements .........................6-318 6-17.3(3) Submittals ................................................6-318 6-17.3(4) Preconstruction Conference .................................6-319 6-17.3(5) Tendon Fabrication .........................................6-320 6-17.3(6) Tendon Storage and Handling ...............................6-322 6-17.3(7) Installing Permanent Ground Anchors ........................6-322 6-17.3(8) Testing and Stressing .......................................6-324 6-17.3(9) Permanent Ground Anchor Acceptance Criteria ................6-327 6-17.4 Measurement ...........................................................6-328 6-17.5 Payment ...............................................................6-328 Page 30 2020 Standard Specifications M 41-10 Contents 6-18 Shotcrete Facing ..................................................................6-329 6-18.1 Description .............................................................6-329 6-18.2 Materials ...............................................................6-329 6-18.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-329 6-18.3(1) Submittals ................................................6-329 6-18.3(2) Mix Design ................................................6-329 6-18.3(3) Testing ...................................................6-330 6-18.3(4) Qualifications of Contractor’s Personnel ......................6-331 6-18.3(5) Placing Wire Reinforcement .................................6-331 6-18.3(6) Alignment Control .........................................6-331 6-18.3(7) Shotcrete Application ......................................6-331 6-18.3(8) Shotcrete Finishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-332 6-18.4 Measurement ...........................................................6-333 6-18.5 Payment ...............................................................6-333 6-19 Shafts ...........................................................................6-334 6-19.1 Description .............................................................6-334 6-19.2 Materials ...............................................................6-334 6-19.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-334 6-19.3(1) Quality Assurance ..........................................6-334 6-19.3(2) Shaft Construction Submittal ................................6-336 6-19.3(3) Shaft Excavation ...........................................6-340 6-19.3(4) Slurry Installation Requirements .............................6-344 6-19.3(5) Assembly and Placement of Reinforcing Steel ..................6-347 6-19.3(6) Contractor Furnished Accessories for Nondestructive QA Testing 6-348 6-19.3(7) Placing Concrete ...........................................6-350 6-19.3(8) Casing Removal ............................................6-352 6-19.3(9) Nondestructive QA Testing of Shafts .........................6-352 6-19.3(10) Engineer’s Final Acceptance of Shafts. . . . . . . . . . . . . . . . . . . . . . . . .6-356 6-19.4 Measurement ...........................................................6-356 6-19.5 Payment ...............................................................6-356 2020 Standard Specifications M 41-10 Page 31 Contents Division 7 Drainage Structures, Storm Sewers, Sanitary Sewers, Water Mains, and Conduits ....................................................7-1 7-01 Drains .............................................................................7-1 7-01.1 Description ...............................................................7-1 7-01.2 Materials .................................................................7-1 7-01.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-01.3(1) Drain Pipe ..................................................7-2 7-01.3(2) Underdrain Pipe .............................................7-2 7-01.4 Measurement .............................................................7-2 7-01.5 Payment .................................................................7-3 7-02 Culverts ...........................................................................7-4 7-02.1 Description ...............................................................7-4 7-02.2 Materials .................................................................7-4 7-02.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7-02.3(1) Placing Culvert Pipe – General .................................7-6 7-02.3(2) Installation of Metal End Sections ..............................7-6 7-02.3(3) Headwalls ..................................................7-7 7-02.3(4) Removing and Relaying Culverts ...............................7-7 7-02.3(5) Safety Bars for Culvert Pipe ...................................7-7 7-02.3(6) Precast Reinf. Conc. Three Sided Structures, Box Culverts and Split Box Culverts ............................................7-7 7-02.4 Measurement ............................................................7-13 7-02.5 Payment ................................................................7-13 7-03 Structural Plate Pipe, Pipe Arch, Arch, and Underpass ..................................7-15 7-03.1 Description ..............................................................7-15 7-03.2 Materials ................................................................7-15 7-03.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 7-03.3(1) Foundations, General ........................................7-16 7-03.3(2) Assembling ................................................7-16 7-03.3(3) Backfilling .................................................7-16 7-03.3(4) Invert Treatment ............................................7-17 7-03.3(5) Headwalls .................................................7-17 7-03.3(6) Safety Bars for Culvert Pipe ..................................7-17 7-03.4 Measurement ............................................................7-17 7-03.5 Payment ................................................................7-18 Page 32 2020 Standard Specifications M 41-10 Contents 7-04 Storm Sewers .....................................................................7-19 7-04.1 Description ..............................................................7-19 7-04.2 Materials ................................................................7-19 7-04.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19 7-04.3(1) Cleaning and Testing ........................................7-20 7-04.4 Measurement ............................................................7-22 7-04.5 Payment ................................................................7-22 7-05 Manholes, Inlets, Catch Basins, and Drywells ..........................................7-23 7-05.1 Description ..............................................................7-23 7-05.2 Materials ................................................................7-23 7-05.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23 7-05.3(1) Adjusting Manholes and Catch Basins to Grade .................7-25 7-05.3(2) Abandon Existing Manholes ..................................7-25 7-05.3(3) Connections to Existing Manholes ............................7-25 7-05.3(4) Drop Manhole Connection ...................................7-25 7-05.4 Measurement ............................................................7-26 7-05.5 Payment ................................................................7-26 7-06 Vacant ............................................................................7-28 7-07 Cleaning Existing Drainage Structures ................................................7-29 7-07.1 Description ..............................................................7-29 7-07.2 Vacant ..................................................................7-29 7-07.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29 7-07.4 Vacant ..................................................................7-29 7-07.5 Payment ................................................................7-29 7-08 General Pipe Installation Requirements ...............................................7-30 7-08.1 Description ..............................................................7-30 7-08.2 Materials ................................................................7-30 7-08.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30 7-08.3(1) Excavation and Preparation of Trench. . . . . . . . . . . . . . . . . . . . . . . . . .7-30 7-08.3(2) Laying Pipe ................................................7-32 7-08.3(3) Backfilling .................................................7-35 7-08.3(4) Plugging Existing Pipe .......................................7-36 7-08.4 Measurement ............................................................7-36 7-08.5 Payment ................................................................7-37 2020 Standard Specifications M 41-10 Page 33 Contents 7-09 Water Mains ......................................................................7-38 7-09.1 Description ..............................................................7-38 7-09.1(1) Definitions .................................................7-38 7-09.2 Materials ................................................................7-39 7-09.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 7-09.3(1) General ....................................................7-40 7-09.3(2) Ungraded Streets ...........................................7-40 7-09.3(3) Clearing and Grubbing in Ungraded Streets ....................7-40 7-09.3(4) Removal of Existing Street Improvements ......................7-40 7-09.3(5) Grade and Alignment ........................................7-41 7-09.3(6) Existing Utilities ............................................7-41 7-09.3(7) Trench Excavation ..........................................7-41 7-09.3(8) Removal and Replacement of Unsuitable Materials ..............7-43 7-09.3(9) Bedding the Pipe ...........................................7-43 7-09.3(10) Backfilling Trenches .........................................7-44 7-09.3(11) Compaction of Backfill ......................................7-44 7-09.3(12) General Pipe Installation .....................................7-44 7-09.3(13) Handling of Pipe ............................................7-44 7-09.3(14) Cutting Pipe ................................................7-45 7-09.3(15) Laying of Pipe on Curves .....................................7-45 7-09.3(16) Cleaning and Assembling Joint ................................7-46 7-09.3(17) Laying Ductile Iron Pipe With Polyethylene Encasement .........7-46 7-09.3(18) Coupled Pipe 4 inches in Diameter and Larger ..................7-46 7-09.3(19) Connections ...............................................7-46 7-09.3(20) Detectable Marking Tape ....................................7-48 7-09.3(21) Concrete Thrust Blocking ....................................7-48 7-09.3(22) Blowoff Assemblies .........................................7-48 7-09.3(23) Hydrostatic Pressure Test ....................................7-48 7-09.3(24) Disinfection of Water Mains ..................................7-51 7-09.4 Measurement ............................................................7-54 7-09.5 Payment ................................................................7-55 7-10 Vacant ............................................................................7-56 7-11 Vacant ............................................................................7-57 7-12 Valves for Water Mains .............................................................7-58 7-12.1 Description ..............................................................7-58 7-12.2 Materials ................................................................7-58 7-12.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58 7-12.3(1) Installation of Valve Marker Post .............................7-59 Page 34 2020 Standard Specifications M 41-10 Contents 7-12.4 Measurement ............................................................7-59 7-12.5 Payment ................................................................7-59 7-13 Vacant ............................................................................7-60 7-14 Hydrants ..........................................................................7-61 7-14.1 Description ..............................................................7-61 7-14.2 Materials ................................................................7-61 7-14.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61 7-14.3(1) Setting Hydrants ............................................7-61 7-14.3(2) Hydrant Connections ........................................7-62 7-14.3(3) Resetting Existing Hydrants ..................................7-62 7-14.3(4) Moving Existing Hydrants ....................................7-62 7-14.3(5) Reconnecting Existing Hydrants ..............................7-63 7-14.3(6) Hydrant Extensions .........................................7-63 7-14.4 Measurement ............................................................7-63 7-14.5 Payment ................................................................7-63 7-15 Service Connections ...............................................................7-65 7-15.1 Description ..............................................................7-65 7-15.2 Materials ................................................................7-65 7-15.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65 7-15.3(1) Flushing and Disinfection ....................................7-66 7-15.4 Measurement ............................................................7-66 7-15.5 Payment ................................................................7-66 7-16 Vacant ............................................................................7-67 7-17 Sanitary Sewers ...................................................................7-68 7-17.1 Description ..............................................................7-68 7-17.2 Materials ................................................................7-68 7-17.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-68 7-17.3(1) Protection of Existing Sewerage Facilities ......................7-68 7-17.3(2) Cleaning and Testing ........................................7-69 7-17.4 Measurement ............................................................7-73 7-17.5 Payment ................................................................7-74 2020 Standard Specifications M 41-10 Page 35 Contents 7-18 Side Sewers .......................................................................7-75 7-18.1 Description ..............................................................7-75 7-18.2 Materials ................................................................7-75 7-18.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-75 7-18.3(1) General ....................................................7-75 7-18.3(2) Fittings ....................................................7-75 7-18.3(3) Testing ....................................................7-75 7-18.3(4) Extending Side Sewers Into Private Property ...................7-76 7-18.3(5) End Pipe Marker ............................................7-76 7-18.4 Measurement ............................................................7-76 7-18.5 Payment ................................................................7-76 7-19 Sewer Cleanouts ...................................................................7-77 7-19.1 Description ..............................................................7-77 7-19.2 Materials ................................................................7-77 7-19.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-77 7-19.4 Measurement ............................................................7-77 7-19.5 Payment ................................................................7-77 Page 36 2020 Standard Specifications M 41-10 Contents Division 8 Miscellaneous Construction .......................................8-1 8-01 Erosion Control and Water Pollution Control ...........................................8-1 8-01.1 Description ...............................................................8-1 8-01.1(1) Definitions ..................................................8-1 8-01.2 Materials .................................................................8-2 8-01.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-01.3(1) General .....................................................8-2 8-01.3(2) Temporary Seeding and Mulching ..............................8-9 8-01.3(3) Placing Erosion Control Blanket ...............................8-11 8-01.3(4) Placing Compost Blanket ....................................8-11 8-01.3(5) Plastic Covering ............................................8-11 8-01.3(6) Check Dams ...............................................8-12 8-01.3(7) Stabilized Construction Entrance ..............................8-12 8-01.3(8) Street Cleaning .............................................8-13 8-01.3(9) Sediment Control Barriers ....................................8-13 8-01.3(10) Wattles ....................................................8-16 8-01.3(11) Outlet Protection ...........................................8-16 8-01.3(12) Compost Sock ..............................................8-16 8-01.3(13) Temporary Curb ............................................8-17 8-01.3(14) Temporary Pipe Slope Drain ..................................8-17 8-01.3(15) Maintenance ...............................................8-17 8-01.3(16) Removal ...................................................8-18 8-01.4 Measurement ............................................................8-18 8-01.4(1) Lump Sum Bid for Project (No Unit Items) .....................8-18 8-01.4(2) Item Bids ..................................................8-19 8-01.4(4) Items not included with Lump Sum Erosion Control and Water Pollution Prevention ........................................8-20 8-01.5 Payment ................................................................8-20 8-01.5(1) Lump Sum Bid for Project (No Unit Items) ......................8-20 8-01.5(2) Item Bids ..................................................8-21 8-01.5(3) Reinstating Unit Items with Lump Sum Erosion Control and Water Pollution Prevention ..................................8-22 8-01.5(4) Items not included with Lump Sum Erosion Control and Water Pollution Prevention ..................................8-22 8-02 Roadside Restoration ...............................................................8-23 8-02.1 Description ..............................................................8-23 8-02.2 Materials ................................................................8-23 8-02.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-23 8-02.3(1) Responsibility During Construction ............................8-23 2020 Standard Specifications M 41-10 Page 37 Contents 8-02.3(2) Work Plans ................................................8-24 8-02.3(3) Weed and Pest Control ......................................8-26 8-02.3(4) Topsoil ....................................................8-27 8-02.3(5) Roadside Seeding, Lawn and Planting Area Preparation ..........8-28 8-02.3(6) Mulch and Amendments .....................................8-30 8-02.3(7) Layout of Planting, Lawn and Seeding Areas ....................8-31 8-02.3(8) Planting ...................................................8-31 8-02.3(9) Seeding, Fertilizing, and Mulching .............................8-33 8-02.3(10) Lawn Installation ............................................8-35 8-02.3(11) Mulch .....................................................8-37 8-02.3(12) Completion of Initial Planting .................................8-38 8-02.3(13) Plant Establishment .........................................8-39 8-02.3(14) Plant Replacement ..........................................8-40 8-02.3(15) Bioengineering .............................................8-40 8-02.3(16) Roadside Maintenance Under Construction ....................8-42 8-02.4 Measurement ............................................................8-42 8-02.5 Payment ................................................................8-43 8-03 Irrigation Systems ..................................................................8-47 8-03.1 Description ..............................................................8-47 8-03.2 Materials ................................................................8-47 8-03.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-47 8-03.3(1) Layout of Irrigation System ...................................8-47 8-03.3(2) Excavation .................................................8-47 8-03.3(3) Piping .....................................................8-48 8-03.3(4) Jointing ....................................................8-49 8-03.3(5) Installation .................................................8-49 8-03.3(6) Electrical Wire Installation ...................................8-50 8-03.3(7) Flushing and Testing .........................................8-51 8-03.3(8) Adjusting System ...........................................8-52 8-03.3(9) Backfill ....................................................8-52 8-03.3(10) As Built Plans ..............................................8-52 8-03.3(11) System Operation ...........................................8-52 8-03.3(12) Cross Connection Control Device Installation ...................8-53 8-03.3(13) Irrigation Water Service ......................................8-53 8-03.3(14) Irrigation Electrical Service ...................................8-54 8-03.4 Vacant ..................................................................8-54 8-03.5 Payment ................................................................8-54 Page 38 2020 Standard Specifications M 41-10 Contents 8-04 Curbs, Gutters, and Spillways ........................................................8-55 8-04.1 Description ..............................................................8-55 8-04.2 Materials ................................................................8-55 8-04.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-55 8-04.3(1) Cement Concrete Curbs, Gutters, and Spillways ................8-55 8-04.3(2) Extruded Asphalt Concrete Curbs and Gutters ..................8-57 8-04.3(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-57 8-04.3(4) Metal Spillways .............................................8-57 8-04.3(5) Spillways at Bridge Ends .....................................8-57 8-04.4 Measurement ............................................................8-58 8-04.5 Payment ................................................................8-58 8-05 Vacant ............................................................................8-60 8-06 Cement Concrete Driveway Entrances ................................................8-61 8-06.1 Description ..............................................................8-61 8-06.2 Materials ................................................................8-61 8-06.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-61 8-06.4 Measurement ............................................................8-61 8-06.5 Payment ................................................................8-62 8-07 Precast Traffic Curb ................................................................8-63 8-07.1 Description ..............................................................8-63 8-07.2 Materials ................................................................8-63 8-07.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-63 8-07.3(1) Installing Curbs .............................................8-63 8-07.3(2) Painting of Curbs ...........................................8-64 8-07.4 Measurement ............................................................8-64 8-07.5 Payment ................................................................8-64 8-08 Rumble Strips .....................................................................8-65 8-08.1 Description ..............................................................8-65 8-08.2 Vacant ..................................................................8-65 8-08.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-65 8-08.4 Measurement ............................................................8-65 8-08.5 Payment ................................................................8-66 2020 Standard Specifications M 41-10 Page 39 Contents 8-09 Raised Pavement Markers ..........................................................8-67 8-09.1 Description ..............................................................8-67 8-09.2 Materials ................................................................8-67 8-09.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-67 8-09.3(1) Preliminary Spotting .........................................8-67 8-09.3(2) Surface Preparation .........................................8-67 8-09.3(3) Marker Preparation .........................................8-68 8-09.3(4) Adhesive Preparation ........................................8-68 8-09.3(5) Application Procedure .......................................8-68 8-09.3(6) Recessed Pavement Marker ..................................8-69 8-09.3(7) Tolerances for Pavement Markers .............................8-69 8-09.4 Measurement ............................................................8-69 8-09.5 Payment ................................................................8-69 8-10 Guide Posts .......................................................................8-70 8-10.1 Description ..............................................................8-70 8-10.2 Materials ................................................................8-70 8-10.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-70 8-10.4 Measurement ............................................................8-71 8-10.5 Payment ................................................................8-71 8-11 Guardrail ..........................................................................8-72 8-11.1 Description ..............................................................8-72 8-11.2 Materials ................................................................8-72 8-11.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-72 8-11.3(1) Beam Guardrail .............................................8-72 8-11.4 Measurement ............................................................8-75 8-11.5 Payment ................................................................8-76 8-12 Chain Link Fence and Wire Fence ....................................................8-78 8-12.1 Description ..............................................................8-78 8-12.2 Materials ................................................................8-78 8-12.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-78 8-12.3(1) Chain Link Fence and Gates ..................................8-79 8-12.3(2) Wire Fence and Gates .......................................8-81 8-12.4 Measurement ............................................................8-83 8-12.5 Payment ................................................................8-83 Page 40 2020 Standard Specifications M 41-10 Contents 8-13 Monument Cases ..................................................................8-85 8-13.1 Description ..............................................................8-85 8-13.2 Materials ................................................................8-85 8-13.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-85 8-13.4 Measurement ............................................................8-85 8-13.5 Payment ................................................................8-85 8-14 Cement Concrete Sidewalks .........................................................8-86 8-14.1 Description ..............................................................8-86 8-14.2 Materials ................................................................8-86 8-14.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-86 8-14.3(1) Excavation .................................................8-86 8-14.3(2) Forms .....................................................8-86 8-14.3(3) Placing and Finishing Concrete ...............................8-87 8-14.3(4) Curing .....................................................8-87 8-14.3(5) Detectable Warning Surface ..................................8-87 8-14.4 Measurement ............................................................8-87 8-14.5 Payment ................................................................8-88 8-15 Riprap ............................................................................8-89 8-15.1 Description ..............................................................8-89 8-15.2 Materials ................................................................8-89 8-15.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-89 8-15.3(1) Excavation for Riprap ........................................8-89 8-15.3(2) Loose Riprap ...............................................8-89 8-15.3(3) Hand Placed Riprap .........................................8-90 8-15.3(4) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-90 8-15.3(5) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-90 8-15.3(6) Quarry Spalls ...............................................8-90 8-15.3(7) Filter Blanket ...............................................8-90 8-15.4 Measurement ............................................................8-90 8-15.5 Payment ................................................................8-91 2020 Standard Specifications M 41-10 Page 41 Contents 8-16 Concrete Slope Protection ..........................................................8-92 8-16.1 Description ..............................................................8-92 8-16.2 Materials ................................................................8-92 8-16.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-92 8-16.3(1) Footing and Preparation of Slope .............................8-92 8-16.3(2) Placing Semi-Open Concrete Masonry Units ...................8-92 8-16.3(3) Poured in Place Cement Concrete .............................8-93 8-16.3(4) Pneumatically Placed Concrete ...............................8-93 8-16.4 Measurement ............................................................8-94 8-16.5 Payment ................................................................8-94 8-17 Impact Attenuator Systems .........................................................8-95 8-17.1 Description ..............................................................8-95 8-17.2 Materials ................................................................8-95 8-17.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-95 8-17.4 Measurement ............................................................8-96 8-17.5 Payment ................................................................8-96 8-18 Mailbox Support ...................................................................8-97 8-18.1 Description ..............................................................8-97 8-18.2 Materials ................................................................8-97 8-18.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-97 8-18.3(1) Type 3 Mailbox Support .....................................8-97 8-18.4 Measurement ............................................................8-98 8-18.5 Payment ................................................................8-98 8-19 Vacant ............................................................................8-99 8-20 Illumination, Traffic Signal Systems, Intelligent Transportation Systems, and Electrical .....8-100 8-20.1 Description .............................................................8-100 8-20.1(1) Regulations and Code ......................................8-100 8-20.1(2) Industry Codes and Standards ...............................8-101 8-20.1(3) Permitting and Inspections ..................................8-102 8-20.2 Materials ...............................................................8-102 8-20.2(1) Equipment List and Drawings ................................8-102 8-20.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-103 8-20.3(1) General ...................................................8-103 8-20.3(2) Excavating and Backfilling ...................................8-105 8-20.3(3) Removing and Replacing Improvements .......................8-105 8-20.3(4) Foundations ...............................................8-106 8-20.3(5) Conduit ..................................................8-108 Page 42 2020 Standard Specifications M 41-10 Contents 8-20.3(6) Junction Boxes, Cable Vaults, and Pull boxes ..................8-116 8-20.3(7) Messenger Cable, Fittings ...................................8-117 8-20.3(8) Wiring ....................................................8-117 8-20.3(9) Bonding, Grounding ........................................8-121 8-20.3(10) Service, Transformer, and Intelligent Transportation System (ITS) Cabinets .............................................8-122 8-20.3(11) Testing ...................................................8-123 8-20.3(12) Painting ..................................................8-124 8-20.3(13) Illumination Systems .......................................8-124 8-20.3(14) Signal Systems ............................................8-127 8-20.3(15) Grout ....................................................8-130 8-20.3(16) Reinstalling Salvaged Material ...............................8-130 8-20.3(17) “As Built” Plans ............................................8-130 8-20.4 Measurement ...........................................................8-130 8-20.5 Payment ...............................................................8-131 8-21 Permanent Signing ................................................................8-132 8-21.1 Description .............................................................8-132 8-21.2 Materials ...............................................................8-132 8-21.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-132 8-21.3(1) Location of Signs ..........................................8-132 8-21.3(2) Placement of Signs .........................................8-132 8-21.3(3) Sign Covering .............................................8-133 8-21.3(4) Sign Removal ..............................................8-133 8-21.3(5) Sign Relocation ............................................8-134 8-21.3(6) Sign Refacing ..............................................8-134 8-21.3(7) Sign Message Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-135 8-21.3(8) Sign Cleaning ..............................................8-135 8-21.3(9) Sign Structures ............................................8-135 8-21.3(10) Sign Attachment ...........................................8-139 8-21.3(11) Multiple Panel Signs ........................................8-139 8-21.3(12) Steel Sign Posts ............................................8-139 8-21.4 Measurement ...........................................................8-140 8-21.5 Payment ...............................................................8-140 2020 Standard Specifications M 41-10 Page 43 Contents 8-22 Pavement Marking ................................................................8-141 8-22.1 Description .............................................................8-141 8-22.2 Materials ...............................................................8-141 8-22.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-141 8-22.3(1) Preliminary Spotting ........................................8-141 8-22.3(2) Preparation of Roadway Surfaces ............................8-141 8-22.3(3) Marking Application ........................................8-142 8-22.3(4) Tolerances for Lines ........................................8-146 8-22.3(5) Installation Instructions .....................................8-146 8-22.3(6) Removal of Pavement Markings ..............................8-147 8-22.4 Measurement ...........................................................8-147 8-22.5 Payment ...............................................................8-148 8-23 Temporary Pavement Markings .....................................................8-151 8-23.1 Description .............................................................8-151 8-23.2 Materials ...............................................................8-151 8-23.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-151 8-23.3(1) General ...................................................8-151 8-23.3(2) Preliminary Spotting ........................................8-151 8-23.3(3) Preparation of Roadway Surface .............................8-151 8-23.3(4) Pavement Marking Application ..............................8-151 8-23.4 Measurement ...........................................................8-153 8-23.5 Payment ...............................................................8-153 8-24 Rock and Gravity Block Wall and Gabion Cribbing ....................................8-154 8-24.1 Description .............................................................8-154 8-24.2 Materials ...............................................................8-154 8-24.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-154 8-24.3(1) Rock Wall .................................................8-154 8-24.3(2) Gravity Block Wall .........................................8-156 8-24.3(3) Gabion Cribbing ...........................................8-156 8-24.4 Measurement ...........................................................8-158 8-24.5 Payment ...............................................................8-158 Page 44 2020 Standard Specifications M 41-10 Contents 8-25 Glare Screen .....................................................................8-159 8-25.1 Description .............................................................8-159 8-25.2 Materials ...............................................................8-159 8-25.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-159 8-25.3(1) Glare Screen Fabric ........................................8-159 8-25.3(2) Slats .....................................................8-159 8-25.3(3) Posts .....................................................8-160 8-25.3(4) Tension Wire ..............................................8-160 8-25.4 Measurement ...........................................................8-160 8-25.5 Payment ...............................................................8-160 8-26 Vacant ...........................................................................8-161 8-27 Vacant ...........................................................................8-162 8-28 Vacant ...........................................................................8-163 8-29 Wire Mesh Slope Protection .......................................................8-164 8-29.1 Description .............................................................8-164 8-29.2 Materials ...............................................................8-164 8-29.3 Construction Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-164 8-29.3(1) Submittals ................................................8-164 8-29.3(2) Anchors ..................................................8-164 8-29.3(3) Wire Rope ................................................8-165 8-29.3(4) Wire Mesh ................................................8-165 8-29.4 Measurement ...........................................................8-165 8-29.5 Payment ...............................................................8-165 2020 Standard Specifications M 41-10 Page 45 Contents Division 9 Materials ........................................................9-1 9-00 Definitions and Tests ................................................................9-1 9-00.1 Fracture .................................................................9-1 9-00.2 Wood Waste .............................................................9-1 9-00.3 Test for Mass of Galvanizing ................................................9-1 9-00.4 Sieves for Testing Purposes .................................................9-1 9-00.5 Dust Ratio ...............................................................9-1 9-00.6 Sand/Silt Ratio ............................................................9-1 9-00.7 Galvanized Hardware, AASHTO M232 .......................................9-1 9-00.8 Sand Equivalent ...........................................................9-2 9-00.9 Field Test Procedures ......................................................9-2 9-01 Cement ............................................................................9-3 9-01.1 Types of Cement ..........................................................9-3 9-01.2 Specifications .............................................................9-3 9-01.2(1) Portland Cement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9-01.2(2) Rapid Hardening Hydraulic Cement ............................9-4 9-01.3 Tests and Acceptance ......................................................9-4 9-01.4 Storage on the Work Site ...................................................9-5 9-02 Bituminous Materials ................................................................9-6 9-02.1 Asphalt Material, General ..................................................9-6 9-02.1(1) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9-02.1(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9-02.1(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9-02.1(4) Performance Graded (PG) Asphalt Binder .......................9-6 9-02.1(5) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 9-02.1(6) Cationic Emulsified Asphalt ...................................9-7 9-02.1(7) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 9-02.1(8) Flexible Bituminous Pavement Marker Adhesive .................9-7 9-02.2 Sampling and Acceptance ..................................................9-8 9-02.2(1) Certification of Shipment .....................................9-8 9-02.2(2) Samples ....................................................9-8 9-02.3 Temperature of Asphalt ....................................................9-9 9-02.4 Anti-Stripping Additive .....................................................9-9 9-02.5 HMA Additive ............................................................9-9 Page 46 2020 Standard Specifications M 41-10 Contents 9-03 Aggregates ........................................................................9-10 9-03.1 Aggregates for Concrete ..................................................9-10 9-03.1(1) General Requirements .......................................9-10 9-03.1(2) Fine Aggregate for Concrete .................................9-11 9-03.1(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12 9-03.1(4) Coarse Aggregate for Concrete ...............................9-12 9-03.1(5) Combined Aggregate Gradation for Concrete ...................9-14 9-03.2 Aggregate for Job-Mixed Portland Cement or Blended Hydraulic Cement Mortar .9-15 9-03.2(1) Grading for Surface Finishing Applications .....................9-15 9-03.2(2) Grading for Masonry Mortar Applications ......................9-15 9-03.3 Vacant ..................................................................9-16 9-03.4 Aggregate for Bituminous Surface Treatment ................................9-16 9-03.4(1) General Requirements .......................................9-16 9-03.4(2) Grading and Quality .........................................9-16 9-03.5 Vacant ..................................................................9-17 9-03.6 Vacant ..................................................................9-17 9-03.7 Vacant ..................................................................9-17 9-03.8 Aggregates for Hot Mix Asphalt ............................................9-17 9-03.8(1) General Requirements .......................................9-17 9-03.8(2) HMA Test Requirements .....................................9-17 9-03.8(3) Grading ....................................................9-19 9-03.8(4) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19 9-03.8(5) Mineral Filler ...............................................9-19 9-03.8(6) HMA Proportions of Materials ................................9-20 9-03.8(7) HMA Tolerances and Adjustments ............................9-20 9-03.9 Aggregates for Ballast and Crushed Surfacing ................................9-21 9-03.9(1) Ballast .....................................................9-21 9-03.9(2) Permeable Ballast ...........................................9-22 9-03.9(3) Crushed Surfacing ..........................................9-22 9-03.9(4) Maintenance Rock ..........................................9-23 9-03.10 Aggregate for Gravel Base .................................................9-23 9-03.11 Streambed Aggregates ....................................................9-24 9-03.11(1) Streambed Sediment ........................................9-24 9-03.11(2) Streambed Cobbles .........................................9-25 9-03.11(3) Streambed Boulders .........................................9-26 9-03.11(4) Habitat Boulders ............................................9-26 2020 Standard Specifications M 41-10 Page 47 Contents 9-03.12 Gravel Backfill ...........................................................9-27 9-03.12(1) Gravel Backfill for Foundations ...............................9-27 9-03.12(2) Gravel Backfill for Walls .....................................9-27 9-03.12(3) Gravel Backfill for Pipe Zone Bedding .........................9-28 9-03.12(4) Gravel Backfill for Drains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-28 9-03.12(5) Gravel Backfill for Drywells ..................................9-29 9-03.13 Backfill for Sand Drains ...................................................9-29 9-03.13(1) Sand Drainage Blanket ......................................9-29 9-03.14 Borrow .................................................................9-30 9-03.14(1) Gravel Borrow ..............................................9-30 9-03.14(2) Select Borrow ..............................................9-30 9-03.14(3) Common Borrow ...........................................9-31 9-03.14(4) Gravel Borrow for Structural Earth Wall ........................9-31 9-03.15 Native Material for Trench Backfill ..........................................9-32 9-03.16 Vacant ..................................................................9-32 9-03.17 Foundation Material Class A and Class B ....................................9-32 9-03.18 Foundation Material Class C ...............................................9-32 9-03.19 Bank Run Gravel for Trench Backfill .........................................9-33 9-03.20 Test Methods for Aggregates ..............................................9-33 9-03.21 Recycled Material ........................................................9-33 9-03.21(1) General Requirements .......................................9-33 9-04 Joint Sealing Materials ..............................................................9-41 9-04.1 Premolded Joint Fillers ....................................................9-41 9-04.1(1) Asphalt Filler for Contraction and Longitudinal Joints in Concrete Pavements ........................................9-41 9-04.1(2) Premolded Joint Filler for Expansion Joints .....................9-41 9-04.1(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-41 9-04.1(4) Elastomeric Expansion Joint Seals .............................9-41 9-04.2 Joint Sealants ............................................................9-42 9-04.2(1) Hot Poured Joint Sealants ....................................9-42 9-04.2(2) Poured Rubber Joint Sealer ...................................9-42 9-04.2(3) Polyurethane Sealant ........................................9-43 9-04.3 Joint Mortar .............................................................9-43 9-04.4 Pipe Joint Gaskets ........................................................9-43 9-04.4(1) Rubber Gaskets for Concrete Pipes and Precast Manholes .......9-43 9-04.4(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-44 9-04.4(3) Gaskets for Aluminum or Steel Culvert or Storm Sewer Pipe ......9-44 9-04.4(4) Rubber Gaskets for Aluminum or Steel Drain Pipe ...............9-44 9-04.4(5) Protection and Storage ......................................9-44 Page 48 2020 Standard Specifications M 41-10 Contents 9-04.5 Flexible Plastic Gaskets ...................................................9-44 9-04.6 Expanded Polystyrene ....................................................9-45 9-04.7 Expanded Rubber ........................................................9-45 9-04.8 Flexible Elastomeric Seals .................................................9-45 9-04.9 Solvent Cements .........................................................9-45 9-04.10 Butyl Rubber and Nitrile Rubber ...........................................9-45 9-04.11 Butyl Rubber Sealant .....................................................9-45 9-04.12 External Sealing Band .....................................................9-45 9-05 Drainage Structures and Culverts ....................................................9-46 9-05.0 Acceptance and Approval of Drainage Structures, and Culverts .................9-46 9-05.1 Drain Pipe ...............................................................9-46 9-05.1(1) Concrete Drain Pipe .........................................9-46 9-05.1(2) Zinc Coated (Galvanized) or Aluminum Coated (Aluminized) Corrugated Iron or Steel Drain Pipe ...........................9-46 9-05.1(3) Corrugated Aluminum Alloy Drain Pipe ........................9-47 9-05.1(4) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-47 9-05.1(5) PVC Drain Pipe, Couplings, and Fittings ........................9-47 9-05.1(6) Corrugated Polyethylene Drain Pipe, Couplings, and Fittings (Up to 10 inch) .............................................9-47 9-05.1(7) Corrugated Polyethylene Drain Pipe, Couplings, and Fittings (12 inch Through 60 inch) ....................................9-47 9-05.2 Underdrain Pipe .........................................................9-48 9-05.2(1) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-48 9-05.2(2) Perforated Concrete Underdrain Pipe .........................9-48 9-05.2(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-48 9-05.2(4) Zinc Coated (Galvanized) or Aluminum Coated (Aluminized) Corrugated Iron or Steel Underdrain Pipe ......................9-48 9-05.2(5) Perforated Corrugated Aluminum Alloy Underdrain Pipe .........9-48 9-05.2(6) Perforated PVC Underdrain Pipe ..............................9-49 9-05.2(7) Perforated Corrugated Polyethylene Underdrain Pipe (Up to 10 inch) .............................................9-49 9-05.2(8) Perforated Corrugated Polyethylene Underdrain Pipe (12-Inch Through 60-Inch Diameter Maximum), Couplings, and Fittings ....9-49 9-05.3 Concrete Culvert Pipe ....................................................9-50 9-05.3(1) Plain Concrete Culvert Pipe ..................................9-50 9-05.3(2) Reinforced Concrete Culvert Pipe .............................9-50 9-05.3(3) Beveled Concrete End Sections ...............................9-51 2020 Standard Specifications M 41-10 Page 49 Contents 9-05.4 Steel Culvert Pipe and Pipe Arch ...........................................9-52 9-05.4(1) Elliptical Fabrication .........................................9-52 9-05.4(2) Mitered Ends ...............................................9-52 9-05.4(3) Protective Treatment ........................................9-52 9-05.4(4) Asphalt Coatings and Paved Inverts ...........................9-53 9-05.4(5) Polymer Protective Coating ..................................9-53 9-05.4(6) Spun Asphalt Lining .........................................9-53 9-05.4(7) Coupling Bands .............................................9-54 9-05.4(8) Steel Nestable Pipe .........................................9-54 9-05.4(9) Steel End Sections ..........................................9-55 9-05.5 Aluminum Culvert Pipe ...................................................9-55 9-05.5(1) Elliptical Fabrication .........................................9-55 9-05.5(2) Mitered Ends ...............................................9-55 9-05.5(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-56 9-05.5(4) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-56 9-05.5(5) Coupling Bands .............................................9-56 9-05.5(6) Aluminum End Sections ......................................9-56 9-05.6 Structural Plate Pipe, Pipe Arch, Arch, and Underpass .........................9-56 9-05.6(1) General ....................................................9-56 9-05.6(2) Fabrication .................................................9-56 9-05.6(3) Elliptical Fabrication .........................................9-57 9-05.6(4) Structural Plate Pipe Arch ....................................9-57 9-05.6(5) Structural Plate Arch ........................................9-57 9-05.6(6) Structural Plate Underpass ...................................9-57 9-05.6(7) Concrete ..................................................9-57 9-05.6(8) Plates .....................................................9-57 9-05.7 Concrete Storm Sewer Pipe ...............................................9-58 9-05.7(1) Plain Concrete Storm Sewer Pipe .............................9-58 9-05.7(2) Reinforced Concrete Storm Sewer Pipe ........................9-58 9-05.7(3) Concrete Storm Sewer Pipe Joints ............................9-58 9-05.7(4) Testing Concrete Storm Sewer Pipe Joints ......................9-58 9-05.8 Vitrified Clay Sewer Pipe ..................................................9-59 9-05.9 Steel Spiral Rib Storm Sewer Pipe ..........................................9-60 9-05.9(1) Continuous Lock Seam Pipe ..................................9-60 9-05.9(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-60 9-05.9(3) Coupling Bands .............................................9-61 9-05.10 Steel Storm Sewer Pipe ...................................................9-61 9-05.10(1) Coupling Bands .............................................9-61 9-05.10(2) Basis for Acceptance ........................................9-61 Page 50 2020 Standard Specifications M 41-10 Contents 9-05.11 Aluminum Storm Sewer Pipe ..............................................9-62 9-05.11(1) Coupling Bands .............................................9-62 9-05.11(2) Basis for Acceptance ........................................9-62 9-05.12 Polyvinyl Chloride (PVC) Pipe ..............................................9-62 9-05.12(1) Solid Wall PVC Culvert Pipe, Solid Wall PVC Storm Sewer Pipe, and Solid Wall PVC Sanitary Sewer Pipe .......................9-62 9-05.12(2) Profile Wall PVC Culvert Pipe, Profile Wall PVC Storm Sewer Pipe, and Profile Wall PVC Sanitary Sewer Pipe ......................9-62 9-05.13 Ductile Iron Sewer Pipe ...................................................9-63 9-05.14 ABS Composite Sewer Pipe ...............................................9-63 9-05.15 Metal Castings ...........................................................9-64 9-05.15(1) Manhole Ring and Cover .....................................9-64 9-05.15(2) Metal Frame, Grate, and Solid Metal Cover for Catch Basins or Inlets ...................................................9-64 9-05.15(3) Cast Metal Inlets ............................................9-65 9-05.16 Grate Inlets and Drop Inlets ...............................................9-65 9-05.17 Aluminum Spiral Rib Storm Sewer Pipe ......................................9-65 9-05.17(1) Continuous Lock Seam Pipe ..................................9-66 9-05.17(2) Coupling Bands .............................................9-66 9-05.18 Safety Bars for Culvert Pipe ...............................................9-66 9-05.19 Corrugated Polyethylene Culvert Pipe, Couplings, and Fittings .................9-66 9-05.20 Corrugated Polyethylene Storm Sewer Pipe, Couplings, and Fittings ............9-67 9-05.21 Steel Rib Reinforced Polyethylene Culvert Pipe ..............................9-67 9-05.22 Steel Rib Reinforced Polyethylene Storm Sewer Pipe ..........................9-68 9-05.23 High-Density Polyethylene (HDPE) Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-68 9-05.24 Polypropylene Culvert Pipe, Polypropylene Storm Sewer Pipe, and Polypropylene Sanitary Sewer Pipe .........................................9-69 9-05.24(1) Polypropylene Culvert Pipe and Storm Sewer Pipe ..............9-69 9-05.24(2) Polypropylene Sanitary Sewer Pipe ............................9-70 9-05.30 Vacant ..................................................................9-70 9-05.40 Vacant ..................................................................9-70 9-05.50 Precast Concrete Drainage Structures ......................................9-70 9-05.50(1) Fabrication Tolerances and Requirements ......................9-70 9-05.50(2) Manholes ..................................................9-71 9-05.50(3) Precast Concrete Catch Basins ...............................9-71 9-05.50(4) Precast Concrete Inlets ......................................9-71 9-05.50(5) Precast Concrete Drywells ...................................9-72 9-05.50(6) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-72 9-05.50(7) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-72 2020 Standard Specifications M 41-10 Page 51 Contents 9-05.50(8) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-72 9-05.50(9) Synthetic Fibers for Precast Units .............................9-72 9-05.50(10) Synthetic Structural Fibers for Precast Units ....................9-72 9-06 Structural Steel and Related Materials ................................................9-73 9-06.1 Structural Carbon Steel ...................................................9-73 9-06.2 Structural Low Alloy Steel .................................................9-73 9-06.3 Structural High-Strength Steel .............................................9-73 9-06.4 Vacant ..................................................................9-73 9-06.5 Bolts and Rods ...........................................................9-73 9-06.5(1) Unfinished Bolts ............................................9-73 9-06.5(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-73 9-06.5(3) High-Strength Bolts .........................................9-73 9-06.5(4) Anchor Bolts and Anchor Rods ...............................9-75 9-06.6 Vacant ..................................................................9-76 9-06.7 Vacant ..................................................................9-76 9-06.8 Steel Castings ...........................................................9-76 9-06.9 Gray Iron Castings ........................................................9-76 9-06.10 Malleable Iron Castings ...................................................9-76 9-06.11 Steel Forgings and Steel Shafting ...........................................9-76 9-06.12 Bronze Castings ..........................................................9-76 9-06.13 Vacant ..................................................................9-76 9-06.14 Ductile Iron Castings .....................................................9-77 9-06.15 Welded Shear Connectors .................................................9-77 9-06.16 Roadside Sign Structures ..................................................9-77 9-06.17 Noise Barrier Wall Access Door ............................................9-79 9-06.18 Metal Bridge Railing ......................................................9-79 9-06.19 Vacant ..................................................................9-80 9-06.20 Vacant ..................................................................9-80 9-06.21 Vacant ..................................................................9-80 9-06.22 Bolts, Washers, and Other Hardware .......................................9-80 9-07 Reinforcing Steel ...................................................................9-81 9-07.1 General .................................................................9-81 9-07.1(1) Acceptance by Manufacturer’s Certification ....................9-81 9-07.1(2) Bending ...................................................9-82 9-07.1(3) Lengths ....................................................9-83 9-07.1(4) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-83 Page 52 2020 Standard Specifications M 41-10 Contents 9-07.2 Deformed Steel Bars .....................................................9-83 9-07.2(1) Headed Steel Reinforcing Bar .................................9-83 9-07.3 Epoxy-Coated Steel Reinforcing Bars .......................................9-83 9-07.4 Plain Steel Bars ..........................................................9-84 9-07.5 Dowel Bars (for Cement Concrete Pavement) ................................9-84 9-07.5(1) Dowel Bars for Cement Concrete Pavement Rehabilitation .......9-84 9-07.5(2) Corrosion Resistant Dowel Bars (for Cement Concrete Pavement and Cement Concrete Pavement Rehabilitation) .......9-85 9-07.6 Tie Bars (for Cement Concrete Pavement) ...................................9-86 9-07.7 Welded Wire Reinforcement ...............................................9-86 9-07.8 Deformed Wire ..........................................................9-86 9-07.9 Cold Drawn Wire ........................................................9-87 9-07.10 Prestressing Reinforcement Strand .........................................9-87 9-07.11 Prestressing Reinforcement Bar ............................................9-87 9-08 Paints and Related Materials ........................................................9-89 9-08.1 Paint ...................................................................9-89 9-08.1(1) Description ................................................9-89 9-08.1(2) Paint Types ................................................9-89 9-08.1(3) Working Properties .........................................9-91 9-08.1(4) Storage Properties ..........................................9-91 9-08.1(5) Fineness of Grinding ........................................9-91 9-08.1(6) Test Methods ..............................................9-91 9-08.1(7) Acceptance ................................................9-92 9-08.1(8) Standard Colors ............................................9-92 9-08.2 Powder Coating Materials for Coating Galvanized Surfaces ....................9-92 9-08.3 Concrete Surface Treatments ..............................................9-93 9-08.3(1) Pigmented Sealer Materials ..................................9-93 9-08.3(2) Exposed Aggregate Concrete Coatings and Sealers ..............9-93 9-08.3(3) Permeon Treatment .........................................9-94 9-08.4 Abrasive Blast Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-94 9-08.4(1) Abrasive Blast Media ........................................9-94 9-08.4(2) Lead Abatement Additive ....................................9-94 9-08.5 Surface Cleaning Materials ................................................9-94 9-08.5(1) Bird Guano Treatment .......................................9-94 9-08.5(2) Fungicide Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-94 9-08.5(3) Water .....................................................9-94 9-08.6 Filter Fabric .............................................................9-95 9-08.7 Single-Component Urethane Sealant .......................................9-95 9-08.8 Foam Backer Rod ........................................................9-95 2020 Standard Specifications M 41-10 Page 53 Contents 9-09 Timber and Lumber ................................................................9-96 9-09.1 General Requirements ....................................................9-96 9-09.2 Grade Requirements ......................................................9-96 9-09.2(1) Structures .................................................9-97 9-09.2(2) Guardrail Posts and Blocks. ..................................9-97 9-09.2(3) Signposts, Mileposts, Sawed Fence Posts, and Mailbox Posts .....9-97 9-09.3 Preservative Treatment ...................................................9-98 9-09.3(1) General Requirements .......................................9-98 9-10 Piling .............................................................................9-99 9-10.1 Timber Piling ............................................................9-99 9-10.1(1) Untreated Piling ............................................9-99 9-10.1(2) Creosote Treated Piling .....................................9-100 9-10.1(3) Timber Composite Piling ....................................9-100 9-10.1(4) Peeling ...................................................9-100 9-10.2 Concrete Piling .........................................................9-100 9-10.2(1) Concrete .................................................9-100 9-10.2(2) Reinforcement .............................................9-100 9-10.3 Cast-In-Place Concrete Piling .............................................9-101 9-10.4 Steel Pile Tips and Shoes .................................................9-101 9-10.5 Steel Piling .............................................................9-101 9-11 Waterproof Membrane ............................................................9-102 9-11.1 Asphalt for Waterproofing ................................................9-102 9-11.2 Primer for Waterproof Membrane .........................................9-102 9-12 Masonry Units ....................................................................9-103 9-12.1 Concrete Blocks ........................................................9-103 9-12.2 Concrete Brick ..........................................................9-103 9-13 Riprap, Quarry Spalls, Slope Protection, and Rock for Erosion and Scour Protection and Rock Walls ...................................................................9-104 9-13.1 Riprap and Quarry Spalls .................................................9-104 9-13.1(1) General ...................................................9-104 9-13.1(2) Heavy Loose Riprap ........................................9-104 9-13.1(3) Light Loose Riprap .........................................9-104 9-13.1(4) Hand Placed Riprap ........................................9-105 9-13.1(5) Quarry Spalls ..............................................9-105 9-13.2 Vacant .................................................................9-105 9-13.3 Vacant .................................................................9-105 Page 54 2020 Standard Specifications M 41-10 Contents 9-13.4 Rock for Erosion and Scour Protection .....................................9-105 9-13.4(1) Suitable Shape of Rock for Erosion and Scour Protection ........9-105 9-13.4(2) Grading Requirements of Rock for Erosion and Scour Protection .9-106 9-13.5 Concrete Slope Protection ...............................................9-106 9-13.5(1) Semi-Open Concrete Masonry Units Slope Protection ..........9-106 9-13.5(2) Poured Portland Cement or Blended Hydraulic Cement Concrete Slope Protection ..................................9-107 9-13.5(3) Pneumatically Placed Portland Cement or Blended Hydraulic Cement Concrete Slope Protection ...........................9-107 9-13.6 Vacant ................................................................9-107 9-13.7 Rock for Rock Wall ......................................................9-107 9-13.7(1) Rock for Rock Walls and Chinking Material ....................9-107 9-13.7(2) Backfill for Rock Wall .......................................9-108 9-14 Erosion Control and Roadside Planting ..............................................9-109 9-14.1 Materials Submittals and Acceptance ......................................9-109 9-14.2 Topsoil .................................................................9-111 9-14.2(1) Topsoil Type A .............................................9-111 9-14.2(2) Topsoil Type B .............................................9-111 9-14.2(3) Topsoil Type C .............................................9-111 9-14.3 Seed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-111 9-14.4 Fertilizer ...............................................................9-112 9-14.5 Mulch and Amendments .................................................9-112 9-14.5(1) Straw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-112 9-14.5(2) Hydraulically Applied Erosion Control Products (HECPs) ........9-113 9-14.5(3) Bark or Wood Chip Mulch ..................................9-115 9-14.5(4) Wood Strand Mulch ........................................9-115 9-14.5(5) Agricultural Grade Dolomite Lime ............................9-116 9-14.5(6) Agricultural Grade Gypsum .................................9-116 9-14.5(7) Tackifier ..................................................9-116 9-14.5(8) Compost ..................................................9-116 9-14.5(9) Horticultural Grade Perlite ..................................9-118 9-14.6 Erosion Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-118 9-14.6(1) Polyacrylamide (PAM) ......................................9-118 9-14.6(2) Biodegradable Erosion Control Blanket .......................9-119 9-14.6(3) Plastic Covering ...........................................9-120 9-14.6(4) Check Dams ..............................................9-120 9-14.6(5) Wattles ...................................................9-121 9-14.6(6) Compost Socks ...........................................9-121 2020 Standard Specifications M 41-10 Page 55 Contents 9-14.6(7) Coir Log ..................................................9-122 9-14.6(8) High Visibility Fencing ......................................9-122 9-14.6(9) High Visibility Silt Fence ....................................9-122 9-14.7 Plant Materials ..........................................................9-122 9-14.7(1) Description ...............................................9-122 9-14.7(2) Quality ...................................................9-123 9-14.7(3) Handling and Shipping ......................................9-125 9-14.7(4) Sod ......................................................9-125 9-14.8 Stakes, Guys, and Wrapping ..............................................9-126 9-15 Irrigation System ..................................................................9-127 9-15.1 Pipe, Tubing, and Fittings .................................................9-127 9-15.1(1) Galvanized Pipe and Fittings ................................9-127 9-15.1(2) Polyvinyl Chloride Pipe and Fittings ..........................9-127 9-15.1(3) Polyethylene Pipe ..........................................9-127 9-15.2 Drip Tubing .............................................................9-128 9-15.3 Automatic Controllers ...................................................9-128 9-15.4 Irrigation Heads .........................................................9-129 9-15.5 Valve Boxes ............................................................9-129 9-15.6 Gate Valves ............................................................9-129 9-15.7 Control Valves ..........................................................9-129 9-15.7(1) Manual Control Valves ......................................9-129 9-15.7(2) Automatic Control Valves ...................................9-129 9-15.7(3) Automatic Control Valves With Pressure Regulator .............9-130 9-15.8 Quick Coupling Equipment ...............................................9-130 9-15.9 Drain Valves ............................................................9-130 9-15.10 Hose Bibs ..............................................................9-130 9-15.11 Cross Connection Control Devices ........................................9-131 9-15.12 Check Valves ...........................................................9-131 9-15.13 Pressure Regulating Valves ...............................................9-131 9-15.14 Three-Way Valves .......................................................9-131 9-15.15 Flow Control Valves .....................................................9-131 9-15.16 Air Relief Valve ..........................................................9-131 9-15.17 Electrical Wire and Splices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-132 9-15.18 Detectable Marking Tape .................................................9-132 9-15.19 Wye Strainers ..........................................................9-132 Page 56 2020 Standard Specifications M 41-10 Contents 9-16 Fence and Guardrail ...............................................................9-133 9-16.1 Chain Link Fence and Gates ..............................................9-133 9-16.1(1) General ...................................................9-133 9-16.2 Wire Fence and Gates ...................................................9-135 9-16.2(1) General ...................................................9-135 9-16.3 Beam Guardrail .........................................................9-138 9-16.3(1) Rail Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-138 9-16.3(2) Posts and Blocks ...........................................9-138 9-16.3(3) Galvanizing ...............................................9-139 9-16.3(4) Hardware .................................................9-139 9-16.3(5) Anchors ..................................................9-139 9-16.3(6) Inspection and Acceptance ..................................9-140 9-16.4 Wire Mesh Slope Protection ..............................................9-140 9-16.4(1) General ...................................................9-140 9-16.4(2) Wire Mesh ................................................9-140 9-16.4(3) Wire Rope ................................................9-141 9-16.4(4) Hardware .................................................9-141 9-16.4(5) Fasteners and Lacing Wire ..................................9-141 9-16.4(6) Ground Anchors ...........................................9-141 9-16.5 Vacant .................................................................9-142 9-16.6 Glare Screen ............................................................9-142 9-16.6(1) General ...................................................9-142 9-16.6(2) Glare Screen Fabric ........................................9-142 9-16.6(3) Posts .....................................................9-142 9-16.6(4) Tension Wire ..............................................9-143 9-16.6(5) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-143 9-16.6(6) Tension Wire Attachments ..................................9-143 9-16.6(7) Slats .....................................................9-143 9-16.6(8) Fittings ...................................................9-144 9-16.6(9) Fabric Bands and Stretcher Bars .............................9-144 9-16.6(10) Tie Wire and Hog Rings .....................................9-144 9-17 Flexible Guide Posts ...............................................................9-145 9-17.1 General ................................................................9-145 9-17.1(1) Dimensions ...............................................9-145 9-17.1(2) Reflective Sheeting ........................................9-146 9-17.2 Ultraviolet Resistance Test Procedure (Laboratory Test) ......................9-146 9-17.2(1) Acceptance ...............................................9-146 2020 Standard Specifications M 41-10 Page 57 Contents 9-17.3 Field Impact Test Procedure ..............................................9-147 9-17.3(1) Test Observations ..........................................9-147 9-17.3(2) Acceptance ...............................................9-148 9-17.4 Pre-approval ............................................................9-148 9-18 Precast Traffic Curb ...............................................................9-149 9-18.1 Precast Traffic Curb .....................................................9-149 9-18.1(1) Aggregates and Proportioning ...............................9-149 9-18.1(2) Mixing ....................................................9-149 9-18.1(3) Forms ....................................................9-150 9-18.1(4) Placing Concrete ...........................................9-150 9-18.1(5) Removal of Forms ..........................................9-150 9-18.1(6) Curing Concrete ...........................................9-150 9-18.1(7) Finish ....................................................9-151 9-18.1(8) Surface Treatment .........................................9-151 9-18.1(9) Dimensions and Shape .....................................9-151 9-18.1(10) Curb Lengths ..............................................9-151 9-18.1(11) Defective Curb ............................................9-151 9-18.1(12) Repairing Curb ............................................9-152 9-18.1(13) Identification Marking .....................................9-152 9-18.1(14) Shipping ..................................................9-152 9-18.1(15) Sampling and Inspection ....................................9-153 9-18.2 Vacant .................................................................9-153 9-18.3 Vacant .................................................................9-153 9-18.4 Water Repellent Compound ..............................................9-153 9-18.5 Sodium Metasilicate .....................................................9-153 9-19 Vacant ...........................................................................9-154 9-20 Concrete Patching Material, Grout, and Mortar .......................................9-155 9-20.1 Patching Material for Cement Concrete Pavement ...........................9-155 9-20.1(1) Patching Mortar ...........................................9-155 9-20.1(2) Patching Mortar Extended With Aggregate ....................9-155 9-20.1(3) Aggregate ................................................9-156 9-20.1(4) Water ....................................................9-156 9-20.2 Patching Material for Concrete Structure Repair .............................9-156 9-20.3 Grout ..................................................................9-156 9-20.3(1) Grout Type 1 for Post-Tensioning Applications .................9-157 9-20.3(2) Grout Type 2 for Nonshrink Applications ......................9-157 9-20.3(3) Grout Type 3 for Unconfined Applications .....................9-157 9-20.3(4) Grout Type 4 for Multipurpose Applications ...................9-157 Page 58 2020 Standard Specifications M 41-10 Contents 9-20.4 Mortar .................................................................9-158 9-20.4(1) Fine Aggregate for Mortar ..................................9-158 9-20.4(2) Mortar Type 1 for Concrete Surface Finish ....................9-158 9-20.4(3) Mortar Type 2 for Masonry Applications ......................9-158 9-20.4(4) Mortar Type 3 for Concrete Repair ...........................9-158 9-20.5 Bridge Deck Repair Material ..............................................9-158 9-21 Raised Pavement Markers (RPM) ...................................................9-159 9-21.1 Raised Pavement Markers Type 1 .........................................9-159 9-21.1(1) Physical and Chemical Properties ............................9-159 9-21.2 Raised Pavement Markers Type 2 .........................................9-159 9-21.2(1) Standard Raised Pavement Markers Type 2 ....................9-159 9-21.2(2) Abrasion Resistant Raised Pavement Markers Type 2 ...........9-159 9-21.3 Raised Pavement Markers Type 3 .........................................9-160 9-22 Monument Cases .................................................................9-161 9-22.1 Monument Cases, Covers, and Risers ......................................9-161 9-23 Concrete Curing Materials and Admixtures ...........................................9-162 9-23.1 Sheet Materials for Curing Concrete .......................................9-162 9-23.2 Liquid Membrane-Forming Concrete Curing Compounds .....................9-162 9-23.3 Vacant .................................................................9-162 9-23.4 Vacant .................................................................9-162 9-23.5 Burlap Cloth ............................................................9-162 9-23.6 Chemical Admixtures for Concrete ........................................9-162 9-23.6(1) Air-Entraining Admixtures ...................................9-162 9-23.6(2) Type A Water-Reducing Admixtures ..........................9-162 9-23.6(3) Type B Retarding Admixtures ................................9-162 9-23.6(4) Type C Accelerating Admixtures .............................9-163 9-23.6(5) Type D Water-Reducing and Retarding Admixtures .............9-163 9-23.6(6) Type E Water-Reducing and Accelerating Admixtures ...........9-163 9-23.6(7) Type F Water-Reducing, High Range Admixtures ...............9-163 9-23.6(8) Type G Water-Reducing, High Range, and Retarding Admixtures .9-163 9-23.6(9) Type S Specific Performance Admixtures ......................9-163 9-23.7 Vacant .................................................................9-163 9-23.8 Waterproofing ..........................................................9-164 9-23.9 Fly Ash ................................................................9-164 9-23.9(1) Tests and Acceptance ......................................9-164 9-23.10 Ground Granulated Blast Furnace Slag .....................................9-165 9-23.10(1) Tests and Acceptance ......................................9-165 2020 Standard Specifications M 41-10 Page 59 Contents 9-23.11 Microsilica Fume ........................................................9-165 9-23.12 Natural Pozzolan ........................................................9-165 9-23.13 Blended Supplementary Cementitious Material .............................9-165 9-24 Plastic Waterstop .................................................................9-166 9-24.1 Material ................................................................9-166 9-24.1(1) Tests of Material ...........................................9-166 9-25 Water ...........................................................................9-167 9-25.1 Water for Concrete ......................................................9-167 9-25.2 Water for Plants ........................................................9-167 9-26 Epoxy Resins .....................................................................9-168 9-26.1 Epoxy Bonding Agents ...................................................9-168 9-26.1(1) General ...................................................9-168 9-26.1(2) Packaging and Marking .....................................9-168 9-26.1(3) Certification ...............................................9-169 9-26.1(4) Rejection .................................................9-169 9-26.1(5) Acceptance ...............................................9-169 9-26.2 Epoxy Adhesive for Lane Markers .........................................9-169 9-26.2(1) General ...................................................9-169 9-26.2(2) Packaging and Marking .....................................9-169 9-26.2(3) Certification ...............................................9-169 9-26.2(4) Rejection .................................................9-169 9-26.2(5) Acceptance ...............................................9-169 9-26.3 Epoxy Grout/Mortar/Concrete ............................................9-170 9-26.3(1) General ...................................................9-170 9-26.3(2) Packaging and Marking .....................................9-170 9-26.3(3) Certification ...............................................9-170 9-26.3(4) Rejection .................................................9-170 9-26.3(5) Acceptance ...............................................9-170 9-27 Cribbing .........................................................................9-171 9-27.1 Vacant .................................................................9-171 9-27.2 Vacant .................................................................9-171 9-27.3 Gabion Cribbing ........................................................9-171 9-27.3(1) Gabion Fabric .............................................9-171 9-27.3(2) Gabion Baskets ............................................9-171 9-27.3(3) Gabion Mattresses .........................................9-172 9-27.3(4) Fasteners for Basket Assembly ...............................9-173 9-27.3(5) Nonraveling Construction ...................................9-173 9-27.3(6) Stone ....................................................9-173 Page 60 2020 Standard Specifications M 41-10 Contents 9-28 Signing Materials and Fabrication ...................................................9-174 9-28.1 General ................................................................9-174 9-28.2 Manufacturer’s Identification and Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-174 9-28.3 Corner Radius ..........................................................9-174 9-28.4 Extruded Windbeams and “Z” Bar .........................................9-175 9-28.5 Letter and Spacing Formula ...............................................9-175 9-28.6 Destination Sign Messages ...............................................9-175 9-28.7 Process Colors ..........................................................9-175 9-28.8 Sheet Aluminum Signs ...................................................9-176 9-28.9 Fiberglass Reinforced Plastic Signs ........................................9-176 9-28.9(1) Mechanical Properties ......................................9-177 9-28.9(2) Physical Properties .........................................9-177 9-28.10 Digital Printing ..........................................................9-178 9-28.11 Hardware ..............................................................9-179 9-28.12 Reflective Sheeting ......................................................9-179 9-28.12(1) Application ...............................................9-183 9-28.12(2) Edge Treatment ............................................9-183 9-28.12(3) Splices and Color Matching .................................9-183 9-28.13 Demountable Prismatic Reflectorized Message and Borders ..................9-184 9-28.14 Sign Support Structures ..................................................9-184 9-28.14(1) Timber Sign Posts ..........................................9-184 9-28.14(2) Steel Structures and Posts ..................................9-185 9-28.14(3) Aluminum Structures .......................................9-185 9-28.15 Vacant .................................................................9-185 9-29 Illumination, Signal, Electrical .......................................................9-186 9-29.1 Conduit, Innerduct, and Outerduct ........................................9-186 9-29.1(1) Rigid Metal Conduit, Galvanized Steel Outerduct, and Fittings ...9-186 9-29.1(2) Rigid Metal Conduit Fittings and Appurtenances ...............9-186 9-29.1(3) Flexible Metal Conduit .....................................9-187 9-29.1(4) Non-Metallic Conduit ......................................9-187 9-29.1(5) Innerduct and Outerduct ...................................9-188 9-29.1(6) Detectable Underground Warning Tape .......................9-190 9-29.1(7) Steel Casings ..............................................9-190 9-29.1(8) Drilling Fluid ..............................................9-191 9-29.1(9) Repair ....................................................9-191 9-29.1(10) Pull Tape ..................................................9-191 9-29.1(11) Foam Conduit Sealant ......................................9-191 2020 Standard Specifications M 41-10 Page 61 Contents 9-29.2 Junction Boxes, Cable Vaults, and Pull Boxes ................................9-191 9-29.2(1) Junction Boxes ............................................9-191 9-29.2(2) Cable Vaults and Pull Boxes .................................9-194 9-29.2(3) Structure Mounted Junction Box .............................9-196 9-29.2(4) Cover Markings ............................................9-197 9-29.2(5) Testing Requirements ......................................9-197 9-29.3 Fiber Optic Cable, Electrical Conductors, and Cable ..........................9-200 9-29.3(1) Fiber Optic Cable ..........................................9-200 9-29.3(2) Electrical Conductors and Cable .............................9-202 9-29.3(3) Wire Marking Sleeves ......................................9-203 9-29.4 Messenger Cable, Fittings ................................................9-204 9-29.5 Vacant .................................................................9-204 9-29.6 Light and Signal Standards ................................................9-204 9-29.6(1) Steel Light and Signal Standards .............................9-205 9-29.6(2) Slip Base Hardware ........................................9-205 9-29.6(3) Timber Light Standards, Timber Strain Poles, Timber Service Supports ..................................................9-205 9-29.6(4) Welding ..................................................9-206 9-29.6(5) Foundation Hardware ......................................9-206 9-29.7 Luminaire Fusing and Electrical Connections at Light Standard Bases, Cantilever Bases, and Sign Bridge Bases ....................................9-206 9-29.7(1) Unfused Quick-Disconnect Connector Kits ...................9-206 9-29.7(2) Fused Quick-Disconnect Kits ................................9-207 9-29.8 Vacant .................................................................9-207 9-29.9 Ballast, Transformers ....................................................9-208 9-29.9(1) Ballast ....................................................9-208 9-29.9(2) Transformers ..............................................9-209 9-29.10 Luminaires .............................................................9-209 9-29.10(1) Conventional Roadway Luminaires ...........................9-210 9-29.10(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-212 9-29.10(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-212 9-29.10(4) Underdeck and Wall Mount Luminaires .......................9-212 9-29.10(5) Sign Lighting Luminaires ....................................9-212 9-29.11 Control Equipment ......................................................9-215 9-29.11(1) Time Clock Controls ........................................9-215 9-29.11(2) Photoelectric Controls ......................................9-215 Page 62 2020 Standard Specifications M 41-10 Contents 9-29.12 Electrical Splice Materials ................................................9-215 9-29.12(1) Illumination Circuit Splices ..................................9-215 9-29.12(2) Traffic Signal Splice Material .................................9-216 9-29.12(3) Splice Enclosures ..........................................9-216 9-29.12(3)B Molded Splice Enclosure ....................................9-216 9-29.12(4) Re-Enterable Splice Enclosure ...............................9-216 9-29.12(5) Vinyl Electrical Tape for Splices ..............................9-216 9-29.13 Control Cabinet Assemblies ..............................................9-216 9-29.13(1) Environmental, Performance, and Test Standards for Solid-State Traffic Controller Assemblies ................................9-216 9-29.13(3) Traffic Signal Controller .....................................9-218 9-29.13(4) Traffic-Signal Controller Software ............................9-218 9-29.13(5) Flashing Operations ........................................9-222 9-29.13(6) Emergency Preemption .....................................9-222 9-29.13(7) Wiring Diagrams ...........................................9-223 9-29.13(8) Generator Transfer Switch ..................................9-223 9-29.13(9) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-223 9-29.13(10) NEMA, Type 170E, 2070 Controllers and Cabinets .............9-224 9-29.13(11) Traffic Data Accumulator and Ramp Meters ...................9-232 9-29.13(12) Type 331L ITS Cabinet .....................................9-235 9-29.14 Vacant .................................................................9-236 9-29.15 Flashing Beacon Control .................................................9-237 9-29.16 Vehicular Signal Heads, Displays, and Housing ..............................9-237 9-29.16(1) Optically Programmed, Adjustable Face, and Programmable Array 12-Inch Traffic Signal ..................................9-237 9-29.16(2) Conventional Traffic Signal Heads ............................9-240 9-29.16(3) Polycarbonate Traffic Signal Heads ...........................9-242 9-29.16(4) Traffic Signal Cover ........................................9-242 9-29.17 Signal Head Mounting Brackets and Fittings ................................9-242 9-29.18 Vehicle Detector ........................................................9-243 9-29.18(1) Induction Loop Detectors ...................................9-244 9-29.18(2) Magnetometer Detectors ...................................9-244 9-29.19 Pedestrian Push Buttons .................................................9-245 9-29.20 Pedestrian Signals .......................................................9-245 9-29.21 Flashing Beacon ........................................................9-246 9-29.22 Vacant .................................................................9-246 9-29.23 Vacant .................................................................9-246 2020 Standard Specifications M 41-10 Page 63 Contents 9-29.24 Service Cabinets ........................................................9-246 9-29.24(1) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-248 9-29.24(2) Electrical Circuit Breakers and Contactors .....................9-248 9-29.25 Amplifier, Transformer, and Terminal Cabinets ...............................9-248 9-30 Water Distribution Materials .......................................................9-250 9-30.1 Pipe ...................................................................9-250 9-30.1(1) Ductile Iron Pipe ...........................................9-250 9-30.1(2) Polyethylene Encasement ...................................9-250 9-30.1(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-250 9-30.1(4) Steel Pipe .................................................9-251 9-30.1(5) Polyvinyl Chloride (PVC) ....................................9-251 9-30.1(6) Polyethylene (PE) Pressure Pipe (4 inches and Over) ............9-251 9-30.2 Fittings ................................................................9-252 9-30.2(1) Ductile Iron Pipe ...........................................9-252 9-30.2(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-252 9-30.2(3) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-252 9-30.2(4) Steel Pipe .................................................9-252 9-30.2(5) Polyvinyl Chloride (PVC) Pipe ................................9-252 9-30.2(6) Restrained Joints ..........................................9-253 9-30.2(7) Bolted, Sleeve-Type Couplings for Plain End Pipe ..............9-253 9-30.2(8) Restrained Flexible Couplings ...............................9-253 9-30.2(9) Grooved and Shouldered Joints ..............................9-253 9-30.2(10) Polyethylene (PE) Pipe (4 inches and Over) ....................9-253 9-30.2(11) Fabricated Steel Mechanical Slip-Type Expansion Joints .........9-253 9-30.3 Valves .................................................................9-254 9-30.3(1) Gate Valves (3 to 16 inches) .................................9-254 9-30.3(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-254 9-30.3(3) Butterfly Valves ............................................9-254 9-30.3(4) Valve Boxes ...............................................9-254 9-30.3(5) Valve Marker Posts .........................................9-254 9-30.3(6) Valve Stem Extensions ......................................9-255 9-30.3(7) Combination Air Release/Air Vacuum Valves ...................9-255 9-30.3(8) Tapping Sleeve and Valve Assembly ..........................9-255 9-30.4 Vacant .................................................................9-255 9-30.5 Hydrants ...............................................................9-255 9-30.5(1) End Connections ..........................................9-255 9-30.5(2) Hydrant Dimensions .......................................9-256 9-30.5(3) Hydrant Extensions ........................................9-256 9-30.5(4) Hydrant Restraints .........................................9-256 Page 64 2020 Standard Specifications M 41-10 Contents 9-30.5(5) Traffic Flange ..............................................9-256 9-30.5(6) Guard Posts ...............................................9-256 9-30.6 Water Service Connections (2 inches and Smaller) ...........................9-257 9-30.6(1) Saddles ...................................................9-257 9-30.6(2) Corporation Stops .........................................9-257 9-30.6(3) Service Pipes ..............................................9-257 9-30.6(4) Service Fittings ............................................9-258 9-30.6(5) Meter Setters .............................................9-258 9-30.6(6) Bronze Nipples and Fittings .................................9-258 9-30.6(7) Meter Boxes ..............................................9-258 9-31 Fabricated Bridge Bearing Assemblies ...............................................9-259 9-31.1 Steel Plates and Bars ....................................................9-259 9-31.2 Stainless Steel ..........................................................9-259 9-31.3 Bearing Blocks and Keeper Rings ..........................................9-259 9-31.4 Pin Assembly ...........................................................9-259 9-31.5 Welded Shear Connectors ................................................9-260 9-31.6 Bolts, Nuts and Washers .................................................9-260 9-31.7 Anchor Array Rods, Nuts and Washers ....................................9-260 9-31.8 Bearing Pads ...........................................................9-260 9-31.8(1) Elastomeric Pads ..........................................9-260 9-31.8(2) Polytetrafluoroethylene (PTFE) ..............................9-260 9-31.8(3) Pre-formed Fabric Pad ......................................9-261 9-31.9 Polyether Urethane ......................................................9-261 9-31.10 Silicone Grease .........................................................9-261 9-31.11 Epoxy Gel ..............................................................9-262 9-31.12 Resin Filler .............................................................9-262 9-32 Mailbox Support ..................................................................9-263 9-32.1 Steel Posts .............................................................9-263 9-32.2 Bracket, Platform, and Anti-Twist Plate .....................................9-263 9-32.3 Vacant .................................................................9-263 9-32.4 Wood Posts ............................................................9-263 9-32.5 Fasteners ..............................................................9-263 9-32.6 Snow Guard ............................................................9-263 9-32.7 Type 2 Mailbox Support ..................................................9-263 9-32.8 Concrete Base ..........................................................9-263 9-32.9 Steel Pipe ..............................................................9-264 9-32.10 U-Channel Post .........................................................9-264 2020 Standard Specifications M 41-10 Page 65 Contents 9-33 Construction Geosynthetic .........................................................9-265 9-33.1 Geosynthetic Material Requirements ......................................9-265 9-33.2 Geosynthetic Properties .................................................9-266 9-33.2(1) Geotextile Properties .......................................9-266 9-33.2(2) Geotextile Properties for Retaining Walls and Reinforced Slopes .9-268 9-33.2(3) Prefabricated Drainage Mat .................................9-269 9-33.3 Aggregate Cushion of Permanent Erosion Control Geotextile .................9-269 9-33.4 Geosynthetic Material Approval and Acceptance ............................9-270 9-33.4(1) Geosynthetic Material Approval .............................9-270 9-33.4(2) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-270 9-33.4(3) Acceptance Samples .......................................9-271 9-33.4(4) Acceptance by Certificate of Compliance .....................9-272 9-33.4(5) Approval of Seams .........................................9-272 9-34 Pavement Marking Material ........................................................9-273 9-34.1 General ................................................................9-273 9-34.2 Paint ..................................................................9-273 9-34.2(1) Vacant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-273 9-34.2(2) Color .....................................................9-273 9-34.2(3) Prohibited Materials ........................................9-274 9-34.2(4) Low VOC Solvent Based Paint ...............................9-274 9-34.2(5) Low VOC Waterborne Paint .................................9-275 9-34.2(6) Temporary Pavement Marking Paint ..........................9-277 9-34.3 Plastic .................................................................9-277 9-34.3(1) Type A – Liquid Hot Applied Thermoplastic ....................9-277 9-34.3(2) Type B – Pre-Formed Fused Thermoplastic ....................9-278 9-34.3(3) Type C – Cold Applied Pre-Formed Tape ......................9-278 9-34.3(4) Type D – Liquid Cold Applied Methyl Methacrylate .............9-279 9-34.4 Glass Beads for Pavement Marking Materials ...............................9-280 9-34.5 Temporary Pavement Marking Tape ........................................9-282 9-34.5(1) Temporary Pavement Marking Tape – Short Duration (Removable) ...............................................9-282 9-34.5(2) Temporary Pavement Marking Tape – Long Duration (Non-Removable) ..........................................9-282 9-34.6 Temporary Flexible Raised Pavement Markers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-282 9-34.7 Field Testing ............................................................9-282 9-34.7(1) Requirements .............................................9-282 Page 66 2020 Standard Specifications M 41-10 Contents 9-35 Temporary Traffic Control Materials .................................................9-284 9-35.0 General Requirements ...................................................9-284 9-35.1 Stop/Slow Paddles ......................................................9-284 9-35.2 Construction Signs ......................................................9-285 9-35.3 Wood Sign Posts ........................................................9-285 9-35.4 Sequential Arrow Signs ..................................................9-286 9-35.5 Portable Changeable Message Signs .......................................9-286 9-35.6 Barricades ..............................................................9-287 9-35.7 Traffic Safety Drums .....................................................9-288 9-35.8 Vacant .................................................................9-288 9-35.9 Traffic Cones ...........................................................9-288 9-35.10 Tubular Markers .........................................................9-288 9-35.11 Warning Lights and Flashers ..............................................9-288 9-35.12 Transportable Attenuator .................................................9-289 9-35.12(1) Truck-Mounted Attenuator ..................................9-289 9-35.12(2) Trailer-Mounted Attenuator .................................9-289 9-35.12(3) Submittal Requirements ....................................9-289 9-35.13 Tall Channelizing Devices ................................................9-290 9-35.14 Portable Temporary Traffic Control Signal ..................................9-290 9-36 Shaft-Related Materials ............................................................9-292 9-36.1 Shaft Casing ............................................................9-292 9-36.1(1) Permanent Casing .........................................9-292 9-36.1(2) Temporary Casing ..........................................9-292 9-36.2 Shaft Slurry .............................................................9-292 9-36.2(1) Mineral Slurry .............................................9-292 9-36.2(2) Synthetic Slurry ............................................9-292 9-36.2(3) Water Slurry ..............................................9-293 9-36.3 Steel Reinforcing Bar Centralizers .........................................9-293 9-36.4 Access Tubes and Caps ..................................................9-293 9-36.5 Grout for Access Tubes ..................................................9-293 2020 Standard Specifications M 41-10 Page 1-1 Division 1 General Requirements 1-01 Definitions and Terms 1-01.1 General The following abbreviations and terms are defined here as they are used in any Contract documents and Specifications. When used in the Proposal Form to denote items of Work and units of measurements, abbreviations are defined to mean the full expression. 1-01.2 Abbreviations 1-01.2(1) Associations and Miscellaneous These abbreviations are used in Plans and Specifications as defined here: AAA American Arbitration Association AAR Association of American Railroads AASHTO American Association of State Highway and Transportation Officials ACI American Concrete Institute AGA American Gas Association AGC Associated General Contractors of America AI Asphalt Institute AIA American Institute of Architects AISC American Institute of Steel Construction AISI American Iron and Steel Institute AITC American Institute of Timber Construction AMS Aerospace Material Specification ANLA American Nursery and Landscape Association ANSI American National Standards Institute APA American Plywood Association API American Petroleum Institute APWA American Public Works Association ARA American Railway Association AREMA American Railway Engineering and Maintenance Association ARTBA American Road & Transportation Builders Association ASA American Standards Association ASCE American Society of Civil Engineers ASLA American Society of Landscape Architects ASME American Society of Mechanical Engineers ASNT American Society for Nondestructive Testing ASTM American Society for Testing and Materials International AWPA American Wood Protection Association Page 1-2 2020 Standard Specifications M 41-10 1-01 Definitions and Terms AWS American Welding Society AWWA American Water Works Association CFR Code of Federal Regulations CLI Chain Link Institute CRAB County Road Administration Board CRSI Concrete Reinforcing Steel Institute DIPRA Ductile Iron Pipe Research Association ECY Washington State Department of Ecology EEI Edison Electric Institute EPA Environmental Protection Agency ESAL Equivalent Single Axle Loads FHWA Federal Highway Administration FOP Field Operating Procedure FSS Federal Specifications and Standards, General Services Administration HUD United States Department of Housing and Urban Development ICEA Insulated Cable Engineers Association IEEE Institute of Electrical and Electronics Engineers ITE Institute of Transportation Engineers IES Illumination Engineering Society IMSA International Municipal Signal Association LID Local Improvement District LPI Lighting Protection Institute MSHA Mine Safety and Health Act MUTCD Manual on Uniform Traffic Control Devices NEC National Electrical Code NEMA National Electrical Manufacturers’ Association NEPA National Environmental Policy Act NFPA National Fire Protection Association NIST National Institute of Standards and Technology NRMCA National Ready Mix Concrete Association OMWBE Office of Minority and Women’s Business Enterprises OSHA Occupational Safety and Health Administration PCA Portland Cement Association PPI Plastic Pipe Institute P/PCI Precast/Prestressed Concrete Institute QPL Qualified Products List RAM Request for Approval of Material RCW Revised Code of Washington (Laws of the State) RID Road Improvement District SAE Society of Automotive Engineers SEPA State Environmental Policy Act 2020 Standard Specifications M 41-10 Page 1-3 Definitions and Terms 1-01 SOP Standard Operating Procedure SSPC Society of Protective Coatings TIB Transportation Improvement Board UL Underwriters Laboratories ULID Utility Local Improvement District UMTA Urban Mass Transit Administration WAC Washington Administrative Code WAQTC Western Alliance for Quality Transportation Construction WCLIB West Coast Lumber Inspection Bureau WISHA Washington Industrial Safety and Health Administration WRI Wire Reinforcement Institute WSDOT Washington State Department of Transportation WWPA Western Wood Products Association 1-01.2(2) Items of Work and Units of Measurement Plans and Specifications may include common engineering and construction abbreviations. Many such abbreviations need no definition. But when the following abbreviations are used, they will only mean: Agg. Aggregate Al. Aluminum BST Bituminous Surface Treatment Cl. Class Cfm Cubic Feet per Minute Cfs Cubic Feet per Second Comb. Combination Conc. Concrete CPF Composite Pay Factor Crib. Cribbing Culv. Culvert cy or cu yd. Cubic Yard Diam. Diameter ESAL Equivalent Single Axle Loads Est. Estimate or Estimated Excl. Excluding F Fahrenheit gph Gallon per Hour gpm Gallon per Minute Hund. Hundred HMA Hot Mix Asphalt In. Inch Incl. Including Page 1-4 2020 Standard Specifications M 41-10 1-01 Definitions and Terms JMCIF Job Mix Compliance Incentive Factor JMF Job Mix Formula lb Pound(s) LF or Lin. Ft. Linear Foot (Feet) LS Lump Sum M Thousand MBM Thousand Feet Board Measure MUTS Minimum Ultimate Tensile Strength PCPS Precast Prestressed Pres. Pressure psf Pounds per Square Foot psi Pounds per Square inch PVC Polyvinyl Chloride RAP Recycled Asphalt Pavement Reg. Regulator Reinf. Reinforced, Reinforcing Sec. Section St. Steel Str. Structural sy or sq. yd. Square Yard(s) Th. Thick or Thickness Tr. Treatment Va Air Voids VC Vitrified Clay VFA Voids Filled with Asphalt VMA Voids in Mineral Aggregate 1-01.3 Definitions Addendum – A written or graphic document, issued to all Bidders and identified as an Addendum prior to Bid opening, which modifies or supplements the Bid Documents and becomes a part of the Contract. Auxiliary Lane – The part of the Roadway next to Traveled Ways for parking, speed changes, turning, weaving, truck climbing, or for anything that adds to through traffic movement. Award – The formal decision of the Contracting Agency to accept the lowest responsible and responsive Bidder for the Work. Bid, Proposal – The offer of a Bidder on a properly completed Proposal Form to perform the Contract. 2020 Standard Specifications M 41-10 Page 1-5 Definitions and Terms 1-01 Bidder – An individual, partnership, firm, corporation, or joint venture, submitting a Proposal or Bid. When required by law or otherwise the individual, partnership, firm, corporation, or joint venture shall be prequalified. Bid Documents – The component parts of the proposed Contract which may include, but are not limited to, the Proposal Form, the proposed Contract Provisions, the proposed Contract Plans, Addenda, and for projects with Contracting Agency subsurface investigations; the Summary of Geotechnical Conditions and subsurface boring logs (if any). Bridge Approach Embankments – An embankment beneath a Structure and extending 100 feet beyond a Structure’s end (at Subgrade elevation for the full embankment width) plus an access ramp on a 10:1 slope to the original ground elevation. Also, any embankment that replaces unsuitable foundation soil beneath the Bridge Approach Embankment. Call for Bids (Advertisement for Bids) – The published public notice soliciting Proposals or Bids for Work stating, among other things, the time, place, and date for receiving and opening the Bids. Cold Weather Protection Period – A period of time 7 days from the day of concrete placement or the duration of the cure period, whichever is longer. Commission, Washington State Transportation Commission – The appointive body having authority over state transportation matters as provided by law. Completion Dates – Substantial Completion Date is the day the Engineer determines the Contracting Agency has full and unrestricted use and benefit of the facilities, both from the operational and safety standpoint, all the initial plantings are completed and only minor incidental work, replacement of temporary substitute facilities, plant establishment periods, or correction or repair remains for the Physical Completion of the total Contract. Physical Completion Date is the day all of the Work is physically completed on the project. All documentation required by the Contract and required by law does not necessarily need to be furnished by the Contractor by this date. Completion Date is the day all the Work specified in the Contract is completed and all the obligations of the Contractor under the Contract are fulfilled by the Contractor. All documentation required by the Contract and required by law must be furnished by the Contractor before establishment of this date. Contract – The written agreement between the Contracting Agency and the Contractor. It describes, among other things: 1. What work will be done, and by when; 2. Who provides labor and materials; and 3. How Contractors will be paid. Page 1-6 2020 Standard Specifications M 41-10 1-01 Definitions and Terms The Contract includes the Contract (agreement) Form, Bidder’s completed Proposal Form, Contract Provisions, Contract Plans, Standard Specifications, Standard Plans, Addenda, various certifications and affidavits, supplemental agreements, change orders, and subsurface boring logs (if any). Contract Bond – The approved form of security furnished by the Contractor and the Contractor’s Surety as required by the Contract, that guarantees performance of all the Work required by the Contract and payment to anyone who provides supplies or labor for the performance of the Work. Contract Form (Agreement Form) – The form provided by the Contracting Agency that requires the authorized signatures of the Contractor and the Contracting Agency to result in formal execution of the Contract. Contracting Agency – Agency of Government that is responsible for the execution and administration of the Contract. Contractor – The individual, partnership, firm, corporation, or joint venture, Contracting with the Contracting Agency to do prescribed Work. Contract Plans – A publication addressing the Work required for an individual project. At the time of the call for Bids, the Contract Plans may include, but are not limited to, the following: a vicinity map, a summary of quantities, structure notes, signing information, traffic control plans, and detailed drawings; all for a specific individual project. At the time of the Contract execution date, the Contract Plans include any Addenda. Contract Provisions – A publication addressing the Work required for an individual project. At the time of the call for Bids, the Contract Provisions may include, for a specific individual project, the amendments to the Standard Specifications, the Special Provisions, a listing of the applicable Standard Plans, the prevailing minimum hourly wage rates, and an informational Proposal Form with the listing of Bid items. The proposed Contract Provisions may also include, for a specific individual project, the Required Contract Provisions Federal-aid Construction Contracts, and various required certifications or declarations. At the time of the Contract execution date, the Contract Provisions include the proposed Contract Provisions and include any Addenda, a copy of the Contract Form, and a copy of the Proposal Form with the Contract prices and extensions. Department, Department of Transportation – The State Agency authorized by law to administer transportation-related work. Engineer – The Contracting Agency’s representative who directly supervises the engineering and administration of a construction Contract. Federal Highway Administration – The Federal Agency authorized to approve plans and contracts for Federal-Aid Highway projects. They also inspect such projects to ensure Contract compliance. Frontage Road – A local street or road usually next to an arterial Highway that serves abutting property and adjacent areas and controls access. 2020 Standard Specifications M 41-10 Page 1-7 Definitions and Terms 1-01 Highway – A public way for vehicles, including the entire Right of Way. Inspector – The Engineer’s representative who inspects Contract performance in detail. Laboratory – The laboratories of the Contracting Agency, or other laboratories the Contracting Agency authorizes to test Work, soils, and materials. Plans – The Contract Plans or Standard Plans which show location, character, and dimensions of prescribed Work including layouts, profiles, cross-sections, and other details. Project Engineer – Same as Engineer. Proposal Form – The form provided to Bidders by the Contracting Agency for submittal of a Proposal or Bid to the Contracting Agency for a specific project. The form includes the item number, estimated plan quantity, and item description of the Bid items along with blank spaces to be completed by the Bidder for the unit prices, extensions, the total Bid amount, signatures, date, acknowledgment of Addenda, and the Bidder’s address. The required certifications and declarations are part of the form. Reference Information – Information provided to the Contractor by the Contracting Agency that is not part of the Contract. Right of Way – Land, property, or property interest, usually in a strip, acquired for or devoted to transportation purposes. Roadbed – The graded part of the Roadway within top and side slopes, prepared as a foundation for the pavement structure and Shoulders. Roadside – The area outside the traveled way. Roadway – The portion of the Right of Way within the outside limits of the side slopes. Secretary, Secretary of Transportation – The chief executive officer of the Department and other authorized representatives. Shoulder – The part of the Roadway next to the Traveled Way or Auxiliary Lanes. It provides lateral support of base and surface courses and is an emergency stopping area for vehicles. Sensitive Area – Natural features, which may be previously altered by human activity, that are present on or adjacent to the project location and protected, managed, or regulated by local, tribal, state, or federal agencies. Special Provisions – Supplemental Specifications and modifications to the Standard Specifications and the amendments to the Standard Specifications that apply to an individual project. Specifications – Provisions and requirements for the prescribed Work. Page 1-8 2020 Standard Specifications M 41-10 1-01 Definitions and Terms Standard Plans – A manual of specific plans or drawings adopted by the Contracting Agency which show frequently recurring components of Work that have been standardized for use. State – The state of Washington acting through its representatives. Structures – Bridges, culverts, catch basins, drop inlets, retaining walls, cribbing, manholes, endwalls, buildings, service pipes, sewers, underdrains, foundation drains, and other features found during Work that the Contract may or may not classify as a Structure. Subcontractor – An individual, partnership, firm, corporation, or joint venture who is sublet part of the Contract by the Contractor. Subgrade – The top surface of the Roadbed on which subbase, base, surfacing, pavement, or layers of similar materials are placed. Substructure – The part of the Structure below: 1. The bottom of the grout pad for the simple and continuous span bearing, or 2. The bottom of the girder or bottom slab soffit, or 3. Arch skewbacks and construction joints at the top of vertical abutment members or rigid frame piers. Substructures include endwalls, wingwalls, barrier and railing attached to the wingwalls, and cantilever barriers and railings. Superstructure – The part of the Structure above: 1. The bottom of the grout pad for the simple and continuous span bearing, or 2. The bottom of the block supporting the girder, or 3. Arch skewbacks and construction joints at the top of vertical abutment members or rigid frame piers. Longitudinal limits of the Superstructure extend from end to end of the Structure in accordance with the following criteria: 1. From the face of end diaphragm abutting the bridge approach embankment for end piers without expansion joints, or 2. From the end pier expansion joint for bridges with end pier expansion joints Superstructures include, but are not limited to, the bottom slab and webs of box girders, the bridge deck and diaphragms of all bridges, and the sidewalks when shown on the bridge deck. The Superstructure also includes the girders, expansion joints, bearings, barrier, and railing attached to the Superstructure when such Superstructure components are not otherwise covered by separate unit measured or lump sum bid items. Superstructures do not include endwalls, wingwalls, barrier and railing attached to the wingwalls, and cantilever barriers and railings unless supported by the Superstructure. 2020 Standard Specifications M 41-10 Page 1-9 Definitions and Terms 1-01 Surety – A company that is bound with the Contractor to ensure performance of the Contract, payment of all obligations pertaining to the Work, and fulfillment of such other conditions as are specified in the Contract, Contract Bond, or otherwise required by law. Titles (or 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. Traveled Way – That part of the Roadway made for vehicle travel excluding Shoulders and Auxiliary Lanes. Work – The provision of all labor, materials, tools, equipment, and everything needed to successfully complete a project according to the Contract. Working Drawings – Drawings, plans, diagrams, or any other supplementary data or calculations, including a schedule of submittal dates for Working Drawings where specified, which the Contractor must submit to the Engineer. WSDOT Form – Forms developed and maintained by WSDOT that are required or available for use on a project. These forms can be downloaded from the forms catalogue at: www.wsdot.wa.gov/forms/pdfforms.html Page 1-10 2020 Standard Specifications M 41-10 1-02 Bid Procedures and Conditions 1-02 Bid Procedures and Conditions 1-02.1 Prequalification of Bidders The Contracting Agency will provide a Bid Proposal Form only after a prospective Bidder submits a “Standard Questionnaire and Financial Statement”. This questionnaire enables the Contracting Agency to decide whether or not the Bidder is qualified to perform Highway, road, or other public work. The questionnaire shall be sworn to before a person authorized to take oaths. On the basis of this questionnaire, the Contracting Agency will either specify the type and amount of Work it considers the prospective Bidder prequalified to perform or advise the prospective Bidder of the reasons they failed to be prequalified. To remain prequalified, the Bidder must submit an updated questionnaire once a year and supplements whenever required by the Contracting Agency. A submittal deadline applies to any prospective Bidder not prequalified or from whom a supplemental questionnaire is due. To receive consideration for issuance of a Bid Proposal Form on a specific project, the questionnaire (or supplement) must be received by the Prequalification Engineer no less than 15 days prior to the scheduled Bid opening. The Contracting Agency may withdraw a Bidder’s prequalification or reduce its amount if: 1. The extent of other work the Bidder has under Contract (Contracting Agency or otherwise) justifies such action, or 2. Past or present work on a Contracting Agency Contract has been less than satisfactory. If a Bidder’s questionnaire does not contain sufficient information, the Contracting Agency may refuse to provide a Bid Proposal Form and disregard any Bid submitted. After opening Bids, the Contracting Agency may decide that a prequalified Bidder is not responsible and may refuse to accept the Bid on that basis. Such a refusal will be conclusive unless the Bidder appeals within five days to the Superior Court of Thurston County. Any appeal shall be heard within ten days after it is filed and shall provide at least five days’ notice to the Contracting Agency. The Bidder shall ensure that the combination of the Bid amount and other Contract work with the Contracting Agency does not exceed the prequalification amount. If this combination does exceed the prequalification amount, the Contracting Agency may determine the Bidder to be not responsible and refuse to Award a Contract. Two or more prospective Bidders may, in a joint venture, prequalify and Bid jointly on a single Contract. Each shall have filed a “Standard Questionnaire and Financial Statement”. Together they shall also file a standard form of “Individual Project Statement of Joint Venture” and a joint venture agreement in a form acceptable to the Contracting Agency. 2020 Standard Specifications M 41-10 Page 1-11 Bid Procedures and Conditions 1-02 To Bid jointly on a continuous joint venture on more than one Contract, two or more prospective Bidders shall submit: 1. A “Standard Questionnaire and Financial Statement” compiled for the joint venture; 2. A “Standard Questionnaire and Financial Statement” for each member (if the Contracting Agency has no copy on file); and 3. A copy of the “Joint Venture Agreement” signed by each member of the joint venture and naming each person authorized to sign documents on its behalf. (If any member is a corporation, a corporate resolution shall accompany the agreement. This resolution shall authorize the joint venture agreement and name the officer(s) authorized to sign the joint venture agreement or Contract on behalf of the corporation.) The Contracting Agency will treat the continuing joint venture as a new firm and decide its prequalification on that basis. Any joint venture and each of its members is subject to Section 1-02.14. 1-02.2 Plans and Specifications The Contracting Agency will place review copies of the Plans and Specifications on file in the offices of: 1. All Regional Administrators of the Department; 2. The County Engineer of the county in which the Work is located; and 3. These plans service offices of the Associated General Contractors of America: Seattle, Spokane, and Tacoma, Washington. Prospective Bidders may purchase Plans and Specifications from the Department of Transportation in Olympia, Washington, for the fee given in the call for Bids. The fee shall accompany each request for Plans. Checks shall be payable to the State of Washington, Department of Transportation. After Award of the Contract, the Plans and Specifications will be issued without charge on the following basis: To Contractor No. of Sets Basis of Distribution Reduced Plans (11″ by 17″) and Special Provision 10 Furnished automatically upon Award. Additional reduced Plans (11″ by 17″) and Special Provision 10 Furnished only upon request for projects with more than 100 plan sheets. Large Plans (22″ by 34″) and Special Provisions 1 Furnished automatically upon award. Additional large Plans (22″ by 34″) and Special Provisions 1 Furnished only upon request for projects with more than 100 plan sheets. Page 1-12 2020 Standard Specifications M 41-10 1-02 Bid Procedures and Conditions To Subcontractors and Suppliers No. of Sets Basis of Distribution Reduced Plans (11″ by 17″) and accompanying Special Provisions 1 Furnished only upon request by the Contractor for an approved Subcontractor or material supplier. Additional Plans may be purchased by payment of the current rates. 1-02.3 Estimated Quantities The quantities shown in the Proposal Form and the Contract Forms are estimates and are stated only for Bid comparison purposes. The Contracting Agency does not warrant expressly or by implication, that the actual quantities of Work will correspond with those estimates. Payment will be made on the basis of the actual quantities of each item of Work completed in accordance with the Contract requirements. 1-02.4 Examination of Plans, Specifications, and Site of Work 1-02.4(1) General The Bidder shall carefully examine the Bid Documents as defined in Section 1-01.3. Submittal of a Bid shall be conclusive evidence that the Bidder has made these examinations and understands all requirements for the performance of the completed Work. The Bidder further warrants, agrees, and acknowledges by submitting a Bid that it: 1. Has taken steps reasonably necessary to ascertain the nature and location of the Work; 2. Has investigated and satisfied itself as to the general and local conditions which can affect the Work or its cost, including but not limited to: a. Conditions bearing upon acquisition, transportation, disposal, handling, and storage of materials; b. The availability of labor, materials, water, electric power, and roads; c. Uncertainties of weather, river stages, tides, or similar physical conditions at the site; d. The conformation and condition of the ground; e. The character of equipment and facilities needed preliminary to and during Work performance; and f. The site biological hazards and associated physical hazards. 3. Has satisfied itself as to the character, quality, and quantity of surface and subsurface materials or obstacles to be encountered insofar as this information is reasonably ascertainable from an inspection of the Work site (including material sites) as well as from the Bid Documents and other information made a part of this Contract; and 4. Has satisfied itself as to the adequacy of time allowed for the completion of the physical Work on the Contract. 2020 Standard Specifications M 41-10 Page 1-13 Bid Procedures and Conditions 1-02 Any failure of the Bidder to take the actions described and acknowledged in this clause shall not relieve the Bidder from responsibility for estimating properly the difficulty and cost of successfully performing the Work, or from proceeding to successfully perform the Work without additional expense to the Contracting Agency. The Bidder agrees that the Contracting Agency shall not be liable to it on any claim for additional payment or additional time or any claim whatsoever if the claim directly or indirectly results from the Bidder’s failure to investigate and familiarize itself sufficiently with the conditions under which the Contract is to be performed. The Bidder shall be familiar and comply with all Federal, State, tribal, and local laws, ordinances, and regulations which might affect those engaged in the Work. The Contracting Agency will not consider any plea of misunderstanding or ignorance of such requirements. Bid prices shall reflect what the Bidder anticipates to be the cost of completing the Work, including methods, materials, labor, and equipment. Except as the Contract may provide, the Bidder shall receive no payment for any costs that exceed those in the Bid prices. Prospective Bidders are advised that projects with Work on or adjacent to water may require insurance coverage in compliance with: 1. The Longshoremen’s and Harbor Worker’s Compensation Act (administered by U.S. Department of Labor), or 2. The State Industrial Insurance (administrated by the Washington State Department of Labor and Industries), or 3. Both. The Contractor shall bear all cost for such insurance as provided in Section 1-07.10. No Claim shall be allowed because of any ambiguity in the Contract if: 1. The Bidder discovers an ambiguity but fails to notify the Contracting Agency, or 2. The Bidder failed to discover a patent ambiguity that would be discovered by a reasonably prudent contractor in preparing its Bid. Any prospective Bidder desiring an explanation or interpretation of the Bid Documents, shall request the explanation or interpretation in writing by close of business on the Thursday preceding the bid opening to allow a written reply to reach all prospective Bidders before the submission of their Bids. Oral explanations, interpretations, or instructions given by anyone before the Award of a Contract will not be binding on the Contracting Agency. Any information given a prospective Bidder concerning any of the Bid Documents will be furnished to all prospective Bidders as an Addendum if that information is deemed by the Contracting Agency to be necessary in submitting Bids or if the Contracting Agency concludes that the lack of the information would be prejudicial to other prospective Bidders. Page 1-14 2020 Standard Specifications M 41-10 1-02 Bid Procedures and Conditions Any information provided by the Contracting Agency for inspection by the Bidders as Reference Information will be made available for inspection at the location specified in the Special Provisions. The availability of Reference Information from the Contracting Agency shall not relieve the Bidder or the Contractor from any risks or of any duty to make examinations and investigations as required by this section or any other responsibility under the Contract or as may be required by law. Prospective Bidders are advised that the Contracting Agency may include a partially completed Washington State Department of Ecology (Ecology) Transfer of Coverage (Ecology form ECY 020-87a) for the Construction Stormwater General Permit (CSWGP) as part of the Bid Documents. When the Contracting Agency requires the transfer of coverage of the CSWGP to the Contractor, an informational copy of the Transfer of Coverage and the associated CSWGP will be included in the appendices. As a condition of Section 1-03.3, the Contractor is required to complete sections I, III, and VIII of the Transfer of Coverage and return the form to the Contracting Agency. The Contracting Agency is responsible for compliance with the CSWGP until the end of day that the Contract is executed. Beginning on the day after the Contract is executed, the Contractor shall assume complete legal responsibility for compliance with the CSWGP and full implementation of all conditions of the CSWGP as they apply to the Contract Work. 1-02.4(2) Subsurface Information If the Contracting Agency has made subsurface investigation of the site of the proposed Work, the boring log data, soil sample test data, and geotechnical recommendations reports obtained by the Contracting Agency will be made available for inspection by the Bidders as Reference Information. The Summary of Geotechnical Conditions, as an appendix to the Special Provisions, and the boring logs shall be considered as part of the Contract. However, the Contracting Agency makes no representation or warranty expressed or implied that: 1.The Bidders’ interpretations from the boring logs are correct, 2.Moisture conditions and indicated water tables will not vary from those found at the time the borings were made, and 3.The ground at the location of the borings has not been physically disturbed or altered after the boring was made. The Contracting Agency specifically makes no representations, guarantees, or warranties as to the condition, materials, or proportions of the materials between the specific borings regardless of any subsurface information the Contracting Agency may make available to the prospective Bidders. The availability of subsurface information from the Contracting Agency shall not relieve the Bidder or the Contractor from any risks or of any duty to make examinations and investigations as required by Section 1-02.4(1) or any other responsibility under the Contract or as may be required by law. 2020 Standard Specifications M 41-10 Page 1-15 Bid Procedures and Conditions 1-02 1-02.5 Proposal Forms At the request of a Bidder, the Contracting Agency will provide a physical Proposal Form for any project on which the Bidder is eligible to Bid. For certain projects selected at the sole discretion of the Contracting Agency, the Bidder may also be authorized to access an electronic Proposal Form for submittal via Trns∙Port Expedite® software and BidExpress®. The Proposal Form will identify the project and its location and describe the Work. It will also list estimated quantities, units of measurement, the items of Work, and the materials to be furnished at the unit Bid prices. The Bidder shall complete spaces on the Proposal Form that call for unit prices, extensions, the total Bid amount, signatures, date, acknowledgment of Addenda, and the Bidder’s address. The required certifications are included as part of the Proposal Form. 1-02.6 Preparation of Proposal The Contracting Agency will accept only those Proposals properly executed on the physical forms it provides, or electronic forms that the Bidder has been authorized to access. Unless it approves in writing, the Contracting Agency will not accept Proposals on forms attached to the Plans and stamped “Informational”. All prices shall be in legible figures (not words) written in ink or typed, and expressed in U.S. dollars and cents. The Proposal shall include: 1. A unit price for each item (omitting digits more than two places to the right of the decimal point), 2. An extension for each unit price (omitting digits more than two places to the right of the decimal point), and 3. The total Contract price (the sum of all extensions). In the space provided on the signature sheet, the Bidder shall confirm that all Addenda have been received. The Bidder shall submit with the Bid a completed Underutilized Disadvantaged Business Enterprise (UDBE) Utilization Certification, when required by the Special Provisions. For each and every UDBE firm listed on the Bidder’s completed Underutilized Disadvantaged Business Enterprise Utilization Certification, the Bidder shall submit written confirmation from that UDBE firm that the UDBE is in agreement with the UDBE participation commitment that the Bidder has made in the Bidder’s completed Underutilized Disadvantaged Business Enterprise Utilization Certification. WSDOT Form 422-031U (Underutilized Disadvantaged Business Enterprise Written Confirmation Document) is available for this purpose. Bidder must submit good faith effort documentation with the Underutilized Disadvantaged Business Enterprise Utilization Certification ONLY In The Event the bidder’s efforts to solicit sufficient UDBE participation have been unsuccessful. Directions for delivery of the Underutilized Disadvantaged Business Enterprise Written Confirmation Documents and Underutilized Disadvantaged Business Enterprise Good Faith Effort documentation are included in Sections 1-02.9 and 1-02.10. Page 1-16 2020 Standard Specifications M 41-10 1-02 Bid Procedures and Conditions The Bidder shall submit with the Bid a list of: 1. Subcontractors who will perform the work of heating, ventilation and air conditioning, plumbing as described in RCW 18.106 and electrical as described in RCW 19.28, and 2. The work those Subcontractors will perform on the Contract. 3. Shall not list more than one Subcontractor for each category of work identified, except, when Subcontractors vary with Bid alternates, in which case the Bidder shall identify which Subcontractor will be used for which alternate. If no Subcontractor is listed, the Bidder acknowledges that it does not intend to use any Subcontractor to perform those items of work. The Bidder shall submit with their Bid a completed Contractor Certification Wage Law Compliance form (WSDOT Form 272-009). Failure to return this certification as part of the Bid Proposal package will make this Bid Nonresponsive and ineligible for Award. A Contractor Certification of Wage Law Compliance form is included in the Proposal Forms. Proposals of corporations shall be signed by the officer or officers having authority to sign them. If a Bidder is a copartnership, the Proposal shall be signed by an authorized member of the copartnership. When the Bidder is a joint venture, the Proposal shall be signed by one or more individuals as authorized by the Joint Venture. 1-02.7 Bid Deposit A deposit of at least 5 percent of the total Bid shall accompany each Bid. This deposit may be cash, certified check, cashier’s check, or a proposal bond (Surety bond). For projects that are selected by the Contracting Agency to be Bid electronically, the proposal bond may be in either a physical format, or an electronic format via Surety2000.com or Insurevision.com and BidExpress®. When a physical Bid deposit or proposal bond is furnished to accompany an electronic Proposal Form, the Bid deposit shall be received by the Contracting Agency at the location specified for receipt of Bids prior to the time set for receipt of Bids. Any proposal bond shall be on a form acceptable to the Contracting Agency and shall be signed by the Bidder and the Surety. A proposal bond shall not be conditioned in any way to modify the minimum 5 percent required. The Surety shall: (1) be registered with the Washington State Insurance Commissioner, and (2) appear on the current Authorized Insurance List in the State of Washington published by the Office of the Insurance Commissioner. The failure to furnish a Bid deposit of a minimum of 5 percent with the Bid or as a physical supplement to the electronic Proposal Form shall make the Bid nonresponsive and shall cause the Bid to be rejected by the Contracting Agency. 2020 Standard Specifications M 41-10 Page 1-17 Bid Procedures and Conditions 1-02 1-02.8 Noncollusion Declaration and Lobbying Certification 1-02.8(1) Noncollusion Declaration When required by Section 112(c) Title 23, United States Code, a declaration shall be provided certifying that the Bidder has not taken part in collusion or other action that would restrain competitive Bidding. The Code of Federal Regulations 23 CFR 635.112(f)(1) requires that: “Each Bidder shall file a sworn or unsworn statement executed by, or on behalf of the person, firm, association, or corporation submitting the Bid, certifying that such persons, firm, association, or corporation has not either directly or indirectly, entered into any agreement, participated in any collusion, or otherwise taken any action in restraint of free competitive Bidding in connection with the submitted Bid. Failure to submit the sworn or unsworn statement as part of the Bid Proposal package will make the Bid nonresponsive and not eligible for Award consideration”. In addition, 23 CFR 635.112(f)(1) requires that the Contracting Agency provide the form for the declaration to prospective Bidders and that the declaration shall be executed by such persons, firm, association, or corporation under penalty of perjury under the laws of the United States. Therefore, by including the Non-collusion Declaration as part of the signed bid Proposal, the Bidder is deemed to have certified and agreed to the requirements of the Declaration. 1-02.8(2) Lobbying Certification Section 319 of Public Law 101-121 prohibits payment of Federal Funds for contract lobbying by the Contractor and any Subcontractor or lower tier subcontractor whose contract exceeds $100,000. A Certification for Federal-Aid Contracts (WSDOT Form 272-040) is provided in the Proposal Form for Contracts exceeding $100,000 to address this requirement. By signing the proposal, the Bidder will be deemed to have signed and agreed to the conditions and requirements of the Certification for Federal-Aid Contracts. The Contractor shall ensure that a Certification for Federal-Aid Contracts (WSDOT Form 272-040) is included in every contract with any Subcontractor or lower tier subcontractor whose contract exceeds $100,000. By signing the contract any Subcontractor or lower tier subcontractor will be deemed to have signed and agreed to the conditions and requirements of the Certification for Federal-Aid Contracts. The Contractor shall keep evidence in their files that such Subcontractor or lower tier subcontractor has committed to this requirement. Section 319 of Public Law 101-121 also provides that, if any funds other than Federal appropriated funds have been paid or will be paid to any person for influencing or attempting to influence an officer or employee of any Federal agency, a Member of Congress, an officer or employee of Congress, or an employee of a Member of Congress in connection with this Federal Contract, grant, loan, or cooperative agreement, the Contractor shall complete and submit to the Contracting Agency the Standard Form LLL, DISCLOSURE OF LOBBYING ACTIVITIES, in accordance with the instructions Page 1-18 2020 Standard Specifications M 41-10 1-02 Bid Procedures and Conditions on the form. Any Subcontractor or lower tier subcontractor whose contract exceeds $100,000 shall disclose in the same manner as the Contractor, except that, Standard Form LLL shall be submitted to the Contractor for processing to the Contracting Agency. Audits will be conducted to ensure compliance with this section. The Certification for Federal-Aid Contracts (WSDOT Form 272-040) may be reproduced from the Proposal form. The disclosure form is available from the Washington State Department of Transportation’s Contract Ad and Award Office, Transportation Building, Olympia, WA 98504. 1-02.9 Delivery of Proposal For projects scheduled for Bid opening in Olympia, the Proposal shall be sealed and submitted in the envelope provided with it to the address provided below or shall be submitted electronically via Trns∙Port Expedite® software and BidExpress®. The Bidder shall fill in all blanks on this envelope to ensure proper handling and delivery. Bids are to be received no later than until 11:00:59 A.M. Pacific time on the date of Bid opening: Washington State Department of Transportation Room 2D20 310 Maple Park Avenue SE Olympia WA 98501-2361 For projects scheduled for Bid opening in other locations, the Proposal shall be sealed and submitted in the envelope provided with it at the location and time identified in the Special Provisions. The Bidder shall fill in all blanks on this envelope to ensure proper handling and delivery. Proposals that are received as required will be publicly opened and read as specified in Section 1-02.12. The Contracting Agency will not open or consider any Proposal when the Proposal or Bid deposit is received after the time specified for receipt of Proposals or received in a location other than that specified for receipt of Proposals unless an emergency or unanticipated event interrupts normal work processes of the Contracting Agency so that Proposals cannot be received. If an emergency or unanticipated event interrupts normal work processes of the Contracting Agency so that Proposals cannot be received at the office designated for receipt of bids as specified in Section 1-02.12 the time specified for receipt of the Proposal will be deemed to be extended to the same time of day specified in the solicitation on the first work day on which the normal work processes of the Contracting Agency resume. When a Bid deposit is furnished in a physical format as specified in Section 1-02.7 the Bid deposit shall be submitted in a sealed envelope marked as “BID SUPPLEMENT” and with the Bidder’s company name, project title, and Bid date. 2020 Standard Specifications M 41-10 Page 1-19 Bid Procedures and Conditions 1-02 1-02.10 Withdrawing, Revising, or Supplementing Proposal After submitting a physical Bid Proposal to the Contracting Agency, the Bidder may withdraw, revise, or supplement it if: 1. The Bidder submits a written request signed by an authorized person, and 2. The Contracting Agency receives the request before the time set for receipt of Proposals. The original physical Bid Proposal may be supplemented, or revised and resubmitted as the official Bid Proposal if the Contracting Agency receives it before the time set for receipt of Proposals. Faxed Bid revisions and supplements will be accepted only if they are submitted in accordance with the “Example Format for Facsimile Bid Changes” instructions posted on the WSDOT website at www.wsdot.wa.gov/biz/contaa/bulletin. Unless specifically allowed in the Contract, emailed requests to withdraw, revise, or supplement a Proposal are not acceptable. The Contracting Agency is not responsible fordelayed, partial, failed, illegible, or partially legible FAX document transmissions, and such documents may be rejected as incomplete at the Bidder’s risk. The Contracting Agency will not accept requests to revise or withdraw electronic Bid Proposals. Such requests shall be furnished directly to BidExpress® and in accordance with their terms and conditions. 1-02.11 Combination and Multiple Proposals A project may be organized for Bidding and construction by various methods to enable proposals to be submitted for combined projects or for the construction method specified. The Contracting Agency reserves the right to Award combined or separate Bids or by such other method deemed most advantageous to the Contracting Agency. Only those combined Bids specifically prescribed in the project Special Provisions will be accepted. If contracts are Awarded for combinations of projects, separate contracts will be written for each project included in the combination. A Bidder submitting more than one Proposal at a letting may attach one of the following statements to each Proposal: “We prefer to be Awarded not more than (Number) Contracts for projects for which we have submitted Bids at this letting;” or “We prefer to be Awarded Contracts of a total value of not more than $____ for projects for which we have submitted Bids at this letting”. Such attachments will not make the Proposals irregular. The Contracting Agency will Award each Contract to the lowest responsible Bidder but will consider such attachment in determining the responsibility of the Bidder to perform each Contract for which a statement has been attached. Page 1-20 2020 Standard Specifications M 41-10 1-02 Bid Procedures and Conditions 1-02.12 Public Opening of Proposals Proposals will be opened and publicly read at the time indicated in the call for Bids unless the Bid opening has been delayed or canceled. Bidders, their authorized agents, and other interested parties are invited to be present. If an emergency or unanticipated event interrupts normal work processes of the Contracting Agency so that Proposals cannot be opened at the time indicated in the call for Bids the time specified for opening of Proposals will be deemed to be extended to the same time of day on the first work day on which the normal work processes of the Contracting Agency resume. 1-02.13 Irregular Proposals 1. A Proposal will be considered irregular and may be rejected if: a. The Bidder is not prequalified; b. The Bidder adds provisions reserving the right to reject or accept the Award, or enter into the Contract; c. A price per unit cannot be determined from the Bid Proposal; d. The Proposal form is not properly executed; e. The Bidder fails to submit or properly complete a Subcontractor list, if applicable, as required in Section 1-02.6; f. The Bidder fails to submit or properly complete an Underutilized Disadvantaged Business Enterprise Utilization Certification, if applicable, as required in Section 1-02.6; g. The Bidder fails to submit written confirmation from each UDBE firm listed on the Bidder’s completed Underutilized Disadvantaged Business Enterprise Utilization Certification that they are in agreement with the Bidder’s UDBE participation commitment, if applicable, as required in Section 1-02.6, or if the written confirmation that is submitted fails to meet the requirements of the Special Provisions; h. The Bidder fails to submit Underutilized Disadvantaged Business Enterprise Good Faith Effort documentation, if applicable, as required in Section 1-02.6, or if the documentation that is submitted fails to demonstrate that a Good Faith Effort to meet the Condition of Award was made; i. The Bidder fails to submit a UDBE Bid Item Breakdown form, if applicable, as required in Section 1-02.6, or if the documentation that is submitted fails to meet the requirements of the Special Provisions; j. The Bidder fails to submit UDBE Trucking Credit Forms, if applicable, as required in Section 1-02.6, or if the documentation that is submitted fails to meet the requirements of the Special Provisions; or k. The Bid Proposal does not constitute a definite and unqualified offer to meet the material terms of the Bid invitation. 2020 Standard Specifications M 41-10 Page 1-21 Bid Procedures and Conditions 1-02 2. A Proposal may be considered irregular and may be rejected if: a. The Proposal does not include a unit price for every Bid item; b. Any of the unit prices are excessively unbalanced (either above or below the amount of a reasonable Bid) to the potential detriment of the Contracting Agency; c. The authorized Proposal Form furnished by the Contracting Agency is not used or is altered; d. The completed Proposal form contains any unauthorized additions, deletions, alternate Bids, or conditions; e. Receipt of Addenda is not acknowledged; f. A member of a joint venture or partnership and the joint venture or partnership submit Proposals for the same project (in such an instance, both Bids may be rejected); or g. If Proposal form entries are not made in ink. 1-02.14 Disqualification of Bidders A Bidder may be deemed not responsible and the Proposal rejected if: 1. More than one Proposal is submitted for the same project from a Bidder under the same or different names; 2. Evidence of collusion exists with any other Bidder. Participants in collusion will be restricted from submitting further Bids; 3. A Bidder is not prequalified for the Work or to the full extent of the Bid; 4. An unsatisfactory performance record exists based on past or current Contracting Agency Work; 5. There is uncompleted work (Contracting Agency or otherwise) which might hinder or prevent the prompt completion of the Work Bid upon; 6. The Bidder failed to settle bills for labor or materials on past or current Contracts; 7. The Bidder has failed to complete a written public contract or has been convicted of a crime arising from a previous public contract; 8. The Bidder is unable, financially or otherwise, to perform the Work; 9. A Bidder is not authorized to do business in the state of Washington; or 10. There are any other reasons deemed proper by the Contracting Agency. Page 1-22 2020 Standard Specifications M 41-10 1-02 Bid Procedures and Conditions 1-02.15 Pre-Award Information Before Awarding any Contract, the Contracting Agency may require one or more of these items or actions of the apparent lowest responsible Bidder: 1. A complete statement of the origin, composition, and manufacture of any or all materials to be used; 2. Samples of these materials for quality and fitness tests; 3. A progress schedule (in a form the Contracting Agency requires) showing the order of and time required for the various phases of the Work; 4. A breakdown of costs assigned to any Bid item; 5. Attendance at a conference with the Engineer or representatives of the Engineer; or 6. Any other information or action taken that is deemed necessary to ensure that the Bidder is the lowest responsible Bidder. 2020 Standard Specifications M 41-10 Page 1-23 Award and Execution of Contract 1-03 1-03 Award and Execution of Contract 1-03.1 Consideration of Bids After opening and reading Proposals, the Contracting Agency will check them for correctness of extensions of the prices per unit and the total price. If a discrepancy exists between the price per unit and the extended amount of any Bid item, the price per unit will control. The total of extensions, corrected where necessary, will be used by the Contracting Agency for Award purposes and to fix the amount of the Contract Bond. The right is reserved by the Contracting Agency to waive informalities in the bidding, accept a Proposal of the lowest responsible Bidder, reject any or all Bids, republish the call for Bids, revise or cancel the Work, or require the Work to be done in another way if the best interest of the Contracting Agency is served. A Bidder who wishes to claim error after the Bids have been publicly opened and read as required by RCW 47.28.090 shall promptly notify the Contracting Agency that an error occurred. The Bidder shall submit a notarized affidavit or declaration under penalty of perjury signed by the Bidder and accompanied by the work sheets used in the preparation of the Bid, requesting relief from the responsibilities of Award. The affidavit or declaration shall describe the specific error(s) and certify that the work sheets are the ones used in preparing the Bid. The affidavit or declaration shall be submitted no later than 5:00 p.m. on the first business day after Bid opening or the claim will not be considered. The Contracting Agency will review the affidavit or declaration and the certified work sheets to determine the validity of the claimed error and if the error is of the kind for which the law allows relief from forfeiture of the Bid deposit. If the Contracting Agency concurs in the claim of error and determines that the error is of the kind which allows relief from forfeiture, the Bidder will be relieved of responsibility and the Bid deposit of the Bidder will be returned. If the Contracting Agency does not concur in the error or determines that the error is not the kind for which the law allows relief, the Contracting Agency may Award the Contract and if the Bidder refuses to execute the Contract, the Bidder’s Bid deposit shall be forfeited as required by RCW 47.28.100. 1-03.1(1) Identical Bid Totals After opening Bids, if two or more lowest responsive Bid totals are exactly equal, then the tie-breaker will be determined by drawing as described in this section. Two or more slips of paper will be marked as follows: one marked “Winner” and the other(s) marked “unsuccessful”. The slips will be folded to make the marking unseen. The slips will be placed inside a box. One authorized representative of each Bidder shall draw a slip from the box. Bidders shall draw in alphabetic order by the name of the firm as registered with the Washington State Department of Licensing. The slips shall be unfolded and the firm with the slip marked “Winner” will be determined to be the successful Bidder and eligible for Award of the Contract. Only those Bidders who submitted a Bid total that is exactly equal to the lowest responsive Bid are eligible to draw. Page 1-24 2020 Standard Specifications M 41-10 1-03 Award and Execution of Contract 1-03.2 Award of Contract Normally, Contract Award or Bid rejection will occur within 45 calendar days after Bid opening. If the lowest responsible Bidder and the Contracting Agency agree, this deadline may be extended. If they cannot agree on an extension by the 45 calendar day deadline, the Contracting Agency reserves the right to Award the Contract to the next lowest responsible Bidder or reject all Bids. The Contracting Agency will notify the successful Bidder of the Contract Award in writing. 1-03.3 Execution of Contract Within 20 calendar days after the Award date, the successful Bidder shall return the signed Contracting Agency-prepared Contract, an insurance certification as required by Section 1-07.18, a satisfactory bond as required by law and Section 1-03.4, the Transfer of Coverage form for the Construction Stormwater General Permit with sections I, III, and VIII completed when provided, and shall be registered as a contractor in the state of Washington. Until the Contracting Agency executes a Contract, no Proposal shall bind the Contracting Agency nor shall any Work begin within the project limits or within Contracting Agency- furnished sites. The Contractor shall bear all risks for any Work begun outside such areas and for any materials ordered before the Contract is executed by the Contracting Agency. If the Bidder experiences circumstances beyond their control that prevents return of the Contract documents within 20 calendar days after the Award date, the Contracting Agency may grant up to a maximum of 20 additional calendar days for return of the documents, provided the Contracting Agency deems the circumstances warrant it. 1-03.4 Contract Bond The successful Bidder shall provide an executed Contract Bond for the full Contract amount. This Contract Bond shall: 1. Be on a Contracting Agency-furnished form; 2. Be signed by an approved Surety (or Sureties) that: a. Is registered with the Washington State Insurance Commissioner; and b. Appears on the current Authorized Insurance List in the State of Washington published by the Office of the Insurance Commissioner, 3. Be conditioned upon the faithful performance of the Contract by the Contractor within the prescribed time; 4. Be conditioned upon the payment of taxes, increases, and penalties incurred on the project under titles 50, 51, and 82 RCW; and 2020 Standard Specifications M 41-10 Page 1-25 Award and Execution of Contract 1-03 5. Guarantee that the Surety shall indemnify, defend, and protect the Contracting Agency against any claim of direct or indirect loss resulting from the failure: a. Of the Contractor (or any of the employees, Subcontractors, or lower tier subcontractors of the Contractor) to faithfully perform the Contract; or b. Of the Contractor (or the Subcontractors or lower tier subcontractors of the Contractor) to pay all laborers, mechanics, Subcontractors, lower tier subcontractors, material person, or any other person who provides supplies or provisions for carrying out the Work. The Contracting Agency may require Sureties or Surety companies on the Contract Bond to appear and qualify themselves. Whenever the Contracting Agency deems the Surety or Sureties to be inadequate, it may, upon written demand, require the Contractor to furnish additional Surety to cover any remaining Work. Until the added Surety is furnished, payments on the Contract will stop. 1-03.5 Failure to Execute Contract Failure to return the insurance certification and bond with the signed Contract as required in Section 1-03.3, or failure to provide Disadvantaged, Minority or Women’s Business Enterprise information if required in the Contract, or failure or refusal to sign the Contract, or failure to register as a contractor in the state of Washington, or failure to return the completed Transfer of Coverage for the Construction Stormwater General Permit to the Contracting Agency when provided shall result in forfeiture of the proposal bond or deposit of this Bidder. If this should occur, the Contracting Agency may then Award the Contract to the second lowest responsible Bidder or reject all remaining Bids. If the second lowest responsible Bidder fails to return the required documents as stated above within the time provided after Award, the Contract may then be Awarded successively in a like manner to the remaining lowest responsible Bidders until the above requirements are met or the remaining Proposals are rejected. 1-03.6 Return of Bid Deposit When Proposals have been examined and corrected as necessary, proposal bonds and deposits accompanying Proposals ineligible for further consideration will be returned. All other proposal bonds and deposits will be held until the Contract has been properly executed. When the Contract has been properly executed, all remaining deposits or bonds, except those subject to forfeiture, will be returned. 1-03.7 Judicial Review Any decision made by the Contracting Agency regarding the Award and execution of the Contract or Bid rejection shall be conclusive subject to the scope of judicial review permitted under Washington Law. Such review, if any, shall be timely filed in the Superior Court of Thurston County, Washington. Page 1-26 2020 Standard Specifications M 41-10 1-04 Scope of the Work 1-04 Scope of the Work 1-04.1 Intent of the Contract The intent of the Contract is to prescribe a complete Work. Omissions from the Contract of details of Work that are necessary to carry out the intent of the Contract shall not relieve the Contractor from performing the omitted Work. 1-04.1(1) Bid Items Included in the Proposal The Contractor shall provide all labor, materials, tools, equipment, transportation, supplies, and incidentals required to complete all Work for the items included in the Proposal. 1-04.1(2) Bid Items Not Included in the Proposal When the Contract specifies Work that has no Bid item, and the Work is not specified as being included with or incidental to other Bid items, an equitable adjustment will be made in accordance with Section 1-04.4 unless that Work is customarily considered as incidental to other items. 1-04.2 Coordination of Contract Documents, Plans, Special Provisions, Specifications, and Addenda The complete Contract includes these parts: the Contract Form, Bidder’s completed Proposal Form, Contract Plans, Contract Provisions, Standard Specifications, Standard Plans, Addenda, various certifications and affidavits, supplemental agreements, change orders, and subsurface boring logs (if any). These parts complement each other in describing a complete Work. Any requirement in one part binds as if stated in all parts. The Contractor shall provide any Work or materials clearly implied in the Contract even if the Contract does not mention it specifically. Any inconsistency in the parts of the Contract shall be resolved by following this order of precedence (e.g., 1 presiding over 2, 3, 4, 5, 6, and 7; 2 presiding over 3, 4, 5, 6, and 7; and so forth): 1. Addenda, 2. Proposal Form, 3. Special Provisions, 4. Contract Plans, 5. Amendments to the Standard Specifications, 6. Standard Specifications, and 7. Standard Plans. On the Contract Plans, Working Drawings, and Standard Plans, figured dimensions shall take precedence over scaled dimensions. 2020 Standard Specifications M 41-10 Page 1-27 Scope of the Work 1-04 This order of precedence shall not apply when Work is required by one part of the Contract but omitted from another part or parts of the Contract. The Work required in one part must be furnished even if not mentioned in other parts of the Contract. Whenever reference is made in these Specifications or the Special Provisions to codes, rules, specifications, and standards, the reference shall be construed to mean the code, rule, specification, or standard that is in effect on the Bid advertisement date, unless otherwise stated or as required by law. If any part of the Contract requires Work that does not include a description for how the Work is to be performed, the Work shall be performed in accordance with standard trade practice(s). For purposes of the Contract, a standard trade practice is one having such regularity of observance in the trade as to justify an expectation that it will be observed by the Contractor in doing the Work. In case of any ambiguity or dispute over interpreting the Contract, the Engineer’s decision will be final as provided in Section 1-05.1. 1-04.3 Reference Information Reference Information provided to the Contractor is not part of the Contract. The Contracting Agency does not guarantee the accuracy of the Reference Information and is not responsible for the content of the Reference Information in any manner. Any use of Reference Information by the Contractor is done solely at the Contractor’s risk. If a document that is provided as reference information contains material also included as a part of the Contract, that portion of the document shall be considered a part of the Contract and not as Reference Information. 1-04.4 Changes The Engineer reserves the right to make, 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. Among others, these changes and alterations may include: 1. Deleting any part of the Work. 2. Increasing or decreasing quantities. 3. Altering Specifications, designs, or both. 4. Altering the way the Work is to be done. 5. Adding new Work. 6. Altering facilities, equipment, materials, services, or sites, provided by the Contracting Agency. 7. Ordering the Contractor to speed up or delay the Work. Page 1-28 2020 Standard Specifications M 41-10 1-04 Scope of the Work The Engineer will issue a written change order for any change unless the remainder of this section provides otherwise. If the alterations or changes in quantities significantly change the character of the Work under the Contract, whether or not changed by any such different quantities or alterations, an adjustment, excluding loss of anticipated profits, 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. The term significant change shall be construed to apply only to the following circumstances: A. When the character of the Work as altered differs materially in kind or nature from that involved or included in the original proposed construction; or B. When an item of Work, as defined elsewhere in the Contract, is increased in excess of 125 percent or decreased below 75 percent of the original Contract quantity. For the purpose of this Section, an item of Work will be defined as any item that qualifies for adjustment under the provisions of Section 1-04.6. For item 1, an equitable adjustment for deleted Work will be made as provided in Section 1-09.5. For item 2, if the actual quantity of any item, exclusive of added or deleted amounts included in agreed change orders, increases or decreases by more than 25 percent from the original Plan quantity, the unit Contract prices for that item may be adjusted in accordance with Section 1-04.6. For any changes except item 1 (deleted Work) or item 2 (increasing or decreasing quantities), the Engineer will determine if the change should be paid for at unit Contract price(s). If the Engineer determines that the change increased or decreased the Contractor’s costs or time to do any of the Work including unchanged Work, the Engineer will make an equitable adjustment to the Contract. The equitable adjustment will be by agreement with the Contractor. However, if the parties are unable to agree, the Engineer will determine the amount of the equitable adjustment in accordance with Section 1-09.4 and adjust the time as the Engineer deems appropriate. Extensions of time will be evaluated in accordance with Section 1-08.8. The Engineer’s decision concerning equitable adjustment and extension of time shall be final as provided in Section 1-05.1. The Contractor shall proceed with the Work upon receiving: 1. A written change order approved by the Engineer, or 2. An oral order from the Engineer before actually receiving the written change order. Within 14 calendar days of delivery of the change order the contractor shall endorse and return the change order, request an extension of time for endorsement or respond in accordance with Section 1-04.5. The Contracting Agency may unilaterally process the change order if the Contractor fails to comply with these requirements. Changes 2020 Standard Specifications M 41-10 Page 1-29 Scope of the Work 1-04 normally noted on field stakes or variations from estimated quantities, except as provided in subparagraph A or B above, will not require a written change order. These changes shall be made at the unit prices that apply. The Contractor shall respond immediately to changes shown on field stakes without waiting for further notice. The Contractor shall obtain written consent of the Surety or Sureties if the Engineer requests such consent. 1-04.4(1) Minor Changes Payments or credits for changes amounting to $25,000 or less may be made under the Bid item “Minor Change”. At the discretion of the Contracting Agency, this procedure for Minor Changes may be used in lieu of the more formal procedure as outlined in Section 1-04.4, Changes. The Contractor will be provided a copy of the completed order for Minor Change. The agreement for the Minor Change will be documented by signature of the Contractor, or notation of verbal agreement. If the Contractor is in disagreement with anything required by the order for Minor Change, the Contractor may protest the order as provided in Section 1-04.5. Payments or credits will be determined in accordance with Section 1-09.4. For the purpose of providing a common Proposal for all Bidders, the Contracting Agency has entered an amount for “Minor Change” in the Proposal to become a part of the total Bid by the Contractor. 1-04.4(2) Value Engineering Change Proposal (VECP) 1-04.4(2)A General A VECP is a Contractor proposed change to the Contract Provisions which will accomplish the projects functional requirements in a manner that is equal to or better than the requirements in the Contract. The VECP may be: (1) at a less cost or time, or (2) either no cost savings or a minor increase in cost with a reduction in Contract time. The net savings or added costs to the Contract Work are shared by the Contractor and Contracting Agency. The Contractor may submit a VECP for changing the Plans, Specifications, or other requirements of the Contract. The Engineer’s decision to accept or reject all or part of the proposal is final and not subject to arbitration under the arbitration clause or otherwise subject to litigation. The VECP shall meet all of the following: 1. Not adversely affect the long term life cycle costs. 2. Not adversely impact the ability to perform maintenance. 3. Provide the required safety and appearance. 4. Provide substitution for deleted or reduced Condition of Award Work, Apprentice Utilization and Training. Page 1-30 2020 Standard Specifications M 41-10 1-04 Scope of the Work VECPs that provide a time reduction shall meet the following requirements: 1. Time saving is a direct result of the VECP. 2. Liquidated damages penalties are not used to calculate savings. 3. Administrative/overhead cost savings experienced by either the Contractor or Contracting Agency as a result of time reduction accrue to each party and are not used to calculate savings. 1-04.4(2)B VECP Savings 1-04.4(2)B1 Proposal Savings The incentive payment to the Contractor shall be one-half of the net savings of the proposal calculated as follows: 1. (gross cost of deleted work) – (gross cost of added work) = (gross savings) 2. (gross savings) – (Contractor’s engineering costs) – (Contracting Agency’s costs) = (net savings) 3. (net savings) / 2 = (incentive pay) The Contracting Agency’s costs shall be the actual consultant costs billed to the Contracting Agency and in-house costs. Costs for personnel assigned to the Engineer’s office shall not be included. 1-04.4(2)B2 Added Costs to Achieve Time Savings The cost to achieve the time savings shall be calculated as follows: 1. (cost of added work) + (Contractor’s engineering costs - Contracting Agency’s engineering costs) = (cost to achieve time savings) 2. (cost to achieve time savings) / 2 = (Contracting Agency’s share of added cost) If the timesaving proposal also involves deleting work and, as a result, creates a savings for the Contracting Agency, then the Contractor shall also receive one-half of the savings realized through the deletion. 1-04.4(2)C VECP Approval 1-04.4(2)C1 Concept Approval The Contractor shall submit a written proposal to the Engineer for consideration. The proposal shall contain the following information: 1. An explanation outlining the benefit provided by the change(s). 2. A narrative description of the proposed change(s). If applicable, the discussion shall include a demonstration of functional equivalency or a description of how the proposal meets the original contract scope of work. 2020 Standard Specifications M 41-10 Page 1-31 Scope of the Work 1-04 3. A cost discussion estimating any net savings. Savings estimates will generally follow the outline below under the section, “Proposal Savings”. 4. A statement providing the Contracting Agency with the right to use all or any part of the proposal on future projects without future obligation or compensation. 5. A statement acknowledging and agreeing that the Engineer’s decision to accept or reject all or part of the proposal is final and not subject to arbitration under the arbitration clause or otherwise be subject to claims or disputes. 6. A statement giving the dates the Engineer must make a decision to accept or reject the conceptual proposal, the date that approval to proceed must be received, and the date the work must begin in order to not delay the contract. If the Contracting Agency does not approve the VECP by the date specified by the Contractor in their proposal the VECP will be deemed rejected. 7. The submittal will include an analysis on other Work that may have costs that changed as a result of the VECP. Traffic control and erosion control shall both be included in addition to any other impacted Work. After review of the proposal, the Engineer will respond in writing with acceptance or rejection of the concept. This acceptance shall not be construed as authority to proceed with any change contract work. Concept approval allows the Contractor to proceed with the Work needed to develop final plans and other information to receive formal approval and to support preparation of a change order. 1-04.4(2)C2 Formal Approval The Contractor’s submittal to the Engineer for formal approval shall include the following: 1. Deleted Work – Include the calculated quantities of unit price Work to be deleted. Include the proposed partial prices for portions of lump sum Work deleted. For deletion of force account items include the time and material estimates. 2. Added Work – Include the calculated quantities of unit price Work to be added, either by original unit Contract prices or by new, negotiated unit prices. For new items of Work include the quantities and proposed prices. 3. Contractor’s Engineering Costs – Submit the labor costs for the engineering to develop the proposal; costs for Contractor employees utilized in contract operations on a regular basis shall not be included. 4. Schedule Analysis – If the VECP is related to time savings, the Contractor shall submit a partial progress schedule showing the changed Work. The submittal shall also include a discussion comparing the partial progress schedule with the approved progress schedule for the project. 5. Working Drawings – Type 3 Working Drawings shall be submitted; those drawings which require engineering shall be a Type 3E. Page 1-32 2020 Standard Specifications M 41-10 1-04 Scope of the Work Formal approval of the proposal will be documented by issuance of a change order. The VECP change order will contain the following statements which the Contractor agrees to by signing the change order: 1. The Contractor accepts design risk of all features, both temporary and permanent, of the changed Work. 2. The Contractor accepts risk of constructability of the changed Work. 3. The Contractor provides the Contracting Agency with the right to use all or any part of the proposal on future projects without further obligation or compensation. VECP change orders will contain separate pay items for the items that are applicable to the Proposal. These are as follows: 1. Deleted Work. 2. Added Work. 3. The Contractor’s engineering costs, reimbursed at 100 percent of the Contractor’s cost. 4. Incentive payment to the Contractor. When added Work costs exceed Deleted Work costs, but time savings make a viable proposal, then items 3 and 4 above are replaced with the following: 3. The Contracting Agency’s share of added cost to achieve time savings. 4. The Contractor’s share of savings from deleted Work. 1-04.4(2)C3 Authority to Proceed with Changed Work The authority for the Contractor to proceed with the VECP Work will be provided by one of the following options: 1. Execution of the VECP change order, or 2. At the Contractor’s request the Contracting Agency may provide approval by letter from the Engineer for the Work to proceed prior to execution of a change order. All of the risk for proceeding with the VECP shall be the responsibility of the Contractor. Additionally, the following criteria are required to have been met: a. Concept approval has been granted by the Contracting Agency. b. All design reviews and approvals have been completed, including plans and specifications. c. The Contractor has guaranteed, in writing, the minimum savings to the Contracting Agency. 2020 Standard Specifications M 41-10 Page 1-33 Scope of the Work 1-04 1-04.5 Procedure and Protest by the Contractor The Contractor accepts all requirements of a change order by: (1) endorsing it, (2) writing a separate acceptance, (3) not responding within the allotted time as outlined in Section 1-04.4, or (4) not protesting in the way this section provides. A change order that is not protested as provided in this section shall be full payment and final settlement of all claims for Contract time and for all costs of any kind, including costs of delays, related to any Work either covered or affected by the change. By not protesting as this section provides, the Contractor also waives any additional entitlement and accepts from the Engineer any written or oral order (including directions, instructions, interpretations, and determinations). If in disagreement with anything required in a change order, another written order, or an oral order from the Engineer, including any direction, instruction, interpretation, or determination by the Engineer, the Contractor shall: 1. Immediately give a signed written notice of protest to the Engineer or the Engineer’s field Inspectors before doing the Work; 2. Supplement the written protest within 14 calendar days with a written statement and supporting documents providing the following: a. The date and nature of the protested order, direction, instruction, interpretation or determination; b. A full discussion of the circumstances which caused the protest, including names of persons involved, time, duration and nature of the Work involved, and a review of the Plans and Contract Provisions referenced to support the protest; c. The estimated dollar cost, if any, of the protested Work and a detailed breakdown showing how that estimate was determined; d. An analysis of the progress schedule showing the schedule change or disruption if the Contractor is asserting a schedule change or disruption; and e. If the protest is continuing, the information required above shall be supplemented upon request by the Engineer until the protest is resolved. Throughout any protested Work, the Contractor shall keep complete records of extra costs and time incurred. The Contractor shall permit the Engineer access to these and any other records related to the protested Work as determined by the Engineer. The Engineer will evaluate all protests provided the procedures in this section are followed. If the Engineer determines that a protest is valid, the Engineer will adjust payment for Work or time by an equitable adjustment in accordance with Section 1-09.4. Extensions of time will be evaluated in accordance with Section 1-08.8. No adjustment will be made for an invalid protest. If the Engineer determines that the protest is invalid, that determination and the reasons for it will be provided in writing to the Contractor. The determination will be provided within 14 calendar days after receipt of the Contractor’s supplemental written statement Page 1-34 2020 Standard Specifications M 41-10 1-04 Scope of the Work (including any additional information requested by the Engineer to support a continuing protest) described in item 2 above. If the Contractor does not accept the Engineer’s determination then the Contractor shall pursue the dispute and claims procedures set forth in Section 1-09.11. In spite of any protest or dispute, the Contractor shall proceed promptly with the Work as the Engineer orders. By failing to follow the procedures of Sections 1-04.5 and 1-09.11, the Contractor completely waives any claims for protested Work. 1-04.6 Variation in Estimated Quantities Payment to the Contractor will be made only for the actual quantities of Work performed and accepted in conformance with the Contract. When the accepted quantity of Work performed under a unit item varies from the original Proposal quantity, payment will be at the unit Contract price for all Work unless the total accepted quantity of any Contract item, adjusted to exclude added or deleted amounts included in change orders accepted by both parties, increases or decreases by more than 25 percent from the original Proposal quantity. In that case, payment for Contract Work may be adjusted as described herein. The adjusted final quantity shall be determined by starting with the final accepted quantity measured after all Work under an item has been completed. From this amount, subtract any quantities included in additive change orders accepted by both parties. Then, to the resulting amount, add any quantities included in deductive change orders accepted by both parties. The final result of this calculation shall become the adjusted final quantity and the basis for comparison to the original Proposal quantity. 1. Increased Quantities – Either party to the Contract will be entitled to renegotiate the price for that portion of the adjusted final quantity in excess of 1.25 times the original Proposal quantity. The price for excessive increased quantities will be determined by agreement of the parties, or, where the parties cannot agree, the price will be determined by the Engineer based upon the actual costs to perform the Work, including reasonable markup for overhead and profit. 2. Decreased Quantities – Either party to the Contract will be entitled to an equitable adjustment if the adjusted final quantity of Work performed is less than 75 percent of the original Bid quantity. The equitable adjustment shall be based upon and limited to three factors: a. Any increase or decrease in unit costs of labor, materials or equipment, utilized for Work actually performed, resulting solely from the reduction in quantity; b. Changes in production rates or methods of performing Work actually done to the extent that the nature of the Work actually performed differs from the nature of the Work included in the original plan; and c. An adjustment for the anticipated contribution to unavoidable fixed cost and overhead from the units representing the difference between the adjusted final quantity and 75 percent of the original Plan quantity. 2020 Standard Specifications M 41-10 Page 1-35 Scope of the Work 1-04 The following limitations shall apply to renegotiated prices for increases and/or equitable adjustments for decreases: 1. The equipment rates shall be actual cost but shall not exceed the rates set forth in the AGC/WSDOT Equipment Rental Agreement (referred to in Section 1-09.6) that is in effect at the time the Work is performed. 2. No payment will be made for extended or unabsorbed home office overhead and field overhead expenses to the extent that there is an unbalanced allocation of such expenses among the Contract Bid items. 3. No payment for consequential damages or loss of anticipated profits will be allowed because of any variance in quantities from those originally shown in the Proposal form, Contract Provisions, and Contract Plans. 4. The total payment (including the adjustment amount and unit prices for Work performed) for any item that experiences an equitable adjustment for decreased quantity shall not exceed 75 percent of the amount originally Bid for the item. If the adjusted final quantity of any item does not vary from the quantity shown in the Proposal by more than 25 percent, then the Contractor and the Contracting Agency agree that all Work under that item will be performed at the original Contract unit price. When ordered by the Engineer, the Contractor shall proceed with the Work pending determination of the cost or time adjustment for the variation in quantities. The Contractor and the Contracting Agency agree that there will be no cost adjustment for decreases if the Contracting Agency has entered the amount for the item in the Proposal form only to provide a common Proposal for Bidders. 1-04.7 Differing Site Conditions (Changed Conditions) During the progress of the Work, if preexisting subsurface or latent physical conditions are encountered at the site, differing materially from those indicated in the Contract, or if preexisting 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 site conditions before they are disturbed and before the affected Work is performed. Upon written notification, the Engineer will investigate the conditions and if he/she determines 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 loss of anticipated profits, will be made and the Contract modified in writing accordingly. The Engineer will notify the Contractor of his/her 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. Page 1-36 2020 Standard Specifications M 41-10 1-04 Scope of the Work The equitable adjustment will be by agreement with the Contractor. However, if the parties are unable to agree, the Engineer will determine the amount of the equitable adjustment in accordance with Section 1-09.4. Extensions of time will be evaluated in accordance with Section 1-08.8. If the Engineer determines that different site conditions do not exist and no adjustment in costs or time is warranted, such determination shall be final as provided in Section 1-05.1. If there is a decrease in the costs or time required to perform the Work, failure of the Contractor to notify the Engineer of the differing site conditions shall not affect the Contracting Agency’s right to make an adjustment in the costs or time. No claim by the Contractor shall be allowed unless the Contractor has followed the procedures provided in Sections 1-04.5 and 1-09.11. 1-04.8 Progress Estimates and Payments Engineer-issued progress estimates or payments for any part of the Work shall not be used as evidence of performance or quantities. Progress estimates serve only as basis for partial payments. The Engineer may revise progress estimates any time before final acceptance. If the Engineer deems it proper to do so, changes may be made in progress estimates and in the final estimate. 1-04.9 Use of Buildings or Structures The Engineer will decide whether any building or Structure on the Right of Way may remain during the Work and whether the Contractor may use such a building or Structure. 1-04.10 Use of Materials Found on the Project With the Engineer’s written approval, the Contractor may use on the project: stone, gravel, sand, other materials from on-site excavation, or timbers removed in the course of the Work. Approval will not be granted if: 1. The excavated materials or timber fail to meet Contract requirements; 2. The excavated materials or timber are required for other use under the Contract; 3. The excavated materials are required for use as Selected Materials under Section 2-03.3(10); or 4. Such use is not in the best interests of the Contracting Agency as determined by the Engineer, whose decision shall be final as provided in Section 1-05.1. Any material disturbed by, but not used in, the Work shall be disposed of as provided elsewhere in the Contract or as ordered by the Engineer in accordance with Section 1-04.4. 2020 Standard Specifications M 41-10 Page 1-37 Scope of the Work 1-04 1-04.11 Final Cleanup The Contractor shall perform final cleanup as provided in this section to the Engineer’s satisfaction. The Engineer will not establish the Physical Completion Date until this is done. The Highway Right of Way, material sites, and all ground the Contractor occupied to do the Work shall be left neat and presentable. The Contractor shall: 1. Remove all rubbish, surplus materials, discarded materials, falsework, camp buildings, temporary structures, equipment, and debris; and 2. Deposit in embankments, or remove from the project, all unneeded, oversized rock left from grading, surfacing, or paving. The Contractor shall not remove warning, regulatory, or guide signs unless the Engineer approves. Page 1-38 2020 Standard Specifications M 41-10 1-05 Control of Work 1-05 Control of Work 1-05.1 Authority of the Engineer The Engineer shall be satisfied that all the Work is being done in accordance with the requirements of the Contract. The Contract and Specifications give the Engineer authority over the Work. Whenever it is so provided in this Contract, the decision of the Engineer shall be final: provided, however, that if an action is brought within the time allowed in this Contract challenging the Engineer’s decision, that decision shall be subject to the scope of judicial review provided in such cases under Washington case law. The Engineer’s decisions will be final on all questions including the following: 1. Quality and acceptability of materials and Work, 2. Measurement of unit price Work, 3. Acceptability of rates of progress on the Work, 4. Interpretation of Plans and Specifications, 5. Determination as to the existence of changed or differing site conditions, 6. Fulfillment of the Contract by the Contractor, 7. Payments under the Contract including equitable adjustment, 8. Suspension(s) of Work, 9. Termination of the Contract for default or public convenience, 10. Determination as to unworkable days, and 11. Approval of Working Drawings. The Engineer represents the Contracting Agency with full authority to enforce Contract requirements. If the Contractor fails to respond promptly to the requirements of the Contract or orders from the Engineer: 1. The Engineer may use Contracting Agency resources, other contractors, or other means to accomplish the Work; and 2. The Contracting Agency will not be obligated to pay the Contractor, and will deduct from the Contractor’s payments any costs that result when any other means are used to carry out the Contract requirements or Engineer’s orders. At the Contractor’s risk, the Engineer may suspend all or part of the Work according to Section 1-08.6. 2020 Standard Specifications M 41-10 Page 1-39 Control of Work 1-05 Nothing in these Specifications or in the Contract requires the Engineer to provide the Contractor with direction or advice on how to do the Work. If the Engineer approves or recommends any method or manner for doing the Work or producing materials, the approval or recommendation shall not: 1. Guarantee that following the method or manner will result in compliance with the Contract, 2. Relieve the Contractor of any risks or obligations under the Contract, or 3. Create any Contracting Agency liability. 1-05.2 Authority of Assistants and Inspectors The Engineer may appoint assistants and Inspectors to assist in determining that the Work and materials meet the Contract requirements. Assistants and Inspectors have the authority to reject defective material and suspend Work that is being done improperly, subject to the final decisions of the Engineer. Assistants and Inspectors are not authorized to accept Work, to accept materials, to issue instructions, or to give advice that is contrary to the Contract. Work done or material furnished which does not meet the Contract requirements shall be at the Contractor’s risk and shall not be a basis for a claim even if the Inspectors or assistants purport to change the Contract. Assistants and Inspectors may advise the Contractor of any faulty Work or materials or infringements of the terms of the Contract; however, failure of the Engineer or the assistants or Inspectors to advise the Contractor does not constitute acceptance or approval. 1-05.3 Working Drawings The Contract may require the Contractor to submit Working Drawings for the performance of the work. Working Drawings shall be submitted by the Contractor electronically to the Engineer in PDF format; drawing details shall be prepared in accordance with conventional detailing practices. If the PDF format is found to be unacceptable, at the request of the Engineer, the Contractor shall provide paper copies of the Working Drawings with drawings on 11 by 17 inch sheets and calculations/text on 8½ by 11 inch sheets. Working Drawings will be classified under the following categories: 1. Type 1 – Submitted for Contracting Agency information. Submittal must be received by the Contracting Agency a minimum of 7 calendar days before Work represented by the submittal begins. 2. Type 2 – Submitted for Contracting Agency review and comment. Unless otherwise stated in the Contract, the Engineer will require up to 20 calendar days from the date the Working Drawing is received until it is returned to the Contractor. The Contractor shall not proceed with the Work represented by the Working Drawing until comments from the Engineer have been addressed. Page 1-40 2020 Standard Specifications M 41-10 1-05 Control of Work 3. Type 2E – Same as a Type 2 Working Drawing with Engineering as described below. 4. Type 3 – Submitted for Contracting Agency review and approval. Unless otherwise stated in the Contract, the Engineer will require up to 30 calendar days from the date the Working Drawing is received until it is returned to the Contractor. The Contractor shall obtain the Engineer’s written approval before proceeding with the Work represented by the Working Drawing. 5. Type 3E – Same as a Type 3 Working Drawing with Engineering as described below. All Working Drawings shall be considered Type 3 Working Drawings except as specifically noted otherwise in the Contract. Unless designated otherwise by the Contractor, submittals of Working Drawings will be reviewed in the order they are received by the Engineer. In the event that several Working Drawings are received simultaneously, the Contractor shall specify the sequence in which they are to be reviewed. If the Contractor does not submit a review sequence for simultaneous Working Drawing submittals, the review sequence will be at the Engineer’s discretion. Working Drawings requiring Engineering, Type 2E and 3E, shall be prepared by (or under the direction of) a Professional Engineer, licensed under Title 18 RCW, State of Washington, and in accordance with WAC 196-23-020. Design calculations shall carry the Professional Engineer’s signature and seal, date of signature, and registration number on the cover page. The cover page shall also include the Contract number, Contract title and sequential index to calculation page numbers. If more than the specified number of calendar days is required for the Engineer’s review of any individual Working Drawing or resubmittal, an extension of time will be considered in accordance with Section 1-08.8. Review or approval of Working Drawings shall neither confer upon the Contracting Agency nor relieve the Contractor of any responsibility for the accuracy of the drawings or their conformity with the Contract. The Contractor shall bear all risk and all costs of any Work delays caused by rejection or nonapproval of Working Drawings. Unit Bid prices shall cover all costs of Working Drawings. 1-05.4 Conformity With and Deviations From Plans and Stakes The Special Provisions may require that the Contractor be contractually responsible for part or all of the project surveying. For survey requirements not the responsibility of the Contractor, the Engineer will lay out and set construction stakes and marks needed to establish the lines, grades, slopes, cross-sections, and curve superelevations. These stakes and marks will govern the Contractor’s Work. The Contractor shall take full responsibility for detailed dimensions, elevations, and slopes measured from them. All Work performed shall be in conformity with the lines, grades, slopes, cross-sections, superelevation data, and dimensions as shown in the Plans, or as staked. If the Plans, Special Provisions, or these Specifications, state specific tolerances, then the Work shall be performed within those limits. The Engineer’s decision on whether the Work is in conformity shall be final, as provided in Section 1-05.1. 2020 Standard Specifications M 41-10 Page 1-41 Control of Work 1-05 The Contractor shall not deviate from the approved Plans and Working Drawings unless the Engineer approves in writing. When the Contracting Agency is responsible for roadway surveying, and the Contractor trims the Subgrade with an automatic machine guided by reference lines, the Engineer will set control stakes for line and grade only once after grading is complete. To gain better control with unusual pavement widths or for other reasons, the Engineer may set more control stakes without added cost to the Contractor. The Contractor shall set reference lines from these control stakes for trimming Subgrade, for surfacing, and for controlling the paving machines. The Contractor shall work to preserve stakes, marks, and monuments set by the Engineer. The Contracting Agency will deduct from payments due the Contractor all costs to replace such stakes, marks, and monuments carelessly or willfully damaged or destroyed by the Contractor’s operation. The Contractor shall provide enough safe areas to permit the Engineer to set those points and elevations that are the responsibility of the Contracting Agency and to perform random checks of the surveying performed by the Contractor. The Contractor shall keep the Engineer informed of staking requirements to provide the Engineer with adequate time to set the stakes for which the Contracting Agency is responsible. Contractor requests for stakes shall be made at least 3 working days before the Engineer needs to begin the staking operation. 1-05.5 Tolerances Geometrical tolerances shall be measured from the points, lines, and surfaces defined in Contract documents. A plus (+) tolerance increases the amount or dimension to which it applies, or raises a deviation from level. A minus (-) tolerance decreases the amount or dimension to which it applies, or lowers a deviation from level. Where only one signed tolerance is specified (+ or -), there is no specified tolerance in the opposing direction. Tolerances shall not be cumulative. The most restrictive tolerance shall control. Tolerances shall not extend the Work beyond the Right of Way or other legal boundaries identified in the Contract documents. If application of tolerances causes the extension of the Work beyond the Right of Way or legal boundaries, the tolerance shall be reduced for that specific instance. Tolerances shall not violate other Contract requirements. If application of tolerances causes the Work to violate other Contract requirements, the tolerance shall be reduced for that specific instance. If application of tolerances causes conflicts with other components or aspects of the Work, the tolerance shall be reduced for that specific instance. Page 1-42 2020 Standard Specifications M 41-10 1-05 Control of Work 1-05.6 Inspection of Work and Materials The Engineer may inspect all Work and materials for conformity with Contract terms. To ensure the Engineer’s safety and access during these inspections, the Contractor shall provide any equipment needed, such as walkways, railings, ladders, and platforms. When the Engineer requests, the Contractor shall (without charge) provide samples of materials used or to be used in the Work. If the Contractor uses materials tested and approved for one project in an unrelated project, the Contracting Agency may deduct its testing and inspection costs from payments due the Contractor. The Engineer may order the Contractor to remove and replace, and bear the cost of doing so, any materials used without inspection. Any inspections, tests, measurements, or other actions by Contracting Agency employees serve only one purpose: to assure the Engineer that Work, materials, progress rate, and quantities comply with Contract terms. Such work by Contracting Agency employees shall not relieve the Contractor from doing any Contract-assigned Work or from determining whether Contract requirements are being met. The Contractor shall correct any substandard Work or materials. The Engineer will reject unsuitable Work or materials even though inspected or paid for in a progress estimate. If the Engineer requests, then the Contractor shall remove or uncover any area of the completed Work. After the Engineer inspects it, the Contractor shall restore the area to the standard the Contract requires. The Contractor shall bear the cost of uncovering, removing, and restoring the exposed Work: (a) if it proves unacceptable, or (b) if it was placed without authority or without due notice to the Engineer. The Contracting Agency will pay these costs by agreed price or by force account if the Work proves to be acceptable and the Contractor had performed the original Work with the authority of and due notice to the Engineer. The Contractor, if advised to do so by the Engineer, shall permit representatives from other agencies to inspect the Work when it is to be done: 1. On any railroad, utility, or facility of a public agency; or 2. To the satisfaction of any federal, state, or municipal agency. In any crushing or screening operation, the Contractor shall provide and install a mechanical sampler that: 1. Is automatic or semi-automatic; 2. Can safely and easily obtain representative samples of the materials being produced; 3. Can convey the samples to ground level in Contracting Agency-provided sacks; 4. Moves at an even rate through the full width of the materials stream falling from the discharge end of the belt, gate, or chute; 5. Is power driven during the material intercept cycle; and 6. Can be adjusted to take samples of about 100 pounds as often as the Engineer requires. 2020 Standard Specifications M 41-10 Page 1-43 Control of Work 1-05 No material from the crushing or screen operation will be accepted until after the Engineer has approved the design and operation of the sampling equipment. The Contractor shall bear all costs of providing the sampling equipment, the power to operate it, and the space for its use. 1-05.7 Removal of Defective and Unauthorized Work The Contracting Agency will not pay for unauthorized or defective Work. Unauthorized or defective Work includes: Work and materials that do not conform to Contract requirements; Work done beyond the lines and grades set by the Plans or the Engineer; and extra Work and materials furnished without the Engineer’s written approval. At the Engineer’s order, the Contractor shall immediately remedy, remove, replace, or dispose of unauthorized or defective Work or materials and bear all costs of doing so. 1-05.8 Vacant 1-05.9 Equipment Prior to mobilizing equipment on site, the Contractor shall thoroughly remove all loose dirt and vegetative debris from drive mechanisms, wheels, tires, tracks, buckets and undercarriage. The Engineer will reject equipment from the site until it returns clean. At the Engineer’s request, the Contractor shall provide an operating and maintenance manual for each model or type of mixing, placing, or processing equipment before using it in the Work. The Contractor shall also provide test instruments to confirm whether the equipment meets operating requirements, such as vibration rate, revolutions-per-minute, or any other requirements. The Contract may require automatically controlled equipment for some operations. If the automatic controls on such equipment fail, then the Contractor may operate the equipment manually for the remainder of that normal working day, provided the method of operation produces results otherwise meeting the Specifications. Continued operation of the equipment manually beyond this working day will be permitted only by specific authorization of the Engineer. The Engineer will reject equipment that repeatedly breaks down or fails to produce results within the required tolerances. The Contractor shall have no claim for additional payment or for extension of time due to rejection and replacement of any equipment. Upon completion of the Work, the Contractor shall completely remove all loose dirt and vegetative debris from equipment before removing it from the job site. Page 1-44 2020 Standard Specifications M 41-10 1-05 Control of Work 1-05.10 Guarantees The Contractor shall furnish to the Contracting Agency any guarantee or warranty furnished as a customary trade practice in connection with the purchase of any equipment, materials, or items incorporated into the project. 1-05.11 Final Inspection The Engineer will not make the final inspection until the physical Work required by the Contract, including final cleanup and all extra Work ordered by the Engineer, has been completed. The Physical Completion Date for the Contract will be determined as provided in Section 1-08.5. 1-05.12 Final Acceptance The Contractor must perform all the obligations under the Contract before a Completion Date and final acceptance can occur. Failure of the Contractor to perform all the obligations under the Contract shall not bar the Contracting Agency from unilaterally accepting the Contract as provided in Section 1-09.9. The Secretary accepts the completed Contract and the items of Work shown in the final estimate by signature of the Final Contract Voucher Certification. The date of that signature constitutes the acceptance date. Progress estimates or payments shall not be construed as acceptance of any Work under the Contract. The Contractor agrees that neither completion nor final acceptance shall relieve the Contractor of the responsibility to indemnify, defend, and protect the Contracting Agency against any claim or loss resulting from the failure of the Contractor (or the Subcontractors or lower tier subcontractors) to pay all laborers, mechanics, Subcontractors, materialpersons, or any other person who provides labor, supplies, or provisions for carrying out the Work or for any payments required for unemployment compensation under Title 50 RCW or for industrial insurance and medical aid required under Title 51 RCW. Final acceptance shall not constitute acceptance of any unauthorized or defective work or material. The Contracting Agency shall not be barred from requiring the Contractor to remove, replace, repair, or dispose of any unauthorized or defective work or material or from recovering damages for any such work or material. 2020 Standard Specifications M 41-10 Page 1-45 Control of Work 1-05 1-05.13 Superintendents, Labor, and Equipment of Contractor At all times, the Contractor shall keep at the Work site a set of the Plans, Specifications, Special Provisions, and Addenda. The Contractor shall devote the attention required to make reasonable progress on the Work and shall cooperate fully with the Engineer and Inspectors. Either the Contractor in person or an authorized representative shall remain on site whenever the Work is underway. Before the Work begins, the Contractor shall name in writing an experienced superintendent who understands the Contract and is able to supervise the Work. This superintendent shall have full authority to represent and act for the Contractor. Any superintendent who repeatedly fails to follow the Engineer’s written or oral orders, directions, instructions, or determinations, shall be subject to removal from the project. Upon the written request of the Engineer, the Contractor shall immediately remove such superintendent and name a replacement in writing. Competent supervisors experienced in the task being performed shall continuously oversee the Contract Work. At the Engineer’s written request, the Contractor shall immediately remove and replace any incompetent, careless, or negligent employee. Noncompliance with the Engineer’s request to remove and replace personnel at any level shall be grounds for terminating the Contract under the terms of Section 1-08.10. The Contractor shall keep all machinery and equipment in good, workable condition. It shall be adequate for its purpose and used by competent operators. The Engineer will rate the Contractor’s performance and Contract compliance in these categories: 1. Progress of Work, 2. Quality of Work, 3. Equipment, 4. Administration/Management/Supervision, and 5. Coordination and Control of Subcontractors. Whenever the Contracting Agency evaluates the Contractor’s prequalification under RCW 47.28.070, it will take these reports into account. Page 1-46 2020 Standard Specifications M 41-10 1-05 Control of Work 1-05.13(1) Emergency Contact List The Contractor shall submit an Emergency Contact List to the Engineer no later than 5 calendar days after the date the Contract is executed. The list shall include, at a minimum, the Contractor’s Project Manager, or equivalent, the Contractor’s Project Superintendent, the Erosion and Sediment Control (ESC) Lead, and the Traffic Control Supervisor. The list shall identify a representative with delegated authority to act as the emergency contact on behalf of the Contractor and include one or more alternates. The emergency contact shall be available upon the Engineer’s request at other than normal working hours. The Emergency Contact List shall include 24-hour telephone numbers for all individuals identified as emergency contacts or alternates. 1-05.14 Cooperation With Other Contractors The Contracting Agency may perform other work at or near the site, including any material site, with other forces than those of the Contractor. This work may be done with or without a contract. If such work takes place within or next to this project, the Contractor shall cooperate with all other contractors or forces. The Contractor shall carry out Work under this project in a way that will minimize interference and delay for all forces involved. The Engineer will resolve any disagreements that may arise among the contractors or the Contractor and the Contracting Agency over the method or order of doing the Work. The Engineer’s decision in these matters shall be final, as provided in Section 1-05.1. The coordination of the Work shall be taken into account by the Contractor as part of the site investigation in accordance with Section 1-02.4 and any resulting costs shall be incidental and included within the unit Bid prices in the Contract. 1-05.15 Method of Serving Notices Any written notice to the Contractor required under these Specifications may be served on the Contractor either personally or by mailing or by delivery to the last post office address known to the Engineer. All correspondence from the Contractor shall be directed to the Engineer. 2020 Standard Specifications M 41-10 Page 1-47 Control of Material 1-06 1-06 Control of Material 1-06.1 Approval of Materials Prior to Use Prior to use, the Contractor shall notify the Engineer of all proposed materials. The Contractor shall use the Qualified Product List (QPL), the Aggregate Source Approval (ASA) Database, or the Request for Approval of Material (RAM) form. All equipment, materials, and articles incorporated into the permanent Work: 1. Shall be new, unless the Special Provisions or Standard Specifications permit otherwise; 2. Shall meet the requirements of the Contract and be approved by the Engineer; 3. May be inspected or tested at any time during their preparation and use; and 4. Shall not be used in the Work if they become unfit after being previously approved. 1-06.1(1) Qualified Products List (QPL) The QPL is a listing of manufactured products that have been evaluated and determined suitable for use in Highway construction. If the Contractor elects to use the QPL, the most current list available at the time the product is proposed for use, shall be used. The QPL submittal shall be prepared by the Contractor in accordance with the instructions in the QPL and submitted to the Engineer prior to use. The QPL identifies the approved products, the applicable Specification Section, and the basis for acceptance at the project level. The listing is divided into two categories, “Approved” and “Conditionally Approved”. “Approved” products are denoted with an “A”. Those products may be accepted without additional sampling. “Conditionally Approved” products are denoted with a “CA”. The acceptance and use of these products is based upon additional job sampling and/or documentation. All additional acceptance actions need to be completed prior to the material being incorporated into the Work. The Contractor shall advise the Engineer of the intended items for use from the QPL by reference to the Contract Bid item. The use of listed products shall be restricted to the Standard Specification for which they are listed and fulfillment of the acceptance requirement defined in the QPL. Qualified products not conforming to the Specifications, not fulfilling the acceptance requirements, or improperly handled or installed, shall be replaced at the Contractor’s expense. To qualify for continued listing on the QPL, products may be sampled and tested for conformance to the Standard Specifications. The Contracting Agency reserves the right to make revisions to the QPL at any time. If there is a conflict between the QPL and the Contract, the provisions of the Contract shall take precedence over the QPL. The current QPL can be accessed online at www.wsdot.wa.gov/business/materialslab/QPL.htm. Page 1-48 2020 Standard Specifications M 41-10 1-06 Control of Material 1-06.1(2) Request for Approval of Material (RAM) The RAM shall be used when the Contractor elects not to use the QPL or the material is not listed in the QPL. The RAM shall be prepared by the Contractor in accordance with the instructions on Form 350-071 and submitted to the Engineer for approval before the material is incorporated into the Work. Approval of the material does not constitute acceptance of the material for incorporation into the Work. Additional acceptance actions as noted on the RAM need to be completed prior to the materials being incorporated into the Work. When requesting approval of an item that requires fabrication, both the fabricator and the manufacturer of the base material shall be identified on the RAM. 1-06.1(3) Aggregate Source Approval (ASA) Database The ASA database contains the results of WSDOT preliminary testing of aggregate sources as well as the results pertaining to the review of the aggregate source Quality Control Programs. Aggregate sources evaluated after January 1, 2021 shall have Quality Control Program compliant with QC 11 and QC 12. This database is used by the Contracting Agency to indicate the approval status of these aggregate sources for applications that require preliminary testing as defined in the Contract. The ASA ‘Aggregate Source Approval Report’ identifies the currently approved applications for each aggregate source listed. The acceptance and use of these aggregates is contingent upon additional job sampling and/or documentation. The ASA database can be accessed online at the agency website. Aggregates approved for applications on the ASA ‘Aggregate Source Approval Report’ not conforming to the Specifications, not fulfilling the acceptance requirements, or improperly handled or installed, shall be replaced at the Contractor’s expense. Aggregate materials that are not approved for use in the ASA data base may be sampled and tested by the Agency, for a specified use on a project, from the source or from a processed stockpile of the material and all cost for the sampling and testing will be deducted from the Contract. The Contractor agrees to authorize the Engineer to deduct the sampling and testing costs from any money due or coming due to the Contractor. Regardless of the status of the source, whether listed or not listed in the ASA database the source owner may be asked to provide testing results for toxicity in accordance with Section 9-03.21(1). 2020 Standard Specifications M 41-10 Page 1-49 Control of Material 1-06 1-06.1(4) Fabrication Inspection Expense In the event the Contractor elects to have items fabricated beyond 300 miles from Seattle, Washington, the Contracting Agency will deduct from monies due or that may become due to the Contractor all costs to perform plant approval and fabrication acceptance inspection for the items listed in Table 1 and costs for initial plant approval for items listed in Table 2. Plants currently listed on the QPL for the items shown in Table 1 and Table 2 in this section do not require plant approval. Table 1 Items Requiring Plant Approval and Fabrication Acceptance Inspection • Anchor Bolts (ASTM A449 & F1554 Grade 105) • Bridge Bearings (Cylindrical, Disc, Fabric Pad, Low Rise, Pin, Pendulum, and Spherical) • Cattle Guards • Coated Piling and Casing • Epoxy-Coated Reinforcing Steel • Fabricated/Welded Miscellaneous Metal Drainage Items: Grate Inlets, and Drop Inlets • Longitudinal Seismic Restrainers • Metal Bridge Railing and Handrail • Metal Castings for Concrete Drainage, electrical, and Utility Items • Modular Expansion Joints • Paint & Powder Coating Facilities for Table 1 items • Precast Concrete Bridge Deck Panels • Precast Concrete Catch Basins, Manholes, Inlets, Drywells, and Risers • Precast Concrete Drain, Perforated Underdrain, Culvert, Storm Sewer, and Sanitary Sewer Pipe • Precast Concrete Floor Panels • Precast Concrete Junction Boxes, Pull Boxes, Cable Vaults • Precast Concrete Marine Pier Deck Panels • Precast Concrete Pier Caps • Precast Concrete Retaining Walls, including Lagging Panels • Precast Concrete Roof Panels • Precast Concrete Structural Earth Walls, Noise Barrier Walls, Wall Panels, and Wall Stem Panels • Precast Concrete Traffic Barrier • Precast Concrete Vaults (Electrical, Utility, Drainage, etc.) • Precast Concrete Girders and Precast Bridge Components • Prestressed Concrete Girders • Prestressed Concrete Panels • Precast Reinforced Concrete Box Culverts • Precast Reinforced Concrete Split Box Culverts • Precast Reinforced Concrete Three Sided Structures • Prestressed Concrete Piles • Retrofit Guardrail Posts with Welded Base Plates • Signal Standards • Signing Material • Sign Structures – Cantilever, Sign Bridge, and Bridge Mounted, Roadside Type PLT/PLU • Soldier Piles • Steel Bridges and Steel Bridge Components • Steel Column Jackets • Steel Light Standards, and High Mast Light Poles • Strip Seal Expansion Joints • Structural Steel for Ferry Terminal Berthing, Pedestrian and Vehicle Loading Structures • Timber Bridges • Treated Timber and Lumber 6 inch by 6 inch or larger • Welded Structural Steel (Miscellaneous) Page 1-50 2020 Standard Specifications M 41-10 1-06 Control of Material Table 2 Items Requiring Initial Plant Approval Only • Epoxy Coating of Dowels and Tiebars for Concrete Pavement • Guardrail Posts and Blocks • Precast Concrete Blocks for Structural Earth Walls • Steel Pipe Piling The deductions for fabrication inspection costs will be as shown in the Payment Table below. Zone Place of Fabrication or Inspection Site Reduction in Payment 1 Within 300 airline miles from Seattle None* 2 Between 300 and 3,000 airline miles from Seattle $700.00 per inspection day** 3 Over 3,000 airline miles from Seattle $1,000 per inspection day,** but not less than $2,500 per trip *Fabrication inspection expense does not apply for initial acceptance inspection in Zone 1. Re-inspection of items due to unacceptable workmanship or scheduling errors made by the Contractor, fabricator, or facility applying protective coatings will be assessed at $60.00 per hour but not less than $120.00 per inspection. **An inspection day includes any calendar day or portion of a calendar day spent by one inspector inspecting, on standby, or traveling to and from, a place of fabrication. An additional cost per inspection day will be assessed for each additional inspector. Reimbursement will be assessed at $280.00 per day for weekends and holidays for each on site inspector in travel status, but not engaged in inspection or travel activities when fabrication activities are not taking place. Where fabrication of an item takes place in more than one zone, the reduction in payment will be computed on the basis of the entire item being fabricated in the farthest of zones where any fabrication takes place on that item. The rates for Zones 2 and 3 shall be applied for the full duration of time for all fabrication inspection activities, to include, but not be limited to: plant approvals, prefabrication meetings, fabrication, coatings, and final inspection. When an inspection is for more than one Contract the fabrication inspection costs shall be prorated as determined by the Engineer. 1-06.2 Acceptance of Materials 1-06.2(1) Samples and Tests for Acceptance The Contractor shall deliver representative samples (from the Contractor, Producer, or Fabricator) to the Engineer without charge before incorporating material into the Work. In providing samples, the Contractor shall provide the Engineer with sufficient time and quantities for testing before use. The Engineer may require samples at any time. Samples not taken by or in the presence of the Engineer will not be accepted for test, unless the Engineer permits otherwise. The Contractor shall designate specific Contractor employees as points of contact for concrete testing and acceptance. Alternates shall be designated to ensure that direct contact is maintained during concrete placement. If designated by the Contractor to the Engineer, the concrete supplier will receive all 28-day concrete strength test results. 2020 Standard Specifications M 41-10 Page 1-51 Control of Material 1-06 The Engineer will designate specific Contracting Agency employees as points of contact for concrete testing and acceptance. The Contractor may observe any of the sampling and testing performed by the Engineer. If the Contractor observes a deviation from the specified sampling and testing procedures, the Contractor shall verbally describe the deviations observed to the Engineer or designated representative immediately, and shall confirm these observed deviations in writing to the Engineer within 24 hours, referencing the specific procedures and steps. The Engineer will respond in writing within 3 working days of the receipt of the Contractor’s written communications. All field and Laboratory materials testing by the Engineer will follow methods described in Contract documents, or in the WSDOT Materials Manual M 46-01, using qualified testing personnel and calibrated or verified equipment. The standard or tentative standard in effect on the Bid advertising date will apply in each case. Revisions to the WSDOT Materials Manual M 46-01 or revisions to other Specifications or test methods such as AASHTO, ASTM, or Federal Specifications will be considered as in effect 60 calendar days after publication. 1-06.2(2) Statistical Evaluation of Materials for Acceptance 1-06.2(2)A General Where specified, acceptance sampling and testing will be performed by the Contracting Agency and statistically evaluated for acceptance by the provisions of this Subsection. All test results for a lot will be analyzed collectively and statistically by the quality level analysis procedures shown at the end of this Subsection to determine the total percent of the lot that is within Specification limits and to determine an appropriate pay factor. Lots and sublots are defined in the appropriate Subsection of these Specifications for the material being statistically evaluated. Quality level analysis is a statistical procedure for determining the percent compliance of the material with these Specifications. Quality level is the computed percent of material meeting these Specifications and is determined from the arithmetic mean, (Xm), and the sample standard deviation (S), for each constituent of the lot. Any necessary rounding off of test results or calculations will be accomplished according to the individual testing procedure, or, if not defined in the procedure then accomplished according to the following rule: 1. The final significant digit will not be changed when the succeeding digit is less than 5. 2. The final significant digit will be increased by one when the succeeding digit is 5 or greater. Page 1-52 2020 Standard Specifications M 41-10 1-06 Control of Material Table 1 Estimated percent of Work Within Specification Limits Estimated percent Within Specification Limits (PU or PL) Upper Quality Index QU or Lower Quality Index QL n=3 n=4 n=5 n=6 n=7 n=8 n=9 n=10 to n=11 n=12 to n=14 n=15 to n=17 n=18 to n=22 n=23 to n=29 n=30 to n=42 n=43 to n=66 n=67 to ∞ 100 99 98 97 96 95 1.16 1.15 1.14 1.49 1.46 1.43 1.40 1.37 1.34 1.72 1.64 1.58 1.52 1.47 1.42 1.88 1.75 1.66 1.59 1.52 1.47 1.99 1.82 1.72 1.63 1.56 1.49 2.07 1.88 1.75 1.66 1.58 1.51 2.13 1.91 1.78 1.68 1.60 1.52 2.20 1.96 1.81 1.71 1.62 1.54 2.28 2.01 1.84 1.73 1.64 1.55 2.34 2.04 1.87 1.75 1.65 1.56 2.39 2.07 1.89 1.76 1.66 1.57 2.44 2.09 1.91 1.78 1.67 1.58 2.48 2.12 1.93 1.79 1.68 1.59 2.51 2.14 1.94 1.80 1.69 1.59 2.56 2.16 1.95 1.81 1.70 1.60 94 93 92 91 90 1.13 1.12 1.11 1.10 1.31 1.28 1.25 1.22 1.19 1.38 1.33 1.29 1.25 1.21 1.41 1.36 1.31 1.27 1.23 1.43 1.38 1.33 1.28 1.23 1.45 1.39 1.33 1.28 1.24 1.46 1.40 1.34 1.29 1.24 1.47 1.41 1.35 1.29 1.24 1.48 1.41 1.35 1.30 1.25 1.49 1.42 1.36 1.30 1.25 1.50 1.43 1.36 1.30 1.25 1.50 1.43 1.37 1.31 1.25 1.51 1.44 1.37 1.31 1.25 1.51 1.44 1.37 1.31 1.26 1.52 1.44 1.38 1.31 1.26 89 88 87 86 85 1.09 1.07 1.06 1.04 1.03 1.16 1.13 1.10 1.07 1.04 1.18 1.14 1.10 1.07 1.03 1.18 1.14 1.10 1.07 1.03 1.19 1.15 1.10 1.07 1.03 1.19 1.15 1.10 1.06 1.03 1.19 1.15 1.10 1.06 1.02 1.19 1.15 1.10 1.06 1.02 1.20 1.15 1.11 1.06 1.02 1.20 1.15 1.11 1.06 1.02 1.20 1.15 1.11 1.06 1.02 1.20 1.15 1.11 1.06 1.02 1.20 1.15 1.11 1.06 1.02 1.20 1.15 1.11 1.06 1.02 1.20 1.15 1.11 1.06 1.02 84 83 82 81 80 1.01 0.99 0.97 0.95 0.93 1.01 0.98 0.95 0.92 0.89 1.00 0.97 0.93 0.90 0.87 0.99 0.96 0.92 0.89 0.86 0.99 0.95 0.92 0.88 0.85 0.99 0.95 0.92 0.88 0.85 0.99 0.95 0.91 0.88 0.84 0.98 0.95 0.91 0.87 0.84 0.98 0.94 0.91 0.87 0.84 0.98 0.94 0.91 0.87 0.83 0.98 0.94 0.90 0.87 0.83 0.98 0.94 0.90 0.87 0.83 0.98 0.94 0.90 0.87 0.83 0.98 0.94 0.90 0.87 0.83 0.98 0.94 0.90 0.87 0.83 79 78 77 76 75 0.91 0.88 0.86 0.83 0.81 0.86 0.83 0.80 0.77 0.74 0.84 0.81 0.77 0.74 0.71 0.82 0.79 0.76 0.73 0.70 0.82 0.79 0.75 0.72 0.69 0.81 0.78 0.75 0.72 0.69 0.81 0.78 0.74 0.71 0.68 0.81 0.77 0.74 0.71 0.68 0.80 0.77 0.74 0.70 0.67 0.80 0.77 0.73 0.70 0.67 0.80 0.76 0.73 0.70 0.67 0.80 0.76 0.73 0.70 0.67 0.80 0.76 0.73 0.70 0.67 0.80 0.76 0.73 0.70 0.67 0.79 0.76 0.73 0.70 0.66 74 73 72 71 70 0.78 0.75 0.73 0.70 0.67 0.71 0.68 0.65 0.62 0.59 0.68 0.65 0.62 0.59 0.56 0.67 0.64 0.61 0.58 0.55 0.67 0.63 0.60 0.57 0.54 0.65 0.62 0.59 0.57 0.54 0.65 0.62 0.59 0.56 0.53 0.65 0.62 0.59 0.56 0.53 0.64 0.61 0.58 0.55 0.52 0.64 0.61 0.58 0.55 0.52 0.64 0.61 0.58 0.55 0.52 0.64 0.61 0.58 0.55 0.52 0.64 0.61 0.58 0.55 0.52 0.64 0.61 0.58 0.55 0.52 0.63 0.60 0.57 0.54 0.52 69 68 67 66 65 0.64 0.61 0.58 0.55 0.51 0.56 0.53 0.50 0.47 0.44 0.53 0.50 0.47 0.45 0.42 0.52 0.49 0.46 0.43 0.40 0.51 0.48 0.45 0.43 0.40 0.51 0.48 0.45 0.42 0.39 0.50 0.48 0.45 0.42 0.39 0.50 0.47 0.44 0.42 0.39 0.50 0.47 0.44 0.41 0.38 0.49 0.47 0.44 0.41 0.38 0.49 0.46 0.44 0.41 0.38 0.49 0.46 0.43 0.41 0.38 0.49 0.46 0.43 0.41 0.38 0.49 0.46 0.43 0.41 0.38 0.49 0.46 0.43 0.40 0.38 64 63 62 61 60 0.48 0.45 0.41 0.38 0.34 0.41 0.38 0.35 0.30 0.28 0.39 0.36 0.33 0.30 0.28 0.38 0.35 0.32 0.30 0.25 0.37 0.34 0.32 0.29 0.25 0.37 0.34 0.31 0.28 0.25 0.36 0.34 0.31 0.28 0.25 0.36 0.33 0.31 0.28 0.25 0.36 0.33 0.30 0.28 0.25 0.36 0.33 0.30 0.28 0.25 0.35 0.33 0.30 0.28 0.25 0.35 0.33 0.30 0.28 0.25 0.35 0.33 0.30 0.28 0.25 0.35 0.33 0.30 0.28 0.25 0.35 0.32 0.30 0.28 0.25 59 58 57 56 55 0.31 0.30 0.25 0.20 0.18 0.27 0.25 0.20 0.18 0.15 0.25 0.23 0.18 0.16 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 0.23 0.20 0.18 0.15 0.13 54 53 52 51 50 0.15 0.10 0.08 0.05 0.00 0.13 0.10 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 0.10 0.08 0.05 0.03 0.00 2020 Standard Specifications M 41-10 Page 1-53 Control of Material 1-06 Table 2 Pay Factors Pay Factor Required Quality Level for a Given Sample Size (n) and a Given Pay Factor n=3 n=4 n=5 n=6 n=7 n=8 n=9 n=10 to n=11 n=12 to n=14 n=15 to n=17 n=18 to n=22 n=23 to n=29 n=30 to n=42 n=43 to n=66 n=67 to ∞ 1.05 1.04 1.03 1.02 1.01 100 100 100 100 99 98 100 98 97 95 100 99 96 94 92 100 97 94 91 89 100 95 92 89 87 100 96 93 90 88 100 96 93 91 89 100 96 94 92 90 100 97 95 93 91 100 97 95 93 92 100 97 96 94 92 100 97 96 94 93 1.00 0.99 0.98 0.97 0.96 69 66 64 63 61 75 72 70 68 67 78 76 74 72 70 80 78 76 74 72 82 80 78 76 74 83 81 79 77 75 84 82 80 78 76 85 83 81 79 78 86 84 82 81 79 87 85 84 82 81 88 86 85 83 82 89 87 86 84 83 90 89 87 86 84 91 90 88 87 86 92 91 90 88 87 0.95 0.94 0.93 0.92 0.91 59 58 57 55 54 65 63 62 60 59 68 67 65 63 62 71 69 67 66 64 72 71 69 68 66 74 72 71 69 68 75 73 72 70 69 76 75 73 72 70 78 76 75 73 72 79 78 76 75 74 80 79 78 76 75 82 80 79 78 76 83 82 80 79 78 84 83 82 81 79 86 85 84 82 81 0.90 0.89 0.88 0.87 0.86 53 51 50 49 48 57 56 55 53 52 61 59 58 57 55 63 62 60 59 58 65 63 62 61 59 66 65 64 62 61 67 66 65 63 62 69 68 66 65 64 71 69 68 67 66 72 71 70 68 67 74 72 71 70 69 75 74 73 71 70 77 75 74 73 72 78 77 76 75 74 80 79 78 77 76 0.85 0.84 0.83 0.82 0.81 46 45 44 43 41 51 49 48 47 46 54 53 51 50 49 56 55 54 53 51 58 57 56 54 53 60 58 57 56 55 61 60 58 57 56 62 61 60 59 58 64 63 62 61 59 66 65 64 62 61 67 66 65 64 63 69 68 67 66 64 71 70 69 67 66 72 71 70 69 68 75 73 72 71 70 0.80 0.79 0.78 0.77 0.76 0.75 40 39 38 36 35 33 44 43 42 41 39 38 48 46 45 44 43 42 50 49 48 46 45 44 52 51 50 48 47 46 54 52 51 50 49 48 55 54 52 51 50 49 56 55 54 53 52 51 58 57 56 55 54 53 60 59 58 57 56 54 62 61 59 58 57 56 63 62 61 60 59 58 65 64 63 62 61 60 67 66 65 64 63 62 69 68 67 66 65 64 RE JECT Values Less Than Those Shown Above Reject Quality Levels Less Than Those Specified for a 0.75 Pay Factor Note: If the value of (PU + PL) - 100 does not correspond to a (PU + PL) - 100 value in this table, use the next smaller (PU+ PL) - 100 value. Page 1-54 2020 Standard Specifications M 41-10 1-06 Control of Material 1-06.2(2)B Financial Incentive As an incentive to produce superior quality material, a pay factor greater than 1.00 may be obtained with the maximum pay factor being 1.05. A lot containing non-Specification material will be accepted provided the Composite Pay Factor reaches the minimum value specified elsewhere. A lot containing non-Specification material which fails to obtain at least the specified minimum Composite Pay Factor will be rejected by the Engineer. The Engineer will take one or more of the following actions when rejected material has been incorporated into the Work: 1.Require complete removal and replacement with Specification material at no additional cost to the Contracting Agency. 2.At the Contractor’s written request, allow corrective work at no additional cost to the Contracting Agency and then an appropriate price reduction that may range from no reduction to no payment. 3.At the Contractor’s written request, allow material to remain in place with an appropriate price reduction that may range from a designated percentage reduction to no payment. Any lot for which at least three samples have been obtained, and all of the test results meet one of the appropriate criteria listed below, will receive at least a 1.00 Composite Pay Factor: 1.All test results are within the allowable limits specified for the item, or 2.All test results that only have a lower Specification limit are greater than or equal to that limit, or 3.All test results that only have an upper Specification limit are less than or equal to that limit. Computation of the quality level in these instances will be for determining the amount of any bonus that might be warranted. Lots represented by less than three samples or unsampled lots will be exempt from statistical based acceptance. 1-06.2(2)C Removed and Rejected Materials The Contractor may, prior to sampling, elect to remove any defective material and replace it with new material at no expense to the Contracting Agency. Any such new material will be sampled, tested, and evaluated for acceptance as a part of the sublot in accordance with this statistical sampling and testing procedure. The Engineer may reject a sublot that tests show to be defective. Such rejected material shall not be used in the Work, and the results of tests run on the rejected material will not be included in the original lot acceptance tests. 2020 Standard Specifications M 41-10 Page 1-55 Control of Material 1-06 1-06.2(2)D Quality Level Analysis 1-06.2(2)D1 General The quality level calculations for HMA and other materials are completed using the formulas in Section 1-06.2(2)D4. The quality level calculations for HMA compaction are completed using the formulas in Section 1-06.2(2)D5. For HMA, the definition of the “x” value used in the calculations and the definition of the upper and lower specification limit are in Section 1-06.2(2)D2. For other materials, the definition of the “x” value used in the calculations and the definition of the upper and lower specification limit are in Section 1-06.2(2)D3. All other terms and variables are the same for all calculations. 1-06.2(2)D2 Hot Mix Asphalt x = difference between an individual test value and the job mix formula (JMF) USL = maximum allowable limit in Section 9-03.8(7) LSL = minimum allowable limit in Section 9-03.8(7) 1-06.2(2)D3 Other Materials x = individual test value USL = upper specification limit LSL = lower specification limit 1-06.2(2)D4 Quality Level Calculation The procedures for determining the quality level and pay factors for a material, other than HMA compaction, are as follows: 1.Determine the arithmetic mean, Xm, for each specified material constituent:1-06.2(2)D4 Quality Level Calculation X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q.=USL − X"S Q1 =X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q1 =X"−LSLS Where: ∑ = summation of x n = total number test values 2.Compute the sample standard deviation, “S”, for each constituent: 1-06.2(2)D4 Quality Level Calculation X"=ΣxnS = nΣx (− Σx (n n − 1 ,( Q.=USL − X"S Q1 =X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q1 =X"−LSLS Where: 1-06.2(2)D4 Quality Level Calculation X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q.=USL − X"S Q1 =X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q1 =X"−LSLS = summation of the squares of individual test values 1-06.2(2)D4 Quality Level Calculation X "=ΣxnS = nΣx(−Σx (n n − 1 ,( Q .=USL − X"S Q 1 =X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X "=ΣxnS = nΣx(−Σx (n n − 1 ,( Q 1 =X"−LSLS = summation of the individual test values squared 3.Compute the upper quality index, (QU), for each constituent: 1-06.2(2)D4 Quality Level Calculation X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q.=USL − X"S Q1 =X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q1 =X"−LSLS Page 1-56 2020 Standard Specifications M 41-10 1-06 Control of Material 4.Compute the lower quality index, (QL), for each constituent: 1-06.2(2)D4 Quality Level CalculationX"=ΣxnS =nΣx (−Σx (n n − 1 ,( Q.=USL − X"S Q1 =X"−LSLS CPF =f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q1 =X"−LSLS 5.For each constituent determine PU (the percent within the upper Specification limit which corresponds to a given QU) from Table 1. If USL is 100.00 percent or is not specified, PU will be 100. For negative values of QU, PU (e.g., N = 15 and QU = -0.5 will result in PU = 30) is equal to 100 minus the table PU. If the value of QU does not correspond exactly to a figure in the table, use the next higher value. 6.For each constituent determine PL (the percent within the lower Specification limit which corresponds to a given QL) from Table 1. If LSL is zero or not specified, PL will be 100. For negative values of QL, PL is equal to 100 minus the table PL. If the value of QL does not correspond exactly to a figure in the table, use the next higher value. 7.For each constituent determine the quality level (the total percent within Specification limits): Quality Level = (PU + PL) – 100 8.Using the quality level from step 7, determine the pay factor (PFi) from Table 2 for each constituent tested. 9.Determine the Composite Pay Factor (CPF) for each lot. 1-06.2(2)D4 Quality Level Calculation X "=ΣxnS = nΣx(−Σx (n n − 1 ,( Q.=USL − X"S Q1 =X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X "=ΣxnS = nΣx(−Σx (n n − 1 ,( Q1 =X"−LSLS 1-06.2(2)D4 Quality Level Calculation X "=ΣxnS = nΣx(−Σx (n n − 1 ,( Q.=USL − X"S Q1 =X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8 PF8Σf8i = 1 to j 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X "=ΣxnS = nΣx(−Σx (n n − 1 ,( Q1 =X"−LSLS Where: fi = price adjustment factor listed in these Specifications for the applicable material j = number of constituents being evaluated 1-06.2(2)D5 Quality Level Calculation – HMA Compaction The procedures for determining the quality level and pay factor for HMA compaction are as follows: 1.Determine the arithmetic mean, Xm, for the compaction of the lot:1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx(−Σx (n n − 1 ,( Q 1 =X"−LSLS Where: x = individual compaction test values for each sublot in the lot ∑x = summation of individual compaction test values n = total number test values 2.Compute the sample standard deviation, “S”, for each constituent: 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx (− Σx (n n − 1 ,( Q1 =X"−LSLSWhere: 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X"=ΣxnS = nΣx(−Σx (n n − 1 ,( Q 1 =X"−LSLS = summation of the squares of individual compaction test values 1-06.2(2)D5 Quality Level Calculation –HMA Compaction X "=ΣxnS = nΣx(− Σx (n n − 1 ,( Q 1 =X"−LSLS = summation of the individual compaction test values squared 2020 Standard Specifications M 41-10 Page 1-57 Control of Material 1-06 3.Compute the lower quality index, (QL): 1-06.2(2)D5 Quality Level Calculation –HMA CompactionX"=ΣxnS = nΣx (−Σx (n n − 1 ,( Q1 =X"−LSLS Where: LSL = 92.0 4.Determine PL (the percent within the lower Specification limit which corresponds to a given QL) from Table 1. For negative values of QL, PL is equal to 100 minus the table PL. If the value of QL does not correspond exactly to a figure in the table, use the next higher value. 5.Determine the quality level (the total percent within Specification limits): Quality Level = PL 6.Using the quality level from step 5, determine the composite pay factor (CPF) from Table 2. 7.If the CPF determined from step 6 is 1.00 or greater: use that CPF for the compaction lot; however, the maximum HMA compaction CPF using an LSL = 92.0 shall be 1.05. 8.If the CPF from step 6 is not 1.00 or greater: repeat steps 3 through 6 using an LSL = 91.5. The value thus determined shall be the HMA compaction CPF for that lot; however, the maximum HMA compaction CPF using an LSL = 91.5 shall be 1.00. 1-06.3 Manufacturer’s Certificate of Compliance When authorized by these Specifications or the Special Provisions and prior to use, the Engineer may accept certain materials on the basis of a Manufacturer’s Certificate of Compliance as an alternative to material inspection and testing. The Contractor may request, in writing, authority from the Engineer to install such materials prior to submitting the required certification; however, no payment will be made for the Work in the absence of an acceptable Manufacturer’s Certificate of Compliance. The Contracting Agency reserves the right to deny the request for good cause. If for any reason the Contractor has not provided an acceptable Manufacturer’s Certificate of Compliance by the Physical Completion Date established by Section 1-08.5, the Contracting Agency will assess the usefulness of the installed material. At the Engineer’s discretion, the Contracting Agency will either require replacement of the material by the Contractor at no expense to the Contracting Agency or process the final payment as provided by Section 1-09.9 without paying for the materials or any portion of the Work performed to install the materials provided on such a basis. The unit Contract prices for the Work shall be used to determine the amount to be withheld. Where unit Contract prices do not exist, as in a lump sum item, the amount to be withheld shall be an equitable adjustment, covering labor, equipment and materials, determined in accordance with Section 1-09.4. The Manufacturer’s Certificate of Compliance must identify the manufacturer, the type and quantity of material being certified, the applicable Specifications being affirmed, and the signature of a responsible corporate official of the manufacturer and include 4.Compute the lower quality index, (QL), for each constituent: 1-06.2(2)D4QualityLevel CalculationX"=ΣxnS =nΣx(−Σx(nn − 1 ,( Q.=USL− X"S Q1=X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8PF8Σf8i = 1toj 1-06.2(2)D5Quality Level Calculation–HMA Compaction X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q1=X"−LSLS 5.For each constituent determine PU (thepercent within the upper Specification limit which corresponds to a given QU) from Table 1. If USL is 100.00percent or is not specified, PUwill be 100. For negative values of QU, PU (e.g., N = 15 and QU = -0.5 will result in PU = 30) is equal to 100minus the table PU. If the value of QU does not correspond exactly to a figure in the table, use the next higher value. 6.For each constituent determine PL (thepercent within the lower Specification limit which corresponds to a given QL) from Table 1. If LSL is zero or not specified, PLwill be 100. For negative values of QL, PL is equal to 100minus the table PL. If the value of QL does not correspond exactly to a figure in the table, use the next higher value. 7.For each constituent determine the quality level (the totalpercent within Specification limits): Quality Level = (PU + PL) – 100 8.Using the quality level from step 7, determine the pay factor (PFi) from Table 2 for each constituent tested. 9.Determine the Composite Pay Factor (CPF) for each lot. 1-06.2(2)D4QualityLevel Calculation X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q.=USL− X"S Q1=X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8PF8Σf8i = 1toj 1-06.2(2)D5Quality Level Calculation–HMA Compaction X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q1=X"−LSLS 1-06.2(2)D4QualityLevel Calculation X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q.=USL− X"S Q1=X"−LSLSCPF=f,PF,+ f(PF(+ ⋯+ f8PF8Σf8i = 1toj 1-06.2(2)D5Quality Level Calculation–HMA Compaction X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q1=X"−LSLS Where: fi=price adjustment factor listed in these Specifications for the applicable material j=number of constituents being evaluated 1-06.2(2)D5Quality Level Calculation – HMA Compaction The procedures for determining the quality level and pay factor for HMA compaction are as follows: 1.Determine the arithmetic mean, Xm, for the compaction of the lot:1-06.2(2)D5Quality Level Calculation–HMA Compaction X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q1=X"−LSLS Where: x=individual compaction test values for each sublot in the lot ∑x=summation of individual compaction test values n=total number test values 2.Compute the sample standard deviation, “S”, for each constituent: 1-06.2(2)D5Quality Level Calculation–HMA Compaction X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q1=X"−LSLSWhere: 1-06.2(2)D5Quality Level Calculation–HMA Compaction X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q1=X"−LSLS =summation of the squares of individual compaction test values 1-06.2(2)D5Quality Level Calculation–HMA Compaction X"=ΣxnS = nΣx(−Σx(nn − 1 ,( Q1=X"−LSLS =summation of the individual compaction test values squared Page 1-58 2020 Standard Specifications M 41-10 1-06 Control of Material supporting mill tests or documents. A Manufacturer’s Certificate of Compliance shall be furnished with each lot of material delivered to the Work and the lot so certified shall be clearly identified in the certificate. All materials used on the basis of a Manufacturer’s Certificate of Compliance may be sampled and tested at any time. Any material not conforming to the requirements will be subject to rejection whether in place or not. The Contracting Agency reserves the right to refuse to accept materials on the basis of a Manufacturer’s Certificate of Compliance. 1-06.4 Handling and Storing Materials In storage and handling, the Contractor shall protect materials against damage from careless handling, from exposure to weather, from mixture with foreign matter, and from all other causes. The Engineer will reject and refuse to test materials improperly handled or stored. The Contractor shall repair, replace, or make good all Contracting Agency-provided materials that are damaged or lost due to the Contractor’s operation or while in the Contractor’s possession, at no expense to the Contracting Agency. 1-06.5 Owners Manuals and Operating Instructions For equipment and materials that are permanently incorporated in the Work, the Contractor shall provide to the Engineer all owners manuals and operating instructions furnished by the equipment or material manufacturer. 1-06.6 Recycled Materials The Contractor shall make their best effort to utilize recycled materials in the construction of the project; the use of recycled concrete aggregate as specified in Section 1-06.6(1)A is a requirement of the Contract. The Contractor shall submit a Recycled Material Utilization Plan on WSDOT Form 350-075A within 30 calendar days after the Contract is executed. The plan shall provide the Contractor’s anticipated usage of recycled concrete aggregates for meeting the requirements of these Specifications. The quantity of recycled concrete aggregate will be provided in tons and as a percentage of the Plan quantity for eligible material listed in Section 9-03.21(1)E Table on Maximum Allowable percent (By Weight) of Recycled Material. When a Contract does not include Work that requires the use of a material that is included in the requirements for using materials the Contractor may state in their plan that no recycled materials are proposed for use. Within 30 calendar days after Physical Completion the Contractor shall report the quantity of recycled concrete aggregates that were utilized in the construction of the project for each eligible item listed in Section 9-03.21(1)E. The Contractor’s report shall be provided on WSDOT Form 350-075A, Recycled Concrete Aggregate Reporting. 2020 Standard Specifications M 41-10 Page 1-59 Control of Material 1-06 1-06.6(1) Recycling of Aggregate and Concrete Materials 1-06.6(1)A General The minimum quantity of recycled concrete aggregate shall be 25 percent of the total quantity of aggregate that is incorporated into the Contract for those items listed in Section 9-03.21(1)E Table on Maximum Allowable percent (By Weight) of Recycled Material that allow the use of recycled concrete aggregate. The percentage of recycled material incorporated into the project for meeting the required percentage will be calculated in tons based on the quantity of recycled concrete used on the entire Contract and not as individual items. If the Contractor’s total cost for Work with recycled concrete aggregate is greater than without the Contractor may choose to not use recycled concrete aggregate. If the Recycled Material Utilization Plan does not indicate the minimum usage of recycled concrete aggregate required above, or if completed project quantities do not meet the minimum usage required, the Contractor shall develop the following: 1. A cost estimate for each material listed in Section 9-03.21(1)E that is utilized on the Contract. The cost estimate shall include the following: a. The estimated costs for the Work for each material with 25 percent recycled concrete aggregate. The cost estimate shall include for each material a documented price quote from the supplier with the lowest total cost for the Work. b. The estimated costs for the Work for each material without recycled concrete aggregate. The Contractor’s cost estimates shall be submitted as an attachment to the Recycled Material Utilization Plan, or with the Reporting form. Page 1-60 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07 Legal Relations and Responsibilities to the Public 1-07.1 Laws to be Observed The Contractor shall always comply with all Federal, State, tribal, or local laws, ordinances, and regulations that affect Work under the Contract. The Contractor shall indemnify, defend, and save harmless the State (including the Governor, Commission, Secretary, and any agents, officers, and employees) against any claims that may arise because the Contractor (or any employee of the Contractor or Subcontractor or materialperson) violated a legal requirement. The Contractor shall be responsible for the safety of all workers and shall comply with all appropriate state safety and health standards, codes, rules, and regulations, including, but not limited to, those promulgated under the Washington Industry Safety and Health Act RCW 49.17 (WISHA) and as set forth in Title 296 WAC (Department of Labor and Industries). In particular the Contractor’s attention is drawn to the requirements of WAC 296.800 which requires employers to provide a safe workplace. More specifically WAC 296.800.11025 prohibits alcohol and narcotics from the workplace. The Contractor shall likewise be obligated to comply with all federal safety and health standards, codes, rules, and regulations that may be applicable to the Contract Work. A copy of all safety plans (e.g., fall protection work plan) that are developed by the Contractor shall be submitted to the Engineer as a Type 1 Working Drawing. When requested by the Engineer, the Contractor shall provide training to Contracting Agency employees working on-site for any activity covered by a safety plan. Costs for training that is provided solely to Contracting Agency employees will be paid to the Contractor in accordance with Section 1-09.4. U.S. Mine Safety and Health Administration rules apply when the project includes pit or quarry operations. Among other actions, these regulations require the Contractor to notify the nearest Mine Safety and Health sub district office (1) of the project before it begins, (2) of the starting date, and (3) of the Physical Completion Date. Without usurping the authority of other agencies, the Contracting Agency will cooperate with them in their efforts to enforce legal requirements. Upon awareness of a violation of a legal requirement, the Engineer will notify the Contractor in an effort to achieve compliance. The Engineer may also notify the agency responsible for enforcement if the Engineer deems that action is necessary to achieve compliance with legal requirements. The Engineer will also assist the enforcement agency to obtain Contractor compliance to the extent such assistance is consistent with the provisions of the Contract. The Contracting Agency will not adjust payment to compensate the Contractor for changes in legal requirements unless those changes are specifically within the scope of RCW 39.04.120. For changes under RCW 39.04.120, the Contracting Agency will compensate the Contractor by negotiated change order as provided in Section 1-04.4. 2020 Standard Specifications M 41-10 Page 1-61 Legal Relations and Responsibilities to the Public 1-07 Under certain conditions, the Contracting Agency will adjust payment to compensate for tax changes. First, the changes shall involve federal or state taxes on materials or fuel used in or consumed for the project. Second, the changes shall increase or decrease Contractor-paid taxes by more than $500. For items in the original Contract, the tax change must occur after the Bid opening date. For negotiated Contracts or items in a supplemental agreement, the tax change must take place after the execution date of the Contract or agreement. Within these conditions, the Contracting Agency will adjust compensation by the actual dollar amounts of increase or decrease caused by the tax changes. If the Engineer requests it, the Contractor shall certify in writing that the Contract price does not include any extra amount to cover a possible change in taxes. The Contracting Agency may audit the records of the Contractor as provided in Section 1-09.12, to verify any claim for compensation because of changes in laws or taxes. 1-07.2 State Taxes The Washington State Department of Revenue has issued special rules on the state sales tax. Sections 1-07.2(1) through 1-07.2(3) are meant to clarify those rules. The Contracting Agency will not adjust its payment if the Contractor bases a Bid on a misunderstood tax liability. The Contracting Agency may deduct from its payments to the Contractor, retainage or lien the bond, in the amount the Contractor owes the State Department of Revenue, whether the amount owed relates to the Contract in question or not. Any amount so deducted will be paid into the proper State fund on the contractor’s behalf. For additional information on tax rates and application refer to applicable RCWs, WACs or the Department of Revenue website. 1-07.2(1) State Sales Tax: WAC 458-20-171 – Use Tax For Work designated as Rule 171, Use Tax, the Contractor shall include for compensation the amount of any taxes paid in the various unit Bid prices or other Contract amounts. Typically, these taxes are collected on materials incorporated into the project and items such as the purchase or rental of; tools, machinery, equipment, or consumable supplies not integrated into the project. The Summary of Quantities in the Contract Plans identifies those parts of the project that are subject to Use Tax under Section 1-07.2(1). Page 1-62 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.2(2) State Sales Tax: WAC 458-20-170 – Retail Sales Tax For Work designated as Rule 170, Retail Sales Tax, the Contractor shall collect from the Contracting Agency, Retail Sales Tax on the full Contract price. The Contracting Agency will automatically add this Retail Sales Tax to each payment to the Contractor and for this reason; the Contractor shall not include the Retail Sales Tax in the unit Bid prices or in any other Contract amount. The Contractor (Prime or Subcontractor) shall include sales or use tax on the purchase or rental of tools, machinery, equipment, or consumable supplies not integrated into the project, in the unit bid prices. The Summary of Quantities in the Contract Plans identifies those parts of the project that are subject to Retail Sales Tax under Section 1-07.2(2). 1-07.2(3) Services Any contract wholly for professional or other applicable services is generally not subject to Retail Sales Tax and therefore, the Contractor shall not collect Retail Sales Tax from the Contracting Agency on those Contracts. Any incidental taxes paid as part of providing the services shall be included in the payments under the contract. 1-07.3 Fire Prevention and Merchantable Timber Requirements 1-07.3(1) Fire Prevention Control and Countermeasures Plan The Contractor shall prepare and implement a project-specific fire prevention, control, and countermeasures plan (FPCC Plan) for the duration of the project. The Contractor shall submit a Type 2 Working Drawing no later than the date of the preconstruction conference. 1-07.3(1)A FPCC Implementation Requirements The Contractor’s FPCC Plan shall be fully implemented at all times. The Contractor shall update the FPCC Plan throughout project construction so that the plan reflects actual site conditions and practices. The Contractor shall update the FPCC Plan at least annually and maintain a copy of the updated FPCC Plan that is available for inspection on the project site. Revisions to the FPCC Plan and the Industrial Fire Precaution Level (IFPL) shall be discussed at the weekly project safety meetings. 1-07.3(1)A1 FPCC Plan Element Requirements The FPCC Plan shall include the following: 1. The names, titles, and contact information for the personnel responsible for implementing and updating the plan. 2. The names and telephone numbers of the Federal, State, and local agencies the Contractor shall notify in the event of a fire. 3. All potential fire causing activities such as welding, cutting of metal, blasting, fueling operations, etc. 2020 Standard Specifications M 41-10 Page 1-63 Legal Relations and Responsibilities to the Public 1-07 4. The location of fire extinguishers, water, shovels, and other firefighting equipment. 5. The response procedures the Contractor shall follow in the event of a fire. Most of Washington State is covered under the IFPL system which, by law, is managed by the Department of Natural Resources (DNR). In some cases jurisdiction is transferred to the United States Forest Service (USFS) or to the local fire authority. It is the Contractor’s responsibility to be familiar with the IFPL requirements and to verify whether or not IFPL applies to the specific project. If the Contractor wishes to continue a work activity that is prohibited under an industrial fire precaution level, the Contractor shall obtain a waiver from the fire authority with jurisdiction and provide a copy to the Engineer prior to continuation of work on the project. If the IFPL requirements prohibit the Contractor from performing Work the Contractor may be eligible for an unworkable day in accordance with Section 1-08.5. The Contractor shall comply with the requirements of these provisions at no additional cost to the Contracting Agency. 1-07.3(1)A2 Forest Fire Prevention When the Work is in or next to State or Federal forests, the Contractor shall know and observe all laws and rules (State or Federal) on fire prevention and sanitation. The Contractor shall ask the local forest supervisor or regional manager to outline requirements for permits, sanitation, firefighting equipment, and burning. The Contractor shall take all reasonable precautions to prevent and suppress forest fires. In case of forest fire, the Contractor shall immediately notify the nearest forest headquarters of its exact site and shall make every effort to suppress it. If needed, the Contractor shall require his/her employees and those of any Subcontractor to work under forest officials in fire-control efforts. 1-07.3(2) Merchantable Timber Requirements When merchantable timber is to be cut, the Contractor shall obtain a permit from the appropriate regional office of the State Department of Natural Resources and comply fully with the State Forest Practices Act. No person may export from the United States, or sell, trade, exchange, or otherwise convey to any other person for the purpose of export from the United States, timber originating from the project. The Contractor shall comply with the Forest Resources Conservation and Shortage Relief Amendments Act of 1993 (Public Law 103-45) and the Washington State Log Export Regulations (WAC 240-15). Page 1-64 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.4 Sanitation 1-07.4(1) General The Contractor shall provide employees with all accommodations required by the State Department of Health and other agencies. These accommodations shall be kept clean, neat, and sanitized, and shall not create any public nuisance. The Contractor shall keep all campsites clean, properly dispose of all refuse, and leave each site in a neat and sanitary condition. 1-07.4(2) Health Hazards Biological hazards and associated physical hazards may be present in the worksite. The Contractor shall take precautions and perform any necessary Work to provide and maintain a safe and healthful worksite in accordance with applicable laws. Payment for Work necessary to provide and maintain a safe worksite will be incidental to associated items of Contract Work unless the Contract includes provisions to the contrary. 1-07.5 Environmental Regulations 1-07.5(1) General No Work shall occur within areas under the jurisdiction of resource agencies unless authorized in the Contract. Some, though not all, of these rules are summarized below. Any of these agencies may, without prejudice to the Contracting Agency, add rules as needed to protect game, fish, or the environment. The Contractor shall be responsible to immediately report to the Engineer any deviation from the contract provisions pertaining to environmental compliance, including but not limited to spills, unauthorized fill in waters of the State including wetlands, water quality standards, noise, air quality, etc. 1-07.5(2) State Department of Fish and Wildlife In doing the Work, the Contractor shall: 1. Not degrade water in a way that would harm fish, wildlife, or their habitat. 2. Not place materials below or remove them from the ordinary high water line except as may be specified in the Contract. 3. Not allow equipment to enter waters of the State except as specified in the Contract. 4. Revegetate in accordance with the Plans, unless the Special Provisions permit otherwise. 5. Prevent any fish-threatening silt buildup on the bed or bottom of any body of water. 6. Ensure continuous stream flow downstream of the Work area. 7. Dispose of any project debris by removal, burning, or placement above high-water flows. 2020 Standard Specifications M 41-10 Page 1-65 Legal Relations and Responsibilities to the Public 1-07 8. Immediately notify the Engineer and stop all work causing impacts, if at any time, as a result of project activities, fish are observed in distress or a fish kill occurs. If the Work in (1) through (3) above differs little from what the Contract requires, the Contracting Agency will measure and pay for it at unit Contract prices. But if Contract items do not cover those areas, the Contracting Agency will pay pursuant to Section 1-09.4. Work in (4) through (8) above shall be incidental to Contract pay items. 1-07.5(3) State Department of Ecology In doing the Work, the Contractor shall: 1. Comply with Washington State Water Quality Standards. 2. Perform Work in such a manner that all materials and substances not specifically identified in the Contract documents to be placed in the water do not enter waters of the State, including wetlands. These include, but are not limited to, petroleum products, hydraulic fluid, fresh concrete, concrete wastewater, process wastewater, slurry materials and waste from shaft drilling, sediments, sediment-laden water, chemicals, paint, solvents, or other toxic or deleterious materials. 3. Use equipment that is free of external petroleum-based products. 4. Remove accumulations of soil and debris from drive mechanisms (wheels, tracks, tires) and undercarriage of equipment prior to using equipment below the ordinary high water line. 5. Clean loose dirt and debris from all materials placed below the ordinary high water line. No materials shall be placed below the ordinary high water line without the Engineer’s approval. 6. When a violation of the Construction Stormwater General Permit (CSWGP) occurs, immediately notify the Engineer and fill out WSDOT Form 422-011, Contractor ECAP Report, and submit the form to the Engineer within 48 hours of the violation. 7. Once Physical Completion has been given, prepare a Notice of Termination (Ecology Form ECY 020-87) and submit the Notice of Termination electronically to the Engineer in a PDF format a minimum of 7 calendar days prior to submitting the Notice of Termination to Ecology. 8. Transfer the CSWGP coverage to the Contracting Agency when Physical Completion has been given and the Engineer has determined that the project site is not stabilized from erosion. 9. Submit copies of all correspondence with Ecology electronically to the Engineer in a PDF format within four calendar days. Page 1-66 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.5(4) Air Quality The Contractor shall comply with all regional clean air authority and/or State Department of Ecology rules and regulations. The air quality permit process may include additional State Environment Policy Act (SEPA) requirements. Contractors shall contact the appropriate regional air pollution control authority well in advance of beginning Work. When the Work includes demolition or renovation of any existing facility or structure that contains Asbestos Containing Material (ACM) and/or Presumed Asbestos-Containing Material (PACM), the Contractor shall comply with the National Emission Standards for Hazardous Air Pollutants (NESHAP). Any requirements included in Federal regulations regarding air quality that applies to the “owner or operator” shall be the responsibility of the Contractor. 1-07.5(5) U.S. Army Corps of Engineers When temporary fills are permitted, the Contractor shall remove fills in their entirety and the affected areas returned to pre-construction elevations. If a U.S. Army Corps of Engineers permit is noted in Section 1-07.6 of the Special Provisions, the Contractor shall retain a copy of the permit or the verification letter (in the case of a Nationwide Permit) on the worksite for the life of the Contract. The Contractor shall provide copies of the permit or verification letter to all subcontractors involved with the authorized work prior to their commencement of any work in waters of the U.S. 1-07.5(6) U.S. Fish/Wildlife Services and National Marine Fisheries Service The Contracting Agency will provide fish exclusion and handling services if the Work dictates. However, if the Contractor discovers any fish stranded by the project and a Contracting Agency biologist is not available, they shall immediately release the fish into a flowing stream or open water. 1-07.6 Permits and Licenses Contractors shall obtain all required permits and licenses and give any notices these call for. The Contracting Agency will support the Contractor in efforts to obtain a temporary operating permit in its name if: 1. A local rule or an agency policy prevent issuing the permit to a private firm; 2. The Contractor takes all action to obtain the permit; 3. The permit will serve the public interest; 4. The permit applies only to Work under the Contract; 2020 Standard Specifications M 41-10 Page 1-67 Legal Relations and Responsibilities to the Public 1-07 5. The Contractor agrees in writing: (a) to comply with all the issuing agency requires, and (b) to hold the Contracting Agency harmless for any Work-related liability incurred under the permit; and 6. The permit costs the Contracting Agency nothing. 1-07.7 Load Limits 1-07.7(1) General While moving equipment or materials on any public Highway, the Contractor shall comply with all laws that control traffic or limit loads. The Contract neither exempts the Contractor from such laws nor licenses overloads. At the Engineer’s request, the Contractor shall provide any facts needed to compute the equipment’s weight on the Roadway. All Contractor movement or storage of materials or equipment within the project limits (as shown in the Plans): 1. Legal load limits shall apply on any road open to and in use by public traffic. 2. Legal load limits shall apply on any existing road not scheduled for major reconstruction under the current Contract. 3. The Contractor may haul overloads (not more than 25 percent above load limits) on any newly paved roads (with final lift in place) built under this Contract not open to public traffic if this does not damage completed Work. 4. When moving vehicles or operating equipment on or over structures design for direct bearing of live load, buried structures, culverts, pipes, or retaining walls within the project limits, the Contractor shall meet the load-limit restrictions in Section 1-07.7(2). 5. When storing material on a Structure or retaining wall, the Contractor shall meet the load-limit restrictions in Section 1-07.7(2). These requirements are not intended for long term storage of material. 6. The Contractor shall remain responsible for and pay all repair costs due to any load- caused damage on any newly paved roads, new and existing Structures, culverts, pipes and retaining walls. Unit prices shall cover all costs for operating vehicles or storing materials on or over structures, culverts, pipes, and retaining walls. Nothing in this section affects the Contractor’s other responsibilities under these Specifications or under public Highway laws. Bridges that are under construction shall meet the load restrictions in Section 6-01.6. Page 1-68 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.7(2) Load-Limit Restrictions At the request of the Engineer, the Contractor shall provide supporting documentation of vehicle, equipment or material loads, axle or support dimensions and any additional information used to determine the loads. 1. Structures Designed for Direct Bearing of Live Loads The gross vehicle weight or maximum load on each axle shall not exceed the legal load limit nor any posted weight limit on a Structure. Construction equipment that is not considered a legal vehicle licensed for legal travel on the public Highway, including but not limited to track or steel wheeled vehicles, may operate on a Structure. Gross equipment weight, axle spacing, equipment spacing, and other attributes identified in the Plans shall not be exceeded. When loads are not identified in the Plans, the construction equipment shall not exceed the following load restrictions: a. The gross vehicle weight or maximum load on each axle shall not exceed the legal load limit, axle spacing nor any posted weight limit on a Structure. b. A tracked vehicle with a maximum gross vehicle weight of 40,000 pounds and track contact length no less than 8 feet. The maximum gross vehicle weight may increase by 2,000 pounds for each one foot of track contact length over 8 feet, but shall not exceed 80,000 pounds. c. A tracked vehicle with a maximum gross vehicle weight of 20,000 pounds and track contact length less than 8 feet. d. No single axle shall exceed 20,000 pounds. e. No more than one vehicle shall operate over any Structure at one time. Track contact length shall be measured once for two or more parallel tracks. The Contractor shall not store construction materials on timber Structures or Structures posted for weight limits. When a structure within the project limits is not posted for weight limits and there is no other reasonable storage space within the project limits, the Contractor may store construction material on the Structure and shall not exceed the maximum uniformly distributed load and distribution length along the structure per the following table: Maximum Uniform Load (psf) Maximum Distributed Length Along Structure Structure Width (curb-to-curb) 24 feet or less greater than 24 feet 15 ft 250 160 40 ft 125 80 80 ft 75 50 Full Structure Length 50 35 2020 Standard Specifications M 41-10 Page 1-69 Legal Relations and Responsibilities to the Public 1-07 The load restrictions for storing material or operating equipment shall not be combined and shall apply to the full structure length. Materials that are stored in two or more locations on the same structure shall use the total combined length to determine the maximum load restriction. Vehicle traffic and the Contractor’s equipment may operate in the adjacent lanes to the stored materials and shall not be allowed on the structure width that is occupied by the stored materials. Contractor’s equipment that is used to deliver or remove any stored material with the same structure width shall be considered in combination with all stored materials. This equipment shall be assumed to be uniformly distributed over the largest axle spacing and average axle width. The Contractor shall immediately remove any dirt, rock, or debris that may gather on the Structure’s roadway surface. 2. Buried Structures Buried Structures shall include reinforced concrete three sided structures, box culverts, split box culverts, structural plate pipe, pipe arch, and underpasses. Loads shall not exceed 24,000 pounds on a single axle and 16,000 pounds each on tandem axles spaced less than 10 feet apart. These limits are permitted only if the embankment has: (a) been built to Specifications, and (b) reached at least 3 feet above the top of the buried structure. When the embankment has reached 5 feet above the top of the buried structure, the Contractor may increase per-axle loads up to 100,000 pounds if outside wheel spacing is at least 7 feet on axle centers. 3. Pipe Culverts and Sewer Pipes Pipe culverts and sewer pipes shall include pipe for drainage, storm sewers, and sanitary sewers. Loads over pipe culverts and sewer pipes shall not exceed 24,000 pounds on a single axle and 16,000 pounds each on tandem axles spaced less than 10 feet apart. These limits are permitted only if: (a) the culvert or pipe has been installed and backfilled to Specifications, and (b) the embankment has reached at least 2 feet above the top limit of pipe compaction. When the embankment has reached 5 feet above the top limit of pipe compaction, the Contractor may increase per-axle loads up to 100,000 pounds if outside wheel spacing is at least 7 feet on axle centers, except that: a. For Class III reinforced concrete pipes, the embankment shall have risen above the top limit of compaction at least 6 feet. b. For Class II reinforced concrete pipes, the maximum load for each axle shall be 80,000 pounds if outside wheel spacing is at least 7 feet on axle centers. In this case, the embankment shall have risen above the top limit of compaction at least 6 feet. Page 1-70 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 4. Retaining Walls Loads above existing and completed retaining walls designed for vehicular loads, where any part of the load is located within half the retaining wall height, shall not exceed the following load restrictions: a. The gross vehicle weight or maximum load on each axle shall not exceed the legal load limit. b. Construction equipment and material shall not exceed 250 pounds per square foot. If necessary and safe to do so, the Engineer may allow higher loads than those allowed under these load-limit restrictions. For loads on or over structures designed for direct bearing of live load, the Contractor shall submit Type 3E Working Drawings consisting of calculations and other supporting information in accordance with the requirements of Section 6-01.6. For loads on or over pipes, culverts, buried structures, and retaining walls the Contractor shall submit Type 2E Working Drawings. All submittals shall contain the following information: a description of the loading details; arrangement, movement and position of all vehicles, equipment and materials on the Structure, culvert or pipe; and statement that the Contractor assumes all risk for damage. 1-07.8 High-Visibility Apparel The Contractor shall require all personnel under their control (including service providers, Subcontractors, and lower tier subcontractors) that are on foot in the work zone and are exposed to vehicle traffic or construction equipment to wear the high-visibility apparel described in this section. The Contractor shall ensure that a competent person as identified in the MUTCD selects the appropriate high-visibility apparel suitable for the jobsite conditions. High-visibility garments shall always be the outermost garments. High-visibility garments shall be labeled as, and in a condition compliant with the ANSI/ ISEA 107 (2004 or later version) and shall be used in accordance with manufacturer recommendations. 1-07.8(1) Traffic Control Personnel All personnel performing the Work described in Section 1-10 (including traffic control supervisors, flaggers, spotters, and others performing traffic control labor of any kind) shall comply with the following: 1. During daylight hours with clear visibility, workers shall wear a high-visibility ANSI/ISEA 107 Class 2 or 3 vest or jacket, and hardhat meeting the high-visibility headwear requirements of WAC 296-155-305; and 2020 Standard Specifications M 41-10 Page 1-71 Legal Relations and Responsibilities to the Public 1-07 2. During hours of darkness (½ hour before sunset to ½ hour after sunrise) or other low-visibility conditions (snow, fog, etc.), workers shall wear a high-visibility ANSI/ ISEA 107 Class 2 or 3 vest or jacket, high-visibility lower garment meeting ANSI/ ISEA 107 Class E, and hardhat meeting the high-visibility headwear requirements of WAC 296-155-305. 1-07.8(2) Non-Traffic Control Personnel All personnel, except those performing the Work described in Section 1-10, shall wear high-visibility apparel meeting the ANSI/ISEA 107 Class 2 or 3 standard. 1-07.9 Wages 1-07.9(1) General This Contract is subject to the minimum wage requirements of RCW 39.12 and to RCW 49.28 (as amended or supplemented). On Federal-aid projects, Federal wage laws and rules also apply. The hourly minimum rates for wages and fringe benefits are listed in the Contract Provisions. When Federal wage and fringe benefit rates are listed, the rates match those identified by the U.S. Department of Labor’s “Decision Number” shown in the Contract Provisions. The Contractor, any Subcontractor, and all individuals or firms required by RCW 39.12, WAC 296-127, or the Federal Davis-Bacon and Related Acts (DBRA) to pay minimum prevailing wages, shall not pay any worker less than the minimum hourly wage rates and fringe benefits required by RCW 39.12 or the DBRA. Higher wages and benefits may be paid. By including the hourly minimum rates for wages and fringe benefits in the Contract Provisions, the Contracting Agency does not imply that the Contractor will find labor available at those rates. The Contractor shall be responsible for any amounts above the minimums that will actually have to be paid. The Contractor shall bear the cost of paying wages above those shown in the Contract Provisions. When the project is subject to both State and Federal hourly minimum rates for wages and fringe benefits and when the two rates differ for similar kinds of labor, the Contractor shall not pay less than the higher rate unless the State rates are specifically preempted by Federal law. When the project involves highway Work, heavy Work, and building Work, the Contract Provisions may list a Federal wage and fringe benefit rate for the highway Work, and a separate Federal wage and fringe benefit rate for both heavy Work and building Work. The area in which the worker is physically employed shall determine which Federal wage and fringe benefit rate shall be used to compare against the State wage and fringe benefit rate. If employing labor in a class not listed in the Contract Provisions on state funded projects only, the Contractor shall request a determination of the correct wage and benefits rate for that class and locality from the Industrial Statistician, Washington State Department of Labor and Industries (State L&I), and provide a copy of those determinations to the Engineer. Page 1-72 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public If employing labor in a class not listed in the Contract Provisions on federally funded projects, the Contractor shall request a determination of the correct wage and benefit for that class and locality from the U.S. Secretary of Labor through the Engineer. Generally, the Contractor initiates the request by preparing standard form 1444 Request for Authorization of Additional Classification and Rate, available at www.gsa.gov/reference/ forms, and submitting it to the Engineer for further action. The Contractor shall ensure that any firm (Supplier, Manufacturer, or Fabricator) that falls under the provisions of RCW 39.12 because of the definition “Contractor” in WAC 296-127-010, complies with all the requirements of RCW 39.12. The Contractor shall be responsible for compliance with the requirements of the DBRA and RCW 39.12 by all firms (Subcontractors, lower tier subcontractors, Suppliers, Manufacturers, or Fabricators) engaged in any part of the Work necessary to complete this Contract. Therefore, should a violation of this Subsection occur by any firm that is providing Work or materials for completion of this Contract whether directly or indirectly responsible to the Contractor, the Contracting Agency will take action against the Contractor, as provided by the provisions of the Contract, to achieve compliance, including but not limited to, withholding payment on the Contract until compliance is achieved. In the event the Contracting Agency has an error (omissions are not errors) in the listing of the hourly minimum rates for wages and fringe benefits in the Contract Provisions, the Contractor, any Subcontractor, any lower tier subcontractor, or any other firm that is required to pay prevailing wages, shall be required to pay the rates as determined to be correct by State L&I (or by the U.S. Department of Labor when that agency sets the rates). A change order will be prepared to ensure that this occurs. The Contracting Agency will reimburse the Contractor for the actual cost to pay the difference between the correct rates and the rates included in the Contract Provisions, subject to the following conditions: 1. The affected firm relied upon the rates included in the Contract Provisions to prepare its Bid and certifies that it did so; 2. The allowable amount of reimbursement will be the difference between the rates listed and rates later determined to be correct plus only appropriate payroll markup the employer must pay, such as, social security and other payments the employer must make to the Federal or State Government; 3. The allowable amount of reimbursement may also include some overhead cost, such as, the cost for bond, insurance, and making supplemental payrolls and new checks to the employees because of underpayment for previously performed Work; and 4. Profit will not be an allowable markup. Firms that anticipated, when they prepared their Bids, paying a rate equal to, or higher than, the correct rate as finally determined will not be eligible for reimbursement. Listing Recovery Act (and other) new hire opportunities with the Employment Security Department. 2020 Standard Specifications M 41-10 Page 1-73 Legal Relations and Responsibilities to the Public 1-07 There are many talented people currently unemployed. As the signs on the Contracting Agency’s projects advertise, the Recovery Act is about creating jobs and putting people back to work. As a companion effort, the Employment Security Department has been charged with giving people the opportunity to compete for these jobs. Their tool for doing so is WorkSource. WorkSource is a free service located across the State that screens, shortlists, and refers qualified candidates. WorkSource employees are aware that the Contractor has other commitments as part of your business practices and as part of the Contract. Contractors may be subject to hiring commitments such as Equal Employment Opportunity or union commitments. However, utilizing WorkSource can be an essential effort as part of their various good faith efforts. WorkSource is a resource that is available across the State. Contractors who have been awarded WSDOT Contracts shall be prepared to discuss their recruitment plans and how WorkSource will be incorporated into that effort at the preconstruction conference. WorkSource has a simple process for requesting and reporting new hires. The Contractor may contact the ARRA Business Unit at 877-453-5906 (toll free) or ARRA@esd.wa.gov. There is additional information available on the website at https://fortress.wa.gov/esd/worksource. 1-07.9(2) Posting Notices Notices and posters shall be placed in areas readily accessible to read by employees. The Contractor shall ensure the most current edition of the following are posted: 1. EEOC - P/E-1 – Equal Employment Opportunity IS THE LAW published by US Department of Labor. Post for projects with federal-aid funding. 2. Mandatory Supplement to EEOC P/E-1 published by US Department of Labor. Post for projects with federal-aid funding. 3. Pay Transparency Nondiscrimination Provision published by US Department of Labor. Post for projects with federal-aid funding. 4. FHWA 1022 – NOTICE Federal-Aid Project published by Federal Highway Administration (FHWA). Post for projects with federal-aid funding. 5. WH 1321 – Employee Rights Under the Davis-Bacon Act published by US Department of Labor. Post for projects with federal-aid funding. 6. WHD 1088 – Employee Rights Under the Fair Labor Standards Act published by US Department of Labor. Post on all projects. 7. WHD 1420 – Employee Rights and Responsibilities Under The Family And Medical Leave Act published by US Department of Labor. Post on all projects. 8. WHD 1462 – Employee Polygraph Protection Act published by US Department of Labor. Post on all projects. 9. F416-081-909 – Job Safety and Health Law published by Washington State Department of Labor and Industries. Post on all projects. 10. F242-191-909 – Notice To Employees published by Washington State Department of Labor and Industries. Post on all projects. Page 1-74 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 11. F700-074-909 – Your Rights as a Worker in Washington State by Washington State Department of Labor and Industries (L&I). Post on all projects. 12. EMS 9874 – Unemployment Benefits published by Washington State Employment Security Department. Post on all projects. 13. Post one copy of the approved “Statement of Intent to Pay Prevailing Wages” for the Contractor, each Subcontractor, each lower tier subcontractor, and any other firm (Supplier, Manufacturer, or Fabricator) that falls under the provisions of RCW 39.12 because of the definition of “Contractor” in WAC 296-127-010. 14. Post one copy of the prevailing wage rates for the project. 1-07.9(3) Apprentices If employing apprentices, the Contractor shall submit to the Engineer written evidence showing: 1. Each apprentice is enrolled in a program approved by the Washington State Apprenticeship and Training Council; 2. The progression schedule for each apprentice; and 3. The established apprentice-journey level ratios and wage rates in the project locality upon which the Contractor will base such ratios and rates under the Contract. Any worker for whom an apprenticeship agreement has not been registered and approved by the Washington State Apprenticeship and Training Council shall be paid at the prevailing hourly journey level rate as provided in RCW 39.12.021. 1-07.9(4) Disputes If labor and management cannot agree in a dispute over the proper prevailing wage rates, the Contractor shall refer the matter to the Director of State L&I (or to the U.S. Secretary of Labor when that agency sets the rates). The Director’s (or Secretary’s) decision shall be final, conclusive, and binding on all parties. 1-07.9(5) Required Documents On forms provided by the Industrial Statistician of State L&I, the Contractor shall submit to the Engineer the following for itself and for each firm covered under RCW 39.12 that provided Work and materials for the Contract: 1. A copy of an approved “Statement of Intent to Pay Prevailing Wages” State L&I’s form number F700-029-000. The Contracting Agency will make no payment under this Contract for the Work performed until this statement has been approved by State L&I and a copy of the approved form has been submitted to the Engineer. 2. A copy of an approved “Affidavit of Prevailing Wages Paid”, State L&I’s form number F700-007-000. The Contracting Agency will not grant Completion until all approved Affidavit of Wages paid for Contractor and all Subcontractors have been received by the Engineer. The Contracting Agency will not release to the Contractor any funds retained under RCW 60.28.011 until all of the “Affidavit of Prevailing Wages Paid” 2020 Standard Specifications M 41-10 Page 1-75 Legal Relations and Responsibilities to the Public 1-07 forms have been approved by State L&I and a copy of all the approved forms have been submitted to the Engineer. The Contractor shall be responsible for requesting these forms from State L&I and for paying any approval fees required by State L&I. Certified payrolls are required to be submitted by the Contractor to the Engineer, for the Contractor and all Subcontractors or lower tier subcontractors, on all Federal-aid projects and, when requested in writing by the Engineer, on projects funded with only Contracting Agency funds. If these payrolls are not supplied within 10 calendar days of the end of the preceding weekly payroll period for Federal-aid projects or within 10 calendar days from the date of the written request on projects with only Contracting Agency funds, any or all payments may be withheld until compliance is achieved. Also, failure to provide these payrolls could result in other sanctions as provided by State laws (RCW 39.12.050) and/or Federal regulations (29 CFR 5.12). All certified payrolls shall be complete and explicit. Employee labor descriptions used on certified payrolls shall coincide exactly with the labor descriptions listed on the minimum wage schedule in the Contract unless the Engineer approves an alternate method to identify the labor used by the Contractor to compare with the labor listed in the Contract Provisions. When an apprentice is shown on the certified payroll at a rate less than the minimum prevailing journey wage rate, the apprenticeship registration number for that employee from the State Apprenticeship and Training Council shall be shown along with the correct employee classification code. 1-07.9(6) Audits The Contracting Agency may inspect or audit the Contractor’s wage and payroll records as provided in Section 1-09.12. 1-07.10 Worker’s Benefits The Contractor shall make all payments required for unemployment compensation under Title 50 RCW and for industrial insurance and medical aid required under Title 51 RCW. If any payment required by Title 50 or Title 51 is not made when due, the Contracting Agency may retain such payments from any money due the Contractor and pay the same into the appropriate fund. Such payment will be made only after giving the Contractor 15 days prior written notice of the Contracting Agency’s intent to disburse the funds to the Washington State Department of Labor and Industries or Washington State Employment Security Department as applicable. The payment will be made upon expiration of the 15 calendar day period if no legal action has been commenced to resolve the validity of the claim. If legal action is instituted to determine the validity of the claim prior to the expiration of the 15-day period, the Contracting Agency will hold the funds until determination of the action or written settlement agreement of the appropriate parties. For Work on or adjacent to water, the Contractor shall make the determination as to whether workers are to be covered under the Longshoremen’s and Harbor Worker’s Compensation Act administered by the U.S. Department of Labor, or the State Industrial Insurance coverage administered by the Washington State Department of Labor and Industries. Page 1-76 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public The Contractor shall include in the various items in the Bid Proposal all costs for payment of unemployment compensation and for providing either or both of the insurance coverages. The Contractor will not be entitled to any additional payment for: (1) failure to include such costs, or (2) determinations made by the U.S. Department of Labor or the Washington State Department of Labor and Industries regarding the insurance coverage. The Public Works Contract Division of the Washington State Department of Labor and Industries will provide the Contractor with applicable industrial insurance and medical aid classification and premium rates. After receipt of a Revenue Release from the Washington State Department of Revenue, the Contracting Agency will verify through the Department of Labor and Industries that the Contractor is current with respect to the payments of industrial insurance and medical aid premiums. 1-07.11 Requirements for Nondiscrimination 1-07.11(1) General Application Discrimination in all phases of contracted employment, contracting activities and training is prohibited by Title VI of the Civil Rights Act of 1964, Section 162(a) of the Federal-Aid Highway Act of 1973, Section 504 of the Rehabilitation Act of 1973, the Age Discrimination Act of 1975, the Justice System Improvement Act of 1979, the American with Disabilities Act of 1990, the Civil Rights Restoration Act of 1987, 49 CFR Part 21, RCW 49.60 and other related laws and statutes. The referenced legal citations establish the minimum requirements for affirmative action efforts and define the basic nondiscrimination provisions as required by this section of these Standard Specifications. 1-07.11(2) Contractual Requirements 1. The Contractor shall maintain a Work site that is free of harassment, humiliation, fear, hostility and intimidation at all times. Behaviors that violate this requirement include but are not limited to: a. Persistent conduct that is offensive and unwelcome. b. Conduct that is considered to be hazing. c. Jokes about race, gender, or sexuality that are offensive. d. Unwelcome, unwanted, rude or offensive conduct or advances of a sexual nature which interferes with a person’s ability to perform their job or creates an intimidating, hostile, or offensive work environment. e. Language or conduct that is offensive, threatening, intimidating or hostile based on race, gender, or sexual orientation. f. Repeating rumors about individuals in the Work Site that are considered to be harassing or harmful to the individual’s reputation. 2. The Contractor shall not discriminate against any employee or applicant for contracted employment because of race, religion, color, national origin, sex, age, marital status, or the presence of any physical, sensory or mental disability. 2020 Standard Specifications M 41-10 Page 1-77 Legal Relations and Responsibilities to the Public 1-07 3. The Contractor shall, in all solicitations or advertisements for employees, state that all qualified applicants will be considered for employment, without regard to race, religion, color, national origin, sex, age, marital status, or the presence of any physical, sensory, or mental disability. 4. The Contractor shall insert the following notification in all solicitations for bids for Work or material subject to federal laws and regulations and made in connection with all program and activities and, in adapted form in all proposals for negotiated agreements: The Contractor in accordance to Title VI of the Civil Rights Act of 1964, 78 Stat.252, 42 U.S. Code 2000d to 2000d-4, and Title 49 Code of Federal Regulations, Part 21, hereby notifies all bidders that it will affirmatively ensure that in any contract entered into pursuant to this advertisement, minority business enterprises will be afforded full opportunity to submit bids in response to this invitation and will not be discriminated against on the grounds of race, color national origin and sex in consideration for an award. 5. The Contractor shall make decisions with regard to selection and retention of subcontractors, procurement of materials and equipment and similar actions related to the Contract without regard to race, religion, color, national origin, sex, age, marital status, or the presence of any physical, sensory, or mental disability. 6. The Contractor shall send to each labor union, employment agency, or representative of workers with which the Contractor has a collective bargaining agreement or other contract or understanding, a notice advising the labor union, employment agency or worker’s representative, of the Contractor’s commitments under this Contract with regard to nondiscrimination. 7. The Contractor shall permit access to its books, records and accounts by the Contracting Agency for the purpose of investigating to ascertain compliance with these Specifications. In the event that information required of a Contractor is in the possession of another who fails or refuses to furnish this information, the Contractor shall describe, in writing, what efforts were made to obtain the information. 8. The Contractor shall maintain records with the name and address of each minority/ female worker referred to the Contractor and what action was taken with respect to the referred worker. 9. The Contractor shall notify the Contracting Agency whenever the union with which the Contractor has a collective bargaining agreement has impeded the Contractor’s efforts to effect minority/female workforce utilization. This being the case, the Contractor shall show what relief they have sought under such collective bargaining agreements. 10. The Contractor is encouraged to participate in Contracting Agency and Washington State Human Rights Commission approved program(s) designed to train craft- workers for the construction trades. Page 1-78 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.11(2)A Equal Employment Opportunity (EEO) Responsibilities Title VI Responsibilities During the performance of this Contract, the Contractor, for itself, its assignees and successors in interest (hereinafter referred to as the “Contractor”) agrees as follows: 1. Compliance With Regulations – The Contractor shall comply with the Regulations relative to nondiscrimination in federally assisted programs of the Department of Transportation (hereinafter DOT), Title 49, Code of Federal Regulations, part 21, as they may be amended from time to time, (hereinafter referred to as the Regulations), which are herein incorporated by reference and made a part of this Contract. 2. Nondiscrimination – The Contractor, with regard to the Work performed by it during the Contract, shall not discriminate on the grounds of race, color, sex, or national origin in the selection and retention of Subcontractors, including procurement of materials and leases of equipment. The Contractor shall not participate either directly or indirectly in the discrimination prohibited by Section 21.5 of the Regulations, including employment practices when the Contract covers a program set forth in Appendix B of the Regulations. 3. Solicitations for Subcontracts, Including Procurement of Materials and Equipment – In all solicitations either by competitive bidding or negotiations made by the Contractor for Work to be performed under a subcontract, including procurement of materials or leases of equipment, each potential Subcontractor or supplier shall be notified by the Contractor of the Contractor’s obligations under this Contract and the Regulations relative to nondiscrimination on the ground of race, color, sex, or national origin. 4. Information and Reports – The Contractor shall provide all information and reports required by the Regulations or directives issued pursuant thereto, and shall permit access to its books, records, accounts, other sources of information, and its facilities as may be determined by the Washington State Department of Transportation or the Federal Highway Administration to be pertinent to ascertain compliance with such Regulations, orders and instructions. Where any information required of a Contractor is in the exclusive possession of another who fails or refuses to furnish this information, the Contractor shall so certify to the Washington State Department of Transportation, or the Federal Highway Administration as appropriate, and shall set forth what efforts it has made to obtain the information. 5. Sanctions for Noncompliance – In the event of the Contractor’s noncompliance with the nondiscrimination provisions of this Contract, the Washington State Department of Transportation shall impose such Contract sanctions as it or the Federal 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. 2020 Standard Specifications M 41-10 Page 1-79 Legal Relations and Responsibilities to the Public 1-07 6. Incorporation of Provisions – The Contractor shall include the provisions of paragraphs (1) through (5) in every subcontract, including procurement of materials and leases of equipment, unless exempt by the Regulations, or directives issued pursuant thereto. The Contractor shall take such action with respect to any Subcontractor or procurement as the Washington State Department of Transportation or the Federal Highway Administration may direct as a means of enforcing such provisions including sanctions for noncompliance. Provided, however, that in the event a Contractor becomes involved in, or is threatened with, litigation with a Subcontractor or supplier as a result of such direction, the Contractor may request the Washington State Department of Transportation enter into such litigation to protect the interests of the state and, in addition, the Contractor may request the United States to enter into such litigation to protect the interests of the United States. 1-07.11(3) Equal Employment Opportunity Officer The Contractor shall officially designate and make known to the Engineer during the preconstruction conference and discussions the firm’s Equal Employment Opportunity Officer (hereinafter referred to as the EEO Officer). The EEO Officer will also be responsible for making him/herself known to each of the Contractor’s employees. The EEO Officer must possess the responsibility, authority, and capability for administering and promoting an active and effective Contractor program of equal employment opportunity. 1-07.11(4) Dissemination of Policy 1-07.11(4)A Supervisory Personnel All members of the Contractor’s staff who are authorized to hire, supervise, promote, and discharge employees, or who recommend such action, or who are substantially involved in such action, shall be made fully cognizant of, and shall implement the Contractor’s equal employment opportunity policy and contractual responsibilities to provide equal employment opportunity in each grade and classification of employment. To ensure that the above agreement will be met, the following actions shall be taken as a minimum: 1. EEO Meetings – Periodic meetings of supervisory and personnel office employees shall be conducted before the start of Work and then not less often than once every 6 months, at which time the Contractor’s equal employment opportunity policy and its implementation shall be reviewed and explained. The meetings shall be conducted by the EEO Officer or other knowledgeable company official. 2. EEO Indoctrination – All new supervisory or personnel office employees shall be given a thorough indoctrination by the EEO Officer or other knowledgeable company official covering all major aspects of the Contractor’s equal employment opportunity obligations within 30 days following their reporting for duty with the Contractor. 3. Internal EEO Procedures – All personnel who are engaged in direct recruitment for the project shall be instructed by the EEO Officer or appropriate company official in the Contractor’s procedures for locating and hiring minority group and female employees. Page 1-80 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.11(4)B Employees, Applicants, and Potential Employees In order to make the Contractor’s equal employment opportunity policy known to all employees, prospective employees, and potential sources of employees, e.g., schools, employment agencies, labor unions (where appropriate), college placement officers, and community organizations, the Contractor shall take the following actions: 1. Notices and Posters – Notices and posters setting forth the Contractor’s equal employment opportunity policy shall be placed in areas readily accessible to employees, applicants for employment, and potential employees. 2. EEO Indoctrination – The Contractor’s equal employment opportunity policy and the procedures to implement such policy shall be brought to the attention of employees by means of meetings, employee handbooks, or other appropriate means. 1-07.11(5) Sanctions In the event of the Contractor is found in noncompliance with the provisions of Section 1-07.11, the Contracting Agency may impose such Contract sanctions as it or the Federal Highway Administration may determine necessary to gain compliance including, but not limited to: 1. Progress payment requests may not be honored until the noncompliance is remedied to the satisfaction of the Contracting Agency. 2. The Contract may be suspended, in whole or in part, until such time as the Contractor is determined to be in compliance by the Contracting Agency. 3. The Contractor’s pre-qualification may be suspended or revoked pursuant to WAC 468-16. The Contracting Agency may refer the matter to the Federal Highway Administration (FHWA) for possible federal sanctions. 4. The Contract may be terminated. Immediately upon the Engineer’s request, the Contractor shall remove from the Work site any employee engaging in behaviors that promote harassment, humiliation, fear or intimidation including but not limited to those described in these specifications. 1-07.11(6) Incorporation of Provisions The Contractor shall include the provisions of Section 1-07.11(2) Contractual Requirements (1) through (5) and the Section 1-07.11(5) Sanctions in every subcontract including procurement of materials and leases of equipment. The Contractor shall take such action or enforce sanctions with respect to a Subcontractor or supplier as the Contracting Agency or the FHWA may direct as a means of enforcing such provisions. In the event a Contractor becomes involved in litigation with a Subcontractor or supplier as a result of such direction, the Contractor may request the Contracting Agency enter into such litigation to protect their interests and the Contracting Agency may request the federal government to enter into such litigation to protect the interests of the United States. 2020 Standard Specifications M 41-10 Page 1-81 Legal Relations and Responsibilities to the Public 1-07 1-07.11(7) Vacant 1-07.11(8) Vacant 1-07.11(9) Subcontracting, Procurement of Materials, and Leasing of Equipment Nondiscrimination – The Contractor shall not discriminate on the grounds of race, color, religion, sex, national origin, age, or disability in the selection and retention of Subcontractors, including procurement of materials and leases of equipment. Solicitation and Utilization – The Contractor shall use their best effort to solicit bids from, and to utilize, disadvantaged, minority, and women Subcontractors, or Subcontractors with meaningful minority and women representation among their employees. Subcontractor EEO Obligations – The Contractor shall notify all potential Subcontractors and suppliers of the EEO obligations required by the Contract. The Contractor shall use their efforts to ensure Subcontractors compliance with their equal employment opportunity obligations. 1-07.11(10) Records and Reports 1-07.11(10)A General The Contractor shall keep such records as are necessary to determine compliance with the Contractor’s equal employment opportunity obligations. The records kept by the Contractor shall be designated to indicate: 1. Work Force Data – The number of minority and nonminority group members and women employed in each work classification on the project. 2. Good Faith Efforts – Unions – The progress and efforts being made in cooperation with unions to increase employment opportunities for minorities and women (applicable only to contractors who rely in whole or in part on unions as a source of their work force). 3. Good Faith Efforts – Recruitment – The progress and efforts being made in locating, hiring, training, qualifying, and upgrading minority and female employees. 4. Subcontracting – The progress and efforts being made in securing the services of disadvantaged, minority, and women Subcontractors or Subcontractors with meaningful minority and female representation among their employees. Page 1-82 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.11(10)B Required Records and Retention All records must be retained by the Contractor for a period of three years following acceptance of the Contract Work. All records shall be available at reasonable times and places for inspection by authorized representatives of either the Washington State Department of Transportation or the Federal Highway Administration. Federal-Aid Highway Construction Contractors Annual EEO Report FHWA #1391 – This form is required for all federally assisted projects provided the Contract is equal to or greater than $10,000 and for every associated subcontract equal to or greater than $10,000. Each Contract requires separate reports filed for the Contractor and each Subcontractor (subject to the above noted criteria). These forms are due by August 25th in every year during which Work was performed in July. The payroll period to be reflected in the report is the last payroll period in July in which Work was performed. This report is required of each Contractor and Subcontractor for each federally assisted Contract on which the Contractor or Subcontractor performs Work during the month of July. Monthly Employment Utilization Reports WSDOT Form 820-010 – This form (or substitute form as approved by the Contracting Agency) is required for all federally assisted projects if the Contract is equal to or greater then $10,000 and for every associated subcontract equal to or greater than $10,000. These monthly reports are to be maintained in the respective Contractor or Subcontractor’s records. 1-07.12 Federal Agency Inspection Federal laws, rules, and regulations shall be observed by the Contractor on Federal- aid projects. This Work is subject to inspection by the appropriate Federal agency. The Contractor shall cooperate with the Federal agencies in these inspections. These inspections shall not make the Federal Government a party to the Contract and shall not constitute an interference with the rights of the Contracting Agency or the Contractor. 1-07.13 Contractor’s Responsibility for Work 1-07.13(1) General All Work and material for the Contract, including any change order Work, shall be at the sole risk of the Contractor until the entire improvement has been completed as determined by the Engineer, except as provided in this section. The Contractor shall rebuild, repair, restore, and make good all damages to any portion of the permanent or temporary Work occurring before the Physical Completion Date and shall bear all the expense to do so, except damage to the permanent Work caused by: (a) acts of God, such as earthquake, floods, or other cataclysmic phenomenon of nature, or (b) acts of the public enemy or of governmental authorities; or (c) slides in cases where Section 2-03.3(11) is applicable; Provided, however, that these exceptions shall not apply 2020 Standard Specifications M 41-10 Page 1-83 Legal Relations and Responsibilities to the Public 1-07 should damages result from the Contractor’s failure to take reasonable precautions or to exercise sound engineering and construction practices in conducting the Work. If the performance of the Work is delayed as a result of damage by others, an extension of time will be evaluated in accordance with Section 1-08.8. Nothing contained in this section shall be construed as relieving the Contractor of responsibility for, or damage resulting from, the Contractor’s operations or negligence, nor shall the Contractor be relieved from full responsibility for making good any defective Work or materials as provided for under Section 1-05. 1-07.13(2) Relief of Responsibility for Completed Work Upon written request, the Contractor may be relieved of the duty of maintaining and protecting certain portions of the Work, as described below, which have been completed in all respects in accordance with the requirements of the Contract. If the Engineer provides written approval, the Contractor will be relieved of the responsibility for damage to said completed portions of the Work resulting from use by public traffic or from the action of the elements or from any other cause, but not from damage resulting from the Contractor’s operations or negligence. Portions of the Work for which the Contractor may be relieved of the duty of maintenance and protection as provided in the above paragraph include but are not limited to the following: 1. The completion of ¼ mile of Roadway or ¼ mile of one Roadway of a divided Highway or a frontage road including the Traveled Way, Shoulders, drainage control facilities, planned Roadway protection Work, lighting, and any required traffic control and access facilities. 2. A bridge or other Structure of major importance. 3. A complete unit of a traffic control signal system or of a Highway lighting system. 4. A complete unit of permanent Highway protection Work. 5. A building that is functionally complete and open to the public. 6. Any Contract Proposal item. 1-07.13(3) Relief of Responsibility for Damage by Public Traffic When it is necessary for public traffic to utilize a Highway facility during construction, the Contractor will be relieved of responsibility for damages to permanent Work by public traffic under the following circumstances: 1. The Work is in accordance with the Contract Plans or approved stage construction plans, 2. The Work is on a section of Roadway required by the Contract to be opened to public traffic, and 3. The traffic control is in accordance with the approved traffic control plans. Page 1-84 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public If traffic is relocated to another section of Roadway, the Contractor shall resume responsibility for the Work until such time as the section of Roadway is again open to public traffic or the Contractor submits a written request for Work that is completed to a point where relief can be granted in accordance with Section 1-07.13(2). 1-07.13(4) Repair of Damage The Contractor shall promptly repair all damage to either temporary or permanent Work as ordered by the Engineer. For damage qualifying for relief under Sections 1-07.13(1), 1-07.13(2), 1-07.13(3), or 8-17.5, payment will be made in accordance with Section 1-09.4, using the estimated Bid item “Reimbursement for Third Party Damage”. In the event the Contracting Agency pays for damage to the Contractor’s Work or for damage to the Contractor’s equipment caused by third parties, any claim the Contractor had or may have had against the third party shall be deemed assigned to the Contracting Agency, to the extent of the Contracting Agency’s payment for such damage. Payment will be limited to repair of damaged Work only. No payment will be made for delay or disruption of Work. For the purpose of providing a common Proposal for all Bidders, the Contracting Agency has entered an amount for “Reimbursement for Third Party Damage” in the Proposal to become a part of the total Bid by the Contractor. 1-07.14 Responsibility for Damage The State, Governor, Commission, Secretary, and all officers and employees of the State, including but not limited to those of the Department, will not be responsible in any manner: for any loss or damage that may happen to the Work or any part; for any loss of material or damage to any of the materials or other things used or employed in the performance of Work; for injury to or death of any persons, either workers or the public; or for damage to the public for any cause which might have been prevented by the Contractor, or the workers, or anyone employed by the Contractor. The Contractor shall be responsible for any liability imposed by law for injuries to, or the death of, any persons or damages to property resulting from any cause whatsoever during the performance of the Work, or before final acceptance. Subject to the limitations in this section, and RCW 4.24.115, the Contractor shall indemnify, defend, and save harmless the State, Governor, Commission, Secretary, and all officers and employees of the State from all claims, suits, or actions brought for injuries to, or death of, any persons or damages resulting from construction of the Work or in consequence of any negligence or breach of Contract regarding the Work, the use of any improper materials in the Work, caused in whole or in part by any act or omission by the Contractor or the agents or employees of the Contractor during performance or at any time before final acceptance. In addition to any remedy authorized by law, the State may retain so much of the money due the Contractor as deemed necessary by the Engineer to ensure the defense and indemnification obligations of this section until disposition has been made of such suits or claims. 2020 Standard Specifications M 41-10 Page 1-85 Legal Relations and Responsibilities to the Public 1-07 Subject to the limitations in this section and RCW 4.24.115, the Contractor shall indemnify, defend, and save harmless any county, city, or region, its officers, and employees connected with the Work, within the limits of which county, city, or region the Work is being performed, all in the same manner and to the same extent as provided above for the protection of the State, its officers and employees, provided that no retention of money due the Contractor be made by the State except as provided in RCW 60.28, pending disposition of suits or claims for damages brought against the county, city, or district. Pursuant to RCW 4.24.115, if such claims, suits, or actions result from the concurrent negligence of (a) the indemnitee or the indemnitee’s agents or employees and (b) the Contractor or the Contractor’s agent or employees, the indemnity provisions provided in the preceding paragraphs of this section shall be valid and enforceable only to the extent of the Contractor’s negligence or the negligence of its agents and employees. The Contractor shall bear sole responsibility for damage to completed portions of the project and to property located off the project caused by erosion, siltation, runoff, or other related items during the construction of the project. The Contractor shall also bear sole responsibility for any pollution of rivers, streams, ground water, or other waters that may occur as a result of construction operations. The Contractor shall exercise all necessary precautions throughout the life of the Project to prevent pollution, erosion, siltation, and damage to property. The Contracting Agency will forward to the Contractor all claims filed against the State according to RCW 4.92.100 that are deemed to have arisen in relation to the Contractor’s Work or activities under this Contract, and, in the opinion of the Contracting Agency, are subject to the defense, indemnity, and insurance provisions of these Standard Specifications. Claims will be deemed tendered to the Contractor and insurer, who has named the State as a named insured or an additional insured under the Contract’s insurance provisions, once the claim has been forwarded via certified mail to the Contractor. The Contractor shall be responsible to provide a copy of the claim to the Contractor’s designated insurance agent who has obtained/met the Contract’s insurance provision requirements. Within 60 calendar days following the date a claim is sent by the Contracting Agency to the Contractor, the Contractor shall notify the Claimant and WSDOT (Risk Management Office, PO Box 47418, Olympia, WA 98504-7418) of the following: a. Whether the claim is allowed or is denied in whole or in part, and, if so, the specific reasons for the denial of the individual claim, and if not denied in full, when payment has been or will be made to the claimant(s) for the portion of the claim that is allowed, or b. If resolution negotiations are continuing. In this event, status updates will be reported no longer than every 60 calendar days until the claim is resolved or a lawsuit is filed. Page 1-86 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public If the Contractor fails to provide the above notification within 60 calendar days, then the Contractor shall yield to the Contracting Agency sole and exclusive discretion to allow all or part of the claim on behalf of the Contractor, and the Contractor shall be deemed to have WAIVED any and all defenses, objections, or other avoidances to the Contracting Agency’s allowance of the claim, or the amount allowed by the Contracting Agency, under common law, constitution, statute, or the Contract and these Standard Specifications. If all or part of a claim is allowed, the Contracting Agency will notify the Contractor via certified mail that it has allowed all or part of the claim and make appropriate payments to the claimant(s) with State funds. Payments of State funds by the Contracting Agency to claimant(s) under this section will be made on behalf of the Contractor and at the expense of the Contractor, and the Contractor shall be unconditionally obligated to reimburse the Contracting Agency for the “total reimbursement amount”, which is the sum of the amount paid to the claimant(s), plus all costs incurred by the Contracting Agency in evaluating the circumstances surrounding the claim, the allowance of the claim, the amount due to the claimant, and all other direct costs for the Contracting Agency’s administration and payment of the claim on the Contractor’s behalf. The Contracting Agency will be authorized to withhold the total reimbursement amount from amounts due the Contractor, or, if no further payments are to be made to the Contractor under the Contract, the Contractor shall directly reimburse the Contracting Agency for the amounts paid within 30 days of the date notice that the claim was allowed was sent to the Contractor. In the event reimbursement from the Contractor is not received by the Contracting Agency within 30 days, interest shall accrue on the total reimbursement amount owing at the rate of 12 percent per annum calculated at a daily rate from the date the Contractor was notified that the claim was allowed. The Contracting Agency’s costs to enforce recovery of these amounts are additive to the amounts owing. The Contractor specifically assumes all potential liability for actions brought by employees of the Contractor and, solely for the purpose of enforcing the defense and indemnification obligations set forth in Section 1-07.14, the Contractor specifically waives any immunity granted under the State industrial insurance law, Title 51 RCW. This waiver has been mutually negotiated by the parties. The Contractor shall similarly require that each Subcontractor it retains in connection with the project comply with the terms of this paragraph, waive any immunity granted under Title 51 RCW, and assume all liability for actions brought by employees of the Subcontractor. 1-07.15 Temporary Water Pollution Prevention 1-07.15(1) Spill Prevention, Control, and Countermeasures Plan The Contractor shall prepare a Type 2 Working Drawing consisting of a project-specific spill prevention, control, and countermeasures plan (SPCC Plan), and shall implement the plan for the duration of the project. No on-site construction activities may commence until the Contracting Agency accepts an SPCC Plan for the project. An SPCC Plan template and guidance information is available at www.wsdot.wa.gov/environment/ technical/disciplines/hazardous-materials/spill-prevent-report. 2020 Standard Specifications M 41-10 Page 1-87 Legal Relations and Responsibilities to the Public 1-07 The SPCC Plan shall address all fuels, petroleum products, hazardous materials, and other materials defined in Chapter 447 of the WSDOT Environmental Manual M 31- 11. Occupational safety and health requirements that may pertain to SPCC Plan implementation are contained in, but not limited to, WAC 296-824 and WAC 296-843. The SPCC Plan shall address conditions that may be required by Section 3406 of the current International Fire Code, or as approved by the local Fire Marshal. Implementation Requirements The Contractor shall update the SPCC Plan throughout project construction so that the written plan reflects actual site conditions and practices. The Contractor shall update the SPCC Plan at least annually and maintain a copy of the updated SPCC Plan on the project site. The Contractor shall fully implement the SPCC Plan, as accepted and updated, at all times. SPCC Plan Element Requirements The SPCC Plan shall set forth the following information in the following order: 1. Responsible Personnel – Identify the names, titles, and contact information for the personnel responsible for implementing and updating the plan and for responding to spills. 2. Spill Reporting – List the names and telephone numbers of the Federal, State, and local agencies the Contractor shall notify in the event of a spill. 3. Project and Site Information – Describe the following items: a. The project Work. b. The site location and boundaries. c. The drainage pathways from the site. d. Nearby waterways and sensitive areas and their distances from the site. 4. Potential Spill Sources – Describe each of the following for all potentially hazardous materials brought or generated on-site including but not limited to materials used for equipment operation, refueling, maintenance, or cleaning: a. Name of material and its intended use. b. Estimated maximum amount on-site at any one time. c. Location(s) (including any equipment used below the ordinary high water line) where the material will be staged, used, and stored and the distance(s) from nearby waterways and sensitive areas. 5. Preexisting Contamination – Describe any preexisting contamination and contaminant sources (such as buried pipes or tanks) in the project area that are described in the Contract provisions and Plans. Identify equipment and Work practices that shall be used to prevent the release of contamination. Page 1-88 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 6. Spill Prevention and Response Training – Describe how and when all project personnel, including refueling personnel and other Subcontractors, shall be trained in spill prevention, containment, and response and in the location of spill response kits. 7. Spill Prevention – Describe the following items: a. The contents and locations of spill response kits that the Contractor shall supply and maintain that are appropriately stocked, located in close proximity to hazardous materials and equipment, and immediately accessible. b. Security measures for potential spill sources to prevent accidental spills and vandalism. c. Methods used to prevent stormwater from contacting hazardous materials. d. Secondary containment for each potential spill source listed in 4, above. Secondary containment structures shall be in accordance with Section S9.D.9 of Ecology’s Construction Stormwater General NPDES Permit, where secondary containment means placing tanks or containers within an impervious structure capable of containing 110 percent of the volume contained in the largest tank within the containment structure. Double-walled tanks do not require additional secondary containment. e. BMP methods and locations where they are used to prevent discharges to ground or water during mixing and transfer of hazardous materials and fuel. Methods to control pollutants shall use BMPs in accordance with Ecology’s Construction Stormwater General NPDES Permit. BMP guidance is provided in Ecology’s Stormwater Management Manuals, such as Volume II – Construction Stormwater Pollution Prevention, BMP C153, and Volume IV – Source Control BMPs. f. Refueling procedures for equipment that cannot be moved from below the ordinary high water line. g. Daily inspection and cleanup procedures that ensure all equipment used below the ordinary high water line is free of all external petroleum-based products. h. Routine equipment, storage area, and structure inspection and maintenance practices to prevent drips, leaks, or failures of hoses, valves, fittings, containers, pumps, or other systems that contain or transfer hazardous materials. i. Site inspection procedures and frequency. 8. Spill Response – Outline the response procedures the Contractor shall follow for each scenario listed below, indicating that if hazardous materials are encountered or spilled during construction, the Contractor shall do everything possible to control and contain the material until appropriate measures can be taken. Include a description of the actions the Contractor shall take and the specific on-site spill response equipment that shall be used to assess the spill, secure the area, contain and eliminate the spill source, clean up spilled material, decontaminate equipment, and dispose of spilled and contaminated material: 2020 Standard Specifications M 41-10 Page 1-89 Legal Relations and Responsibilities to the Public 1-07 a. A spill of each type of hazardous material at each location identified in 4, above. b. Stormwater that has come into contact with hazardous materials. c. A release or spill of any preexisting contamination and contaminant source described in 5, above. d. A release or spill of any unknown preexisting contamination and contaminant sources (such as buried pipes or tanks) encountered during project Work. e. A spill occurring during Work with equipment used below the ordinary high water line. If the Contractor will use a Subcontractor for spill response, provide contact information for the Subcontractor under item 1 (above), identify when the Subcontractor shall be used, and describe actions the Contractor shall take while waiting for the Subcontractor to respond. 9. Project Site Map – Provide a map showing the following items: a. Site location and boundaries. b. Site access roads. c. Drainage pathways from the site. d. Nearby waterways and sensitive areas. e. Hazardous materials, equipment, and decontamination areas identified in 4, above. f. Preexisting contamination or contaminant sources described in 5, above. g. Spill prevention and response equipment described in 7 and 8, above. 10. Spill Report Forms – Provide a copy of the spill report form(s) that the Contractor shall use in the event of a release or spill. Payment Payment will be made for the following Bid item when it is included in the Proposal: “SPCC Plan”, lump sum. When the written SPCC Plan is accepted by the Contracting Agency, the Contractor shall receive 50 percent of the lump sum Contract price for the plan. The remaining 50 percent of the lump sum price will be paid after the materials and equipment called for in the plan are mobilized to the project. The lump sum payment for the “SPCC Plan” shall be full pay for all costs associated with creating and updating the accepted SPCC Plan, and all costs associated with the set up of prevention measures and for implementing the current SPCC Plan as required by this Specification. Page 1-90 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.16 Protection and Restoration of Property 1-07.16(1) Private/Public Property The Contractor shall not use Contracting Agency owned or controlled property other than that directly affected by the Contract Work without the approval of the Engineer. If the Engineer grants such approval, the Contractor shall then vacate the area when ordered to do so by the Engineer. Approval to temporarily use the property shall not create any entitlement to further use or to compensation for any conditions or requirements imposed. The Contractor shall protect private or public property on or in the vicinity of the Work site. The Contractor shall ensure that it is not removed, damaged, destroyed, or prevented from being used unless the Contract so specifies. Property includes land, utilities, trees, landscaping, improvements legally on the right of way, markers, monuments, buildings, Structures, pipe, conduit, sewer or water lines, signs, and other property of all description whether shown on the Plans or not. If the Engineer orders, or if otherwise necessary, the Contractor shall install protection, acceptable to the Engineer, for property such as that listed in the previous paragraph. The Contractor is responsible for locating and protecting all property that is subject to damage by the construction operation. If the Contractor (or agents/employees of the Contractor) damage, destroy, or interfere with the use of such property, the Contractor shall restore it to original condition. The Contractor shall also halt any interference with the property’s use. If the Contractor refuses or does not respond immediately, the Engineer may have such property restored by other means and subtract the cost from money that will be or is due the Contractor. The Contractor may access the worksite from adjacent properties. The Contractor shall not use or allow others to use this access to merge with public traffic. During non- working hours, the Contractor shall provide a physical barrier that is either locked or physically unable to be moved without equipment. The access shall not go through any existing Structures. The access may go through fencing. The Contractor shall control or prevent animals from entering the worksite to the same degree that they were controlled before the fence was removed. The Contractor shall prevent persons not involved in the Contract Work from entering the worksite through the access or through trails and pathways intersected by the access. If the Contract documents require that existing trails or pathways be maintained during construction, the Contractor will insure the safe passage of trail or pathway users. The Contractor shall effectively control airborne particulates that are generated by use of the access. The location and use of the access shall not adversely affect wetlands or sensitive areas in any manner. The Contractor shall be responsible for obtaining all haul road agreements, permits and/or easements associated with the access. The Contractor shall replace any fence, repair any damage and restore the site to its original state when the access is no longer needed. The Contractor shall bear all costs associated with this worksite access. 2020 Standard Specifications M 41-10 Page 1-91 Legal Relations and Responsibilities to the Public 1-07 1-07.16(2) Vegetation Protection and Restoration Existing vegetation, where shown in the Plans or designated by the Engineer, shall be saved and protected through the life of the Contract. The Engineer will designate the vegetation to be saved and protected by a site preservation line, high visibility fencing, or individual flagging. Damage which may require replacement of vegetation includes torn bark stripping, broken branches, exposed root systems, cut root systems, poisoned root systems, compaction of surface soil and roots, puncture wounds, drastic reduction of surface roots or leaf canopy, changes in grade greater than 6 inches, or any other changes to the location that may jeopardize the survival or health of the vegetation to be preserved. When large roots of trees designated to be saved are exposed by the Contractor’s operation, they shall be wrapped with heavy, moist material, such as burlap or canvas, for protection and to prevent excessive drying. The material shall be kept moist and securely fastened until the roots are covered to finish grade. All material and fastening material shall be removed from the roots before covering. All roots 1 inch or larger in diameter, that are damaged, shall be pruned with a sharp saw or pruning shear. Damaged, torn, or ripped bark shall be removed as ordered by the Engineer at no additional cost to the Contracting Agency. Any pruning activity required to complete the Work as specified shall be performed by a Certified Arborist at the direction of the Engineer. If due to, or for any reason related to the Contractor’s operation, any tree, shrub, ground cover or herbaceous vegetation designated to be saved is destroyed, disfigured, or damaged to the extent that continued life is questionable as determined by the Engineer, it shall be removed by the Contractor at the direction of the Engineer. The Contractor will be assessed damages equal to triple the value of the vegetation as determined in the Guide for Plant Appraisal, Current Edition, published by the International Society of Arboriculture or the estimated cost of restoration with a similar species. Shrub, ground cover, and herbaceous plant values will be determined using the Cost of Cure Method. Any damage so assessed will be deducted from the monies due or that may become due the Contractor. 1-07.16(2)A Wetland and Sensitive Area Protection Existing wetland and other sensitive areas, where shown in the Plans or designated by the Engineer, shall be saved and protected through the life of the Contract. When applicable, a site preservation line has been established as a boundary between work zones and sensitive environmental areas. The Contractor shall install high visibility fence as shown in the Plans or designated by the Engineer in accordance with Section 8-01.3(1). The areas to be protected include critical environmental areas, buffer zones, and other areas of vegetation to be preserved. The Contractor shall keep areas identified by the site preservation lines free of construction equipment, construction materials, debris, and runoff. No access, including, but not Page 1-92 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public limited to, excavation, clearing, staging, or stockpiling, shall be performed inside the protected area. 1-07.16(3) Fences, Mailboxes, Incidentals The Contractor shall maintain any temporary fencing to prevent pedestrians from entering the worksite and to preserve livestock, crops, or property when working through or adjacent to private property. The Contractor is liable for all damages resulting from not complying with this requirement. The usefulness of existing mail or paper boxes shall not be impaired. If the Contract anticipates removing and reinstalling the mail or paper boxes, the provisions of Section 8-18 will apply. If the mail or paper boxes are rendered useless solely by acts (or inaction) of the Contractor or for the convenience of the Contractor, the Work shall be performed as provided in Section 8-18 at the Contractor’s expense. 1-07.16(4) Archaeological and Historical Objects Archaeological or historical objects, such as ruins, sites, buildings, artifacts, fossils, or other objects of antiquity that may have significance from a historical or scientific standpoint, which may be encountered by the Contractor, shall not be further disturbed. The Contractor shall immediately notify the Engineer of any such finds. The Engineer will determine if the material is to be salvaged. The Contractor may be required to stop Work in the vicinity of the discovery until such determination is made. The Engineer may require the Contractor to suspend Work in the vicinity of the discovery until salvage is accomplished. If the Engineer finds that the suspension of Work in the vicinity of the discovery increases or decreases the cost or time required for performance of any part of the Work under this Contract, the Engineer will make an adjustment in payment or the time required for the performance of the Work in accordance with Sections 1-04.4 and 1-08.8. 1-07.16(4)A Inadvertent Discovery of Human Skeletal Remains If human skeletal remains are encountered by the Contractor, they shall not be further disturbed. The Contractor shall immediately notify the Engineer of any such finds, and shall cease all work adjacent to the discovery, in an area adequate to provide for the total security and protection of the integrity of the skeletal remains. The Engineer may require the Contractor to suspend Work in the vicinity of the discovery until final determinations are made and removal of the skeletal remains is completed. If the Engineer finds that the suspension of Work in the vicinity of the discovery increases or decreases the cost or time required for performance of any part of the Work under this Contract, the Engineer will make an adjustment in payment or the time required for the performance of the Work in accordance with Sections 1-04.4 and 1-08.8. 2020 Standard Specifications M 41-10 Page 1-93 Legal Relations and Responsibilities to the Public 1-07 1-07.16(5) Payment All costs to comply with this section and for the protection and repair specified in this section, unless otherwise stated, are incidental to the Contract and are the responsibility of the Contractor. The Contractor shall include all related costs in the unit Bid prices of the Contract. 1-07.17 Utilities and Similar Facilities The Contractor shall protect all private and public utilities from damage resulting from the Work. Among others, these utilities include: telephone, telegraph, and power lines; pipelines, sewer and water lines; railroad tracks and equipment; and highway lighting and signing systems, and intelligent transportation systems (ITS). All costs required to protect public and private utilities shall be at the Contractor’s expense, except as provided otherwise in this section. RCW 19.122 relates to underground utilities. In accordance with this RCW, the Contractor shall call the One-Number Locator Service for field location of utilities. If no locator service is available for the area, notice shall be provided individually to those owners of utilities known to, or suspected of, having underground facilities within the area of the proposed excavation. 1-07.17(1) Utility Construction, Removal, or Relocation by the Contractor If the Work requires removing or relocating a utility, the Contract will assign the task to the Contractor or the utility owner. When the task is assigned to the Contractor it shall be performed in accordance with the Plans and Special Provisions. New utility construction shall be performed according to the appropriate Contract requirements. To ease or streamline the Work for its own convenience, the Contractor may desire to ask utility owners to move, remove, or alter their equipment in ways other than those listed in the Plans or Special Provisions. The Contractor shall make the arrangements and pay all costs that arise from work performed by the utility owner at the Contractor’s request. The Contractor shall submit a Type 2 Working Drawing consisting of plans and details describing the scope and schedule of all work performed at the Contractor’s request by the utility owner. In some cases, the Plans or Special Provisions may not show all underground facilities. If the Work requires these to be moved or protected, the Engineer will assign the task to others or issue a written change order requiring the Contractor to do so as provided in Section 1-04.4. Page 1-94 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.17(2) Utility Construction, Removal, or Relocation by Others Any authorized agent of the Contracting Agency or utility owners may enter the Highway right of way to repair, rearrange, alter, or connect their equipment. The Contractor shall cooperate with such effort and shall avoid creating delays or hindrances to those doing the work. As needed, the Contractor shall arrange to coordinate work schedules. If the Contract provides notice that utility work (including furnishing, adjusting, relocating, replacing, or constructing utilities) will be performed by others during the prosecution of the Work, the Special Provisions will establish the utility owner’s anticipated completion. The Contractor shall carry out the Work in a way that will minimize interference and delay for all forces involved. Any costs incurred prior to the utility owners anticipated completion (or if no completion is specified, within a reasonable period of time) that results from the coordination and prosecution of the Work regarding utility adjustment, relocation, replacement, or construction shall be at the Contractor’s expense as provided in Section 1-05.14. When others delay the Work through late performance of utility work, the Contractor shall adhere to the requirements of Section 1-04.5.The Contracting Agency will either suspend Work according to Section 1-08.6, or order the Contractor to coordinate the Work with the work of the utility owner in accordance with Section 1-04.4. When ordered to coordinate the Work with the work of the utility owner, the Contractor shall prosecute the Work in a way that will minimize interference and delay for all forces involved. 1-07.18 Public Liability and Property Damage Insurance The Contractor shall obtain and keep in force the following policies of insurance. The policies shall be with companies or through sources approved by the State Insurance Commissioner pursuant to RCW 48.05. Unless otherwise indicated below, the policies shall be kept in force from the execution date of the Contract until the date of acceptance by the Secretary (Section 1-05.12). 1. Owners and Contractors Protective (OCP) Insurance providing bodily injury and property damage liability coverage, with limits of $3,000,000 per occurrence and per project in the aggregate for each policy period, written on Insurance Services Office (ISO) form CG0009 1204, together with Washington State Department of Transportation amendatory endorsement CG 2908 1195, specifying the Contracting Agency, the State, the Governor, the Commission, the Secretary, the Department, and all officers and employees of the State as named insured. This policy shall be kept in force from the execution date of the Contract until the Physical Completion Date. 2. Commercial General Liability (CGL) Insurance written under ISO Form CG0001 or its equivalent, with minimum limits of $3,000,000 per occurrence and in the aggregate for each 1-year policy period. This coverage may be any combination of primary, umbrella, or excess liability coverage affording total liability limits of not less than $3,000,000 per occurrence and in the aggregate. Products and completed operations 2020 Standard Specifications M 41-10 Page 1-95 Legal Relations and Responsibilities to the Public 1-07 coverage shall be provided for a period of 3 years following Substantial Completion of the Work. 3. Commercial Automobile Liability Insurance providing bodily injury and property damage liability coverage for all owned and nonowned vehicles assigned to or used in the performance of the Work, with a combined single limit of not less than $1,000, 000 per occurrence. This coverage may be any combination of primary, umbrella, or excess liability coverage affording total liability limits of not less than $1,000,000 per occurrence, with the State named as an additional insured or designated insured in connection with the Contractor’s Performance of the Contract. If pollutants are to be transported, MCS 90 and CA 99 48 endorsements are required on the Commercial Automobile Liability insurance policy unless in-transit pollution risk is covered under a Pollution Liability insurance policy. 4. The Contractor shall be Named Insured and the Contracting Agency, the State, the Governor, the Commission, the Secretary, the Department, all officers and employees of the State, and their respective members, directors, officers, employees, agents, and consultants (collectively the “Additional Insureds”) shall be included as Additional Insureds for all policies and coverages specified in this section, with the exception of the OCP policy. Said insurance coverage shall be primary and noncontributory insurance with respect to the insureds and the Additional Insureds. Any insurance or self-insurance beyond that specified in this Contract that is maintained by any Additional Insured shall be in excess of such insurance and shall not contribute with it. All insurance coverage required by this section shall be written and provided by “occurrence-based” policy forms rather than by “claims made” forms. All endorsements adding Additional Insureds to required policies shall be issued on (i) form CG 20 10 11 85 or a form deemed equivalent by the Contracting Agency, providing the Additional Insureds with all policies and coverages set forth in this section, with the exception of the OCP and Commercial Auto policies or (ii) form CA 20 48 or forms deemed equivalent by Contracting Agency, providing the Additional Insureds with all coverages required under the Commercial Automobile Liability. 5. The coverage limits to be provided by the Contractor for itself and to the Contracting Agency and Additional Insureds pursuant to this section or any Special Provision, shall be on a “per project” aggregate basis with the minimum limits of liability as set forth herein for both general liability and products/completed operations claims. The additional insured coverage required under this section for products/completed operations claims shall remain in full force and effect for not less than 3 years following Substantial Completion of the project. If the Contractor maintains, at any time, coverage limits for itself in excess of limits set forth in this Section 1-07.18 or any Special Provision, then those additional coverage limits shall also apply to the Contracting Agency and the Additional Insured. This includes, but is not limited to, any coverage limits provided under any risk financing program of any description, whether such limits are primary, excess, contingent, or otherwise. Page 1-96 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 6. All insurance policies and coverages required under Sections 1-07.18 and 1-07.10 shall contain a waiver of subrogation against the Contracting Agency, the State, and any Additional Insureds, and their respective departments, agencies, boards, and commissions, and their respective officers, officials, agents, and employees for losses arising from Work performed by or on behalf of the Contractor. This waiver has been mutually negotiated by the parties. 7. Where applicable, the Contractor shall cause each Subcontractor to provide insurance that complies with all applicable requirements of the Contractor- provided insurance as set forth herein, in circumstances where the Subcontractor is not covered by the Contractor-provided insurance. The Contractor shall have sole responsibility for determining the limits of coverage required, if any, to be obtained by Subcontractors, which determination shall be made in accordance with reasonable and prudent business practices. In the event that a Subcontractor is required to add the Contractor as an Additional Insured pursuant to its contract for Work at the Project, then the Contractor shall also cause each Subcontractor to include the Contracting Agency and the Additional Insureds, as Additional Insureds as well, for primary and noncontributory limits of liability under each Subcontractor’s Commercial General Liability, Commercial Automobile Liability, and any other coverages that may be required pursuant to a “Special Provision”. 8. Unless specifically noted otherwise in the Contract Documents, the parties to this Contract do not intend by any of the provisions of this Contract to cause the public or any member thereof or any other Person to be a third-party beneficiary of the Contract Documents. Nothing in this Contract authorizes anyone not a party to this Contract or a designated third-party beneficiary to this Contract to maintain a suit for personal injuries or property damage pursuant to the terms or provisions of this Contract. It is the further intent of the Contracting Agency and the Contractor in executing the Form of Contract that no individual, firm, corporation, or any combination thereof that supplies materials, labor, services, or equipment to the Contractor for the performance of the Work shall become thereby a third-party beneficiary of this Contract. The Contract Documents shall not be construed to create a contractual relationship of any kind between the Contracting Agency and a Subcontractor or any other Person except the Contractor. 9. The Owners and Contractors Protective Insurance policy shall not be subject to a deductible or contain provisions for a deductible. The Commercial General Liability policy and the Commercial Automobile Liability Insurance policy may, at the discretion of the Contractor, contain such provisions. If a deductible applies to any claim under these policies, then payment of that deductible will be the responsibility of the Contractor, notwithstanding any claim of liability against the Contracting Agency. However, in no event shall any provision for a deductible provide for a deductible in excess of $50,000.00. 2020 Standard Specifications M 41-10 Page 1-97 Legal Relations and Responsibilities to the Public 1-07 10. With the exception of the Commercial Automobile liability coverage, no policies of insurance required under this section shall contain an arbitration or alternative dispute resolution clause applicable to disputes between the insurer and its insureds. Any and all disputes concerning (i) terms and scope of insurance coverage afforded by the policies required hereunder and/or (ii) extra contractual remedies and relief, which may be afforded policy holders in connection with coverage disputes, shall be resolved in Washington Superior Court, applying Washington law. 11. Prior to Contract execution, the Contractor shall file with the Department of Transportation, Contract Payment Section, PO Box 47420, Olympia, WA 98504- 7420, ACORD Form Certificates of Insurance evidencing the minimum insurance coverages required under these Specifications. Within 30 days of being awarded a Contract, the Contractor shall provide the Department with complete copies, which may be electronic copies, of all insurance policies required under this section and any Special Provisions. 12. The Contractor shall provide written notice to the Engineer of any policy cancellations and provide the Department of Transportation, Contract Payment Section, PO Box 47420, Olympia, WA 98504-7420, by U.S. Mail, notice of any policy cancellation within two business days of receipt of cancellation. 13. Failure on the part of the Contractor to maintain the insurance as required, or not to provide certification and copies of the insurance prior to the time specified in Subsection 11 above, shall constitute a material breach of Contract upon which the Contracting Agency may, after giving 5-business days notice to the Contractor to correct the breach, immediately terminate the Contract or, at its discretion, procure or renew such insurance and pay any and all premiums in connection therewith, with any sums so expended to be repaid to the Contracting Agency on demand, or at the sole discretion of the Contracting Agency, offset against funds due the Contractor from the Contracting Agency. All costs for insurance, including any payments of deductible amounts, shall be considered incidental to and included in the unit Contract prices and no additional payment will be made. 1-07.19 Gratuities The Contractor shall not extend any loan, gratuity, or gift of money in any form whatsoever to any employee or officer of the Contracting Agency; nor will the Contractor rent or purchase any equipment or materials from any employee or officer of the Contracting Agency. Before payment of the final estimate will be made, the Contractor shall execute and furnish the Contracting Agency an affidavit certifying compliance with these provisions of the Contract. The Contractor shall comply with all applicable sections of the State Ethics law, RCW 42.52, which regulates gifts to State officers and employees. Under that statute, any Contracting Agency officer or employee who has or will participate with the Contractor regarding any aspect of this Contract is prohibited from seeking or accepting any gift, gratuity, favor or anything of economic value from the Contractor. Accordingly, neither the Contractor nor any agent or representative shall offer anything of economic value as a gift, gratuity, or favor directly or indirectly to any such officer or employee. Page 1-98 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.20 Patented Devices, Materials, and Processes The Contractor shall assume all costs arising from the use of patented devices, materials, or processes used on or incorporated in the Work, and agrees to indemnify, defend, and save harmless the State, Governor, Commission, Secretary, and their duly authorized agents and employees from all actions of any nature for, or on account of the use of any patented devices, materials, or processes. 1-07.21 Rock Drilling Safety Requirements It shall be the Contractor’s responsibility to maintain safe working conditions during rock drilling, by keeping dust concentration below the threshold limit value or by providing those protective devices that may be required by the State Department of Labor and Industries. 1-07.22 Use of Explosives When using explosives, the Contractor shall use the utmost care to protect life and property, to prevent slides, and to leave undisturbed all materials, outside the neat lines of the cross-section. Explosives shall be handled, marked, stored, and used in compliance with WAC 296-52 and such local laws, rules, and regulations that may apply. The stricter provisions shall apply. All explosives shall be stored securely as required by all laws and ordinances that apply. Each storage place shall be clearly marked: “Dangerous-Explosives”. No explosives shall be left unprotected. If public utilities or railroads own equipment near the blast site, the Contractor shall notify the owners of the location, date, time, and approximate duration of the blasting. This notice shall be given sufficiently in advance to enable all owners to take any steps as they deem necessary to protect their property from injury. Blasting near proposed Structures shall be completed before Work on them begins. When the use of explosives is necessary for the prosecution of the Work, the Contractor’s insurance shall contain a special clause permitting the blasting. 1-07.23 Public Convenience and Safety The Contractor shall be responsible for providing adequate safeguards, safety devices, protective equipment, and any other needed actions to protect the life, health, and safety of the public, and to protect property in connection with the performance of the Work covered by the Contract. The Contractor shall perform any measures or actions the Engineer may deem necessary to protect the public and property. The responsibility and expense to provide this protection shall be the Contractor’s except that which is to be furnished by the Contracting Agency as specified in other sections of these Specifications. Nothing contained in this Contract is intended to create any third-party beneficiary rights in favor of the public or any individual utilizing the Highway facilities being constructed or improved under this Contract. 2020 Standard Specifications M 41-10 Page 1-99 Legal Relations and Responsibilities to the Public 1-07 1-07.23(1) Construction Under Traffic The Contractor shall conduct all operations with the least possible obstruction and inconvenience to the public. The Contractor shall have under construction no greater length or amount of Work than can be prosecuted properly with due regards to the rights of the public. To the extent possible, the Contractor shall finish each section before beginning Work on the next. The Contractor shall enter interstate Highways only through legal movements from existing roads, streets, and through other access points specifically allowed by the Contract documents. To disrupt public traffic as little as possible, the Contractor shall permit traffic to pass through the Work with the least possible inconvenience or delay. The Contractor shall maintain existing roads, streets, sidewalks, and paths within the project limits, keeping them open and in good, clean, safe condition at all times. Accessibility to existing or temporary pedestrian push buttons shall not be impaired. Deficiencies caused by the Contractor’s operations shall be repaired at the Contractor’s expense. The Contractor shall also maintain roads, streets, sidewalks, and paths adjacent to the project limits when affected by the Contractor’s operations. Snow and ice control will be performed by the Contracting Agency on all projects. Cleanup of snow and ice control debris will be at the Contracting Agency’s expense. The Contractor shall perform the following: 1. Remove or repair any condition resulting from the Work that might impede traffic or create a hazard. 2. Keep existing traffic signal and Highway lighting systems in operation as the Work proceeds. (The Contracting Agency will continue the routine maintenance on such system.) 3. Maintain the striping on the Roadway at the Contracting Agency’s expense. The Contractor shall be responsible for scheduling when to renew striping, subject to the approval of the Engineer. When the scope of the project does not require Work on the Roadway, the Contracting Agency will be responsible for maintaining the striping. 4. Maintain existing permanent signing. Repair of signs will be at the Contracting Agency’s expense, except those damaged due to the Contractor’s operations. 5. Keep drainage Structures clean to allow for free flow of water. Cleaning of existing drainage Structures will be at the Contracting Agency’s expense when approved by the Engineer, except when flow is impaired due to the Contractor’s operations. To protect the rights of abutting property owners, the Contractor shall: 1. Conduct the construction so that the least inconvenience as possible is caused to abutting property owners; 2. Maintain ready access to driveways, houses, and buildings along the line of Work; 3. Provide temporary approaches to crossing or intersecting roads and keep these approaches in good condition; and 4. Provide another access before closing an existing one whenever the Contract calls for removing and replacing an abutting owner’s access. Page 1-100 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public When traffic must pass through grading areas, the Contractor shall: 1. Make cuts and fills that provide a reasonably smooth, even Roadbed; 2. Place, in advance of other grading Work, enough fill at all culverts and bridges to permit traffic to cross; 3. Make Roadway cuts and fills, if ordered by the Engineer, in partial-width lifts, alternating lifts from side to side to permit traffic to pass on the side opposite the Work; 4. Install culverts on half the width of the Traveled Way, keeping the other half open to traffic and unobstructed until the first half is ready for use; 5. After rough grading or placing any subsequent layers, prepare the final Roadbed to a smooth, even surface (free of humps and dips) suitable for use by public traffic; and 6. Settle dust with water, or other dust palliative, as the Engineer may order. If grading Work is on or next to a Roadway in use, the Contractor shall finish the grade immediately after rough grading and place surfacing materials as the Work proceeds. The Contractor shall conduct all operations to minimize any drop-offs (abrupt changes in roadway elevation) left exposed to traffic during nonworking hours. Unless otherwise specified in the Traffic Control Plan, drop-offs left exposed to traffic during nonworking hours shall be protected as follows: 1. Drop-offs up to 0.20 foot, unless otherwise ordered by the Engineer, may remain exposed with appropriate warning signs alerting motorists of the condition. 2. Drop-offs more than 0.20 foot that are in the Traveled Way or Auxiliary Lane will not be allowed unless protected with appropriate warning signs and further protected as indicated in 3b or 3c below. 3. Drop-offs more than 0.20 foot, but no more than 0.50 foot, that are not within the Traveled Way shall be protected with appropriate warning signs and further protected by having one of the following: a. A wedge of compacted stable material placed at a slope of 4:1 or flatter. b. Channelizing devices (Type I barricades, plastic safety drums, or other devices 36 inches or more in height) placed along the traffic side of the drop-off and a new edge of pavement stripes placed a minimum of 3 feet from the drop-off. The maximum spacing between the devices in feet shall be the posted speed in miles per hour. Pavement drop-off warning signs shall be placed in advance and throughout the drop-off treatment. c. Temporary concrete barrier or other approved barrier installed on the traffic side of the drop-off with 2 feet between the drop-off and the back of the barrier and a new edge of pavement stripe a minimum of 2 feet from the face of the barrier. An approved terminal, flare, or impact attenuator will be required at the beginning of the section. For night use, the barrier shall have standard delineation such as paint, reflective tape, lane markers, or warning lights. 2020 Standard Specifications M 41-10 Page 1-101 Legal Relations and Responsibilities to the Public 1-07 4. Drop-offs more than 0.50 foot not within the Traveled Way or Auxiliary Lane shall be protected with appropriate warning signs and further protected as indicated in 3a, 3b, or 3c if all of the following conditions are met: a. The drop-off is less than 2 feet; b. The total length throughout the project is less than 1 mile; c. The drop-off does not remain for more than 3 working days; d. The drop-off is not present on any of the holidays listed in Section 1-08.5; and e. The drop-off is only on one side of the Roadway. 5. Drop-offs more than 0.50 foot that are not within the Traveled Way or Auxiliary Lane and are not otherwise covered by No. 4 above shall be protected with appropriate warning signs and further protected as indicated in 3a or 3c. 6. Open trenches within the Traveled Way or Auxiliary Lane shall have a steel-plate cover placed and anchored over them. A wedge of suitable material, if required, shall be placed for a smooth transition between the pavement and the steel plate. Warning signs shall be used to alert motorists of the presence of the steel plates. 1-07.23(2) Construction and Maintenance of Detours Unless otherwise approved, the Contractor shall maintain two-way traffic during construction. The Contractor shall build, maintain in a safe condition, keep open to traffic, and remove when no longer needed: 1. Detours and detour bridges that will accommodate traffic diverted from the Roadway, bridge, sidewalk, or path during construction; 2. Detour crossings of intersecting Highways; and 3. Temporary approaches. Unit Contract prices will cover construction, maintenance, and removal of all detours shown in the Plans or proposed by the Contracting Agency. The Contractor shall pay all costs to build, maintain, and remove any other detours, whether built for the Contractor’s convenience or to facilitate construction operations. Any detour proposed by the Contractor shall not be built until the Engineer approves. Surfacing and paving shall be consistent with traffic requirements. Upon failure of the Contractor to immediately provide, maintain, or remove detours or detour bridges when ordered to do so by the Engineer, the Contracting Agency may, without further notice to the Contractor or the Surety, provide, maintain, or remove the detours or detour bridges and deduct the costs from any payments due or coming due the Contractor. Page 1-102 2020 Standard Specifications M 41-10 1-07 Legal Relations and Responsibilities to the Public 1-07.24 Rights of Way All rights of way for the completed facility will be provided by the Contracting Agency in advance of construction. Any exceptions will be noted in the Special Provisions. Should the necessary Right of Way not be available as provided in the Contract, an extension of time will be considered in accordance with Section 1-08.8. 1-07.25 Opening of Sections to Traffic The Contracting Agency reserves the right to use and open to traffic any portion of the Work before the Physical Completion Date of the entire Contract without constituting acceptance of any of the Work. This action will not cause the Contracting Agency to incur any liability to the Contractor except as may otherwise be provided in the Contract. If the Contracting Agency opens any portion of the Work prior to the Physical Completion Date of the entire Contract because early opening is specified in the Contract or when the Contractor has failed to prosecute the Work continuously and efficiently, any Work remaining shall be performed by the Contractor at the unit Contract prices for the items of Work involved. No additional payment will be made for costs incurred by the Contractor because of: (1) inconvenience, additional length of travel to conform to established traffic patterns and planned access features; (2) compliance with statutes governing traffic regulations and limitations of loads; or (3) additional flagging costs necessary to protect the operations and the traveling public. The Contractor shall take all costs due to traffic using portions of the Work into account when submitting the Bid Proposal, and the unit Contract prices for the various items of Work involved shall include these costs. 1-07.26 Personal Liability of Public Officers Neither the Governor, the Commission, the Secretary, the Engineer, nor any other officer or employee of the State shall be personally liable for any acts or failure to act in connection with the Contract, it being understood that in such matters, they are acting solely as agents of the State. 2020 Standard Specifications M 41-10 Page 1-103 Legal Relations and Responsibilities to the Public 1-07 1-07.27 No Waiver of State’s Legal Rights The State shall not be precluded or estopped by any measurement, estimate, or certificate made either before or after the completion and acceptance of the Work and payment therefore from showing the true amount and character of the Work performed and materials furnished by the Contractor, or from showing that any such measurement, estimate, or certificate is untrue or incorrectly made, or that the Work or materials do not conform in fact to the Contract. The State shall not be precluded or estopped, notwithstanding any such measurement, estimate, or certificate, and payment in accordance therewith, from recovering from the Contractor and the Sureties such damages as it may sustain by reason of the Contractor’s failure to comply with the terms of the Contract. Neither the acceptance by the Secretary, nor any payment for the whole or any part of the Work, nor any extension of time, nor any possession taken by the State shall operate as a waiver of any portion of the Contract or of any power herein reserved or any right to damages herein provided, or bar recovery of any money wrongfully or erroneously paid to the Contractor. A waiver of any breach of the Contract shall not be held to be a waiver of any other or subsequent breach. The Contractor and the State recognize that the impact of overcharges to the State by the Contractor resulting from antitrust law violations by the Contractor’s suppliers or Subcontractors adversely affects the State rather than the Contractor. Therefore, the Contractor agrees to assign to the State any and all claims for such overcharges. Page 1-104 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress 1-08 Prosecution and Progress 1-08.1 Subcontracting Work done by the Contractor’s own organization shall account for at least 30 percent of the Awarded Contract price. Before computing this percentage, however, the Contractor may subtract (from the Awarded Contract price) the costs of any subcontracted Work on items the Contract designates as specialty items. The Contractor shall not subcontract Work unless the Engineer approves in writing. Each request to subcontract shall be on the form the Engineer provides. If the Engineer requests, the Contractor shall provide proof that the Subcontractor has the experience, ability, and equipment the Work requires. The Contractor shall require each Subcontractor to comply with Section 1-07.9 and to furnish all certificates and statements required by the Contract. Prior to subcontracting any Work, the Contractor shall verify that every first tier Subcontractor meets the responsibility criteria stated below at the time of subcontract execution. The Contractor shall include these responsibility criteria in every subcontract, and require every Subcontractor to: 1. Possess any electrical contractor license required by RCW 19.28 or elevator contractor license required by RCW 70.87, if applicable; 2. Have a certificate of registration in compliance with chapter RCW 18.27; 3. Have a current State unified business identifier number; 4. If applicable, have: a. Industrial insurance coverage for the bidder’s employees working in Washington (Title 51 RCW); b. An employment security department number (Title 50 RCW); c. A State excise tax registration number (Title 82 RCW); 5. Not be disqualified from bidding on any public works contract under RCW 39.06.010 or RCW 39.12.065(3). 6. Verify these responsibility criteria for every lower tier subcontractor at the time of subcontract execution; and, 7. Include these responsibility criteria in every lower tier subcontract. Along with the request to sublet, the Contractor shall submit the names of any contracting firms the Subcontractor proposes to use as lower tier subcontractors. Collectively, these lower tier subcontractors shall not do Work that exceeds 25 percent of the total amount subcontracted to a Subcontractor. When a Subcontractor is responsible for construction of a specific Structure or Structures, the following Work may be performed by lower tier Subcontractors without being subject to the 25 percent limitation: 2020 Standard Specifications M 41-10 Page 1-105 Prosecution and Progress 1-08 1. Furnishing and driving of piling, or 2. Furnishing and installing concrete reinforcing and post-tensioning steel. Except for the 25 percent limit, lower tier subcontractors shall meet the same requirements as Subcontractors. The Engineer will approve the request only if satisfied with the proposed Subcontractor’s record, equipment, experience, and ability. Approval to subcontract shall not: 1. Relieve the Contractor of any responsibility to carry out the Contract, 2. Relieve the Contractor of any obligations or liability under the Contract and the Contractor’s bond, 3. Create any contract between the Contracting Agency and the Subcontractor, or 4. Convey to the Subcontractor any rights against the Contracting Agency. All work that is not performed by the Contractor will be considered as subcontracting except: (1) purchase of sand, gravel, crushed stone, crushed slag, batched concrete aggregates, ready-mix concrete, off-site fabricated structural steel, other off-site fabricated items, and any other materials supplied by established and recognized commercial plants; or (2) delivery of these materials to the Work site in vehicles owned or operated by such plants or by recognized independent or commercial hauling companies hired by those commercial plants. However, the Washington State Department of Labor and Industries may determine that RCW 39.12 applies to the employees of such firms identified in 1 and 2 above in accordance with WAC 296-127. If this should occur, the provisions of Section 1-07.9, as modified or supplemented, shall apply. The Contractor shall not use businesses (material suppliers, vendors, subcontractors, etc.) with federal purchasing exclusions. Businesses with exclusions are identified using the System for Award Management web page at www.SAM.gov. On all projects, the Contractor shall certify to the actual amounts paid to all firms that were used as Subcontractors, lower tier subcontractors, manufacturers, regular dealers, or service providers on the Contract. This includes all Disadvantaged, Minority, Small, Veteran or Women’s Business Enterprise firms. This Certification shall be submitted to the Engineer on a monthly basis each month between Execution of the Contract and Physical Completion of the Contract using the application available at: https://wsdot. diversitycompliance.com. A monthly report shall be submitted for every month between Execution of the Contract and Physical Completion regardless of whether payments were made or work occurred. The Contractor shall comply with the requirements of RCW 39.04.250, 39.76.011, 39.76.020, and 39.76.040, in particular regarding prompt payment to Subcontractors. Whenever the Contractor withholds payment to a Subcontractor for any reason including disputed amounts, the Contractor shall provide notice within 10 calendar days to the Subcontractor with a copy to the Contracting Agency identifying the reason for the withholding and a clear description of what the Subcontractor must do to have the withholding released. Retainage withheld by the Contractor prior to completion of the Page 1-106 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress Subcontractors work is exempt from reporting as a payment withheld and is not included in the withheld amount. The Contracting Agency’s copy of the notice to Subcontractor for deferred payments shall be submitted to the Engineer concurrently with notification to the Subcontractor. If dissatisfied with any part of the subcontracted Work, the Engineer may request in writing that the Subcontractor be removed. The Contractor shall comply with this request at once and shall not employ the Subcontractor for any further Work under the Contract. 1-08.1(1) Prompt Payment, Subcontract Completion and Return of Retainage Withheld The following procedure shall apply to all subcontracts entered into as a part of this Contract: Requirements 1. Upon request, the Engineer will provide a copy of any or all progress payment estimates, with regard to contract payments to any interested party to the project. 2. The Contractor shall make payment to the Lower Tier Subcontractor not later than ten calendar days after receipt of payment for work satisfactorily completed by the Lower Tier Subcontractor, to the extent of the Lower Tier Subcontractor’s interest therein. 3. In the event the Contractor believes they have the right under the Contract or Subcontract to withhold payment in part or whole from a Lower Tier Subcontractor they shall provide immediate notification to that Lower Tier Subcontractor and the Engineer. The notice shall include an accounting of payments to date, the value and reason for the withheld amount, and an explanation of what must be done to have the withheld amount released. The Lower Tier Subcontractor shall be paid within eight calendar days after the Subcontractor completes the remedial action identified. 4. Every subcontract and lower tier subcontract shall have a dispute resolution process incorporated for resolving issues between the parties to the subcontract, or one shall be established as necessary. 5. If the parties agree, the Contracting Agency will make a third party neutral available provided the parties to the dispute agree that the cost of doing so is split between them. 6. The Engineer will withhold the same amount of funds from the Contractor as was withheld if the issue is not resolved by the next progress estimate. 7. Failure by a Contractor or Subcontractor to comply with these requirements may result in one or more of the following: a. Reflected in the Prime Contractor’s Performance Evaluation. b. Cancellation, termination or suspension of the Contract, in whole or in part. c. Sanctions as provided by the Contract; subcontract; or by law under applicable prompt payment statutes including RCW 39.04.250. 2020 Standard Specifications M 41-10 Page 1-107 Prosecution and Progress 1-08 8. The Subcontractor shall make a written request to the Contractor for the release of the Subcontractor’s retainage or retainage bond. 9. Within 10 calendar days of the request, the Contractor shall determine if the subcontract has been satisfactorily completed including any required lien releases, documentation and material testing and shall inform the Subcontractor, in writing, of the Contractor’s determination. 10. If the Contractor determines that the subcontract has been satisfactorily completed, the Subcontractor’s retainage or retainage bond shall be released by the Contractor within 10 calendar days from the date of the written notice. If the Contractor determines that the Subcontractor has not achieved satisfactory completion of the subcontract, the Contractor must provide the Subcontractor with written notice, stating specifically why the subcontract Work is not satisfactorily completed and what has to be done to achieve completion. The Contractor shall release the Subcontractor’s retainage or retainage bond within 10 calendar days after the Subcontractor has satisfactorily completed the Work identified in the notice. 11. In determining whether satisfactory completion has been achieved, the Contractor may require the Subcontractor to provide documentation such as certifications and releases, showing that all laborers, lower-tiered Subcontractors, suppliers of material and equipment, and others involved in the Subcontractor’s Work have been paid in full. The Contractor may also require any documentation from the Subcontractor that is required by the subcontract or by the Contract between the Contractor and Contracting Agency or by law such as affidavits of wages paid, and material acceptance certifications to the extent that they relate to the Subcontractor’s Work. 12. If the Contractor fails to comply with the requirements of the Specification and the Subcontractor’s retainage or retainage bond is wrongfully withheld, the Contractor will be subject to the actions described in No. 7 listed above. The Subcontractor may also seek recovery against the Contractor under applicable prompt pay statutes in addition to any other remedies provided for by the subcontract or by law. Conditions 1. This clause does not create a contractual relationship between the Contracting Agency and any Subcontractor as stated in Section 1-08.1. Also, it is not intended to bestow upon any Subcontractor, the status of a third-party beneficiary to the Contract between the Contracting Agency and the Contractor. 2. This section of the Contract does not apply to retainage withheld by the Contracting Agency from monies earned by the Contractor. The Contracting Agency shall continue to process the release of that retainage based upon the Completion Date of the project as defined in Section 1-08.5 Time for Completion and in accordance with the requirements and procedures set forth in RCW 60.28. Page 1-108 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress Payment The Contractor shall be solely responsible for any additional costs involved in paying retainage to the Subcontractors prior to total project completion. Those costs shall be incidental to the respective Bid items. 1-08.2 Assignment The Contractor shall not assign all or any part of the Work unless the Engineer approves in writing. The Engineer will not approve any proposed assignment that would relieve the original Contractor or Surety of responsibility under the Contract. Money due (or that will become due) to the Contractor may be assigned. If given written notice, the Contracting Agency will honor such an assignment to the extent the law permits. But the assignment shall be subject to all setoffs, withholdings, and deductions required by law and the Contract. 1-08.3 Progress Schedule 1-08.3(1) General Requirements The Contractor shall submit Type A or Type B Progress Schedules and Schedule Updates to the Engineer for approval. Schedules shall show Work that complies with all time and order of Work requirements in the Contract. Scheduling terms and practices shall conform to the standards established in Construction Planning and Scheduling, Second Edition, published by the Associated General Contractors of America. Except for Weekly Look- Ahead Schedules, all schedules shall meet these General Requirements, and provide the following information: 1. Include all activities necessary to physically complete the project. 2. Show the planned order of Work activities in a logical sequence. 3. Show durations of Work activities in working days as defined in Section 1-08.5. 4. Show activities in durations that are reasonable for the intended Work. 5. Define activity durations in sufficient detail to evaluate the progress of individual activities on a daily basis. 6. Show the Physical Completion of all Work within the authorized Contract time. Total float belongs to the project and shall not be for the exclusive benefit of any party. The Contracting Agency allocates its resources to a Contract based on the total time allowed in the Contract. The Contracting Agency may accept a Progress Schedule indicating an early Physical Completion Date but cannot guarantee the Contracting Agency’s resources will be available to meet an accelerated schedule. No additional compensation will be allowed if the Contractor is not able to meet their accelerated schedule due to the unavailability of Contracting Agency’s resources or for other reasons beyond the Contracting Agency’s control. 2020 Standard Specifications M 41-10 Page 1-109 Prosecution and Progress 1-08 If the Engineer determines that the Progress Schedule or any necessary Schedule Update does not provide the required information, then the schedule will be returned to the Contractor for correction and resubmittal. The Engineer’s approval of any schedule shall not transfer any of the Contractor’s responsibilities to the Contracting Agency. The Contractor alone shall remain responsible for adjusting forces, equipment, and Work schedules to ensure completion of the Work within the time(s) specified in the Contract. 1-08.3(2) Progress Schedule Types Type A Progress Schedules are required on all projects that do not contain the Bid item for Type B Progress Schedule. Type B Progress Schedules are required on all projects that contain the Bid item for Type B Progress Schedule. Weekly Look-Ahead Schedules and Schedule Updates are required on all projects. 1-08.3(2)A Type A Progress Schedule The Contractor shall submit five copies of a Type A Progress Schedule no later than 10 days after the date the contract is executed, or some other mutually agreed upon submittal time. The schedule may be a critical path method (CPM) schedule, bar chart, or other standard schedule format. Regardless of which format is used, the schedule shall identify the critical path. The Engineer will evaluate the Type A Progress Schedule and approve or return the schedule for corrections within 15 calendar days of receiving the submittal. 1-08.3(2)B Type B Progress Schedule The Contractor shall submit a preliminary Type B Progress Schedule no later than 5 calendar days after the date the Contract is executed. The preliminary Type B Progress Schedule shall comply with all of these requirements and the requirements of Section 1-08.3(1), except that it may be limited to only those activities occurring within the first 60 working days of the project. The Contractor shall submit five copies of a Type B Progress Schedule depicting the entire project no later than 30 calendar days after the date the Contract is executed. The schedule shall be a critical path method (CPM) schedule developed by the Precedence Diagramming Method (PDM). Restraints may be utilized, but may not serve to change the logic of the network or the critical path. The schedule shall display at least the following information: • Contract Number and Title • Construction Start Date • Critical Path • Activity Description • Milestone Description • Activity Duration • Predecessor Activities Page 1-110 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress • Successor Activities • Early Start (ES) and Early Finish (EF) for each activity • Late Start (LS) and Late Finish (LF) for each activity • Total Float (TF) and Free Float (FF) for each activity • Physical Completion Date • Data Date The Engineer will evaluate the Type B Progress Schedule and approve or return the schedule for corrections within 15 calendar days of receiving the submittal. 1-08.3(2)C Vacant 1-08.3(2)D Weekly Look-Ahead Schedule Each week that Work will be performed, the Contractor shall submit a Weekly Look- Ahead Schedule showing the Contractor’s and all Subcontractors’ proposed Work activities for the next two weeks. The Weekly Look-Ahead Schedule shall include the description, duration and sequence of Work, along with the planned hours of Work. This schedule may be a network schedule, bar chart, or other standard schedule format. The Weekly Look-Ahead Schedule shall be submitted to the Engineer by the midpoint of the week preceding the scheduled Work or some other mutually agreed upon submittal time. 1-08.3(3) Schedule Updates The Engineer may request a Schedule Update when any of the following events occur: 1. The project has experienced a change that affects the critical path. 2. The sequence of Work is changed from that in the approved schedule. 3. The project is significantly delayed. 4. Upon receiving an extension of Contract time. The Contractor shall submit five copies of a Type A or Type B Schedule Update within 15 calendar days of receiving a written request, or when an update is required by any other provision of the Contract. A “significant” delay in time is defined as 10 working days or 10 percent of the original Contract time, whichever is greater. In addition to the other requirements of this section, Schedule Updates shall reflect the following information: 1. The actual duration and sequence of as-constructed Work activities, including changed Work. 2. Approved time extensions. 3. Any construction delays or other conditions that affect the progress of the Work. 4. Any modifications to the as-planned sequence or duration of remaining activities. 5. The Physical Completion of all remaining Work in the remaining Contract time. 2020 Standard Specifications M 41-10 Page 1-111 Prosecution and Progress 1-08 Unresolved requests for time extensions shall be reflected in the Schedule Update by assuming no time extension will be granted, and by showing the effects to follow-on activities necessary to physically complete the project within the currently authorized time for completion. 1-08.3(4) Measurement No specific unit of measurement shall apply to the lump sum item for Type B Progress Schedule. 1-08.3(5) Payment Payment will be made for the following Bid item when it is included in the Proposal: “Type B Progress Schedule”, lump sum. The lump sum price shall be full pay for all costs for furnishing the Type B Progress Schedule and preliminary Type B Progress Schedule. Payment of 80 percent of the lump sum price will be made upon approval of the Progress Schedule. Payment will be increased to 100 percent of the lump sum price upon completion of 80 percent of the original total Contract Award amount. All costs for providing Type A Progress Schedules and Weekly Look-Ahead Schedules are considered incidental to other items of Work in the Contract. No payment will be made for Schedule Updates that are required due to the Contractors operations. Schedule Updates required by events that are attributed to the actions of the Contracting Agency will be paid for in accordance with Section 1-09.4. 1-08.4 Prosecution of Work The Contractor shall begin Work within 21 calendar days from the date of execution of the Contract by the Contracting Agency, unless otherwise approved in writing. The Contractor shall diligently pursue the Work to the Physical Completion Date within the time specified in the Contract. Voluntary shutdown or slowing of operations by the Contractor shall not relieve the Contractor of the responsibility to complete the Work within the time(s) specified in the Contract. When shown in the Plans, the first order of work shall be the installation of high visibility fencing to delineate all areas for protection or restoration, as described in the Contract. Installation of high visibility fencing adjacent to the roadway shall occur after the placement of all necessary signs and traffic control devices in accordance with Section 1-10.1(2). Upon construction of the fencing, the Contractor shall request the Engineer to inspect the fence. No other work shall be performed on the site until the Contracting Agency has accepted the installation of high visibility fencing, as described in the Contract. Page 1-112 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress 1-08.5 Time for Completion The Contractor shall complete all physical Contract Work within the number of “working days” stated in the Contract Provisions or as extended by the Engineer in accordance with Section 1-08.8. Every day will be counted as a “working day” unless it is a nonworking day or an Engineer determined unworkable day. A nonworking day is defined as a Saturday, a Sunday, a whole or half day on which the Contract specifically prohibits Work on the critical path of the Contractor’s approved progress schedule, or one of these holidays: January 1, the third Monday of January, the third Monday of February, Memorial Day, July 4, Labor Day, November 11, Thanksgiving Day, the day after Thanksgiving, and Christmas Day. When any of these holidays fall on a Sunday, the following Monday shall be counted a nonworking day. When the holiday falls on a Saturday, the preceding Friday shall be counted a nonworking day. The days between December 25 and January 1 will be classified as nonworking days. An unworkable day is defined as a half or whole day the Engineer declares to be unworkable because of weather or conditions caused by the weather that prevents satisfactory and timely performance of the Work shown on the critical path of the Contractor’s approved progress schedule. Other conditions beyond the control of the Contractor may qualify for an extension of time in accordance with Section 1-08.8. Contract time shall begin on the first working day following the 21st calendar day after the date the Contracting Agency executes the Contract. If the Contractor starts Work on the project at an earlier date, then Contract time shall begin on the first working day when on-site Work begins. The Contract Provisions may specify another starting date for Contract time, in which case, time will begin on the starting date specified. Each working day shall be charged to the Contract as it occurs, until the Contract Work is physically complete. If Substantial Completion has been granted and all the authorized working days have been used, charging of working days will cease. Each week the Engineer will provide the Contractor a statement that shows the number of working days: (1) charged to the Contract the week before; (2) specified for the Physical Completion of the Contract; and (3) remaining for the Physical Completion of the Contract. The statement will also show the nonworking days and any half or whole day the Engineer declares as unworkable. Within 10 calendar days after the date of each statement, the Contractor shall file a written protest of any alleged discrepancies in it. To be considered by the Engineer, the protest shall be in sufficient detail to enable the Engineer to ascertain the basis and amount of time disputed. By not filing such detailed protest in that period, the Contractor shall be deemed as having accepted the statement as correct. The Engineer will give the Contractor written notice of the Physical Completion Date for all Work the Contract requires. That date shall constitute the Physical Completion Date of the Contract, but shall not imply the Secretary’s acceptance of the Work or the Contract. 2020 Standard Specifications M 41-10 Page 1-113 Prosecution and Progress 1-08 The Engineer will give the Contractor written notice of the Completion Date of the Contract after all the Contractor’s obligations under the Contract have been performed by the Contractor. The following events must occur before the Completion Date can be established: 1. The physical Work on the project must be complete; and 2. The Contractor must furnish all documentation required by the Contract and required by law, to allow the Contracting Agency to process final acceptance of the Contract. The following documents must be received by the Engineer prior to establishing a Completion Date: a. Certified Payrolls (Federal-aid Projects) b. Material Acceptance Certification Documents c. Monthly Reports of Amounts Paid as MBE/WBE Participants, or Monthly Reports of Amounts Credited as DBE Participation, as required by the Contract Provisions d. Final Contract Voucher Certification e. Copies of the approved “Affidavit of Prevailing Wages Paid” for the Contractor and all Subcontractors f. A copy of the Notice of Termination sent to the Washington State Department of Ecology (Ecology); the elapse of 30 calendar days from the date of receipt of the Notice of Termination by Ecology; and no rejection of the Notice of Termination by Ecology. This requirement will not apply if the Construction Stormwater General Permit is transferred back to the Contracting Agency in accordance with Section 8-01.3(16) 1-08.6 Suspension of Work The Engineer may order suspension of all or any part of the Work if: 1. Unsuitable weather prevents satisfactory and timely performance of the Work; or 2. The Contractor does not comply with the Contract; or 3. It is in the public interest. When ordered by the Engineer to suspend or resume Work, the Contractor shall do so immediately. If the Work is suspended for reason (1) above, the period of Work stoppage will be counted as unworkable days. But if the Engineer believes the Contractor should have completed the suspended Work before the suspension, all or part of the suspension period may be counted as working days. The Engineer will set the number of unworkable days (or parts of days) by deciding how long the suspension delayed the entire project. Page 1-114 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress If the Work is suspended for reason (2) above, the period of Work stoppage will be counted as working days. The lost Work time, however, shall not relieve the Contractor from any Contract responsibility. If the performance of all or any part of the Work is suspended, delayed, or interrupted for an unreasonable period of time by an act of the Contracting Agency in the administration of the Contract, or by failure to act within the time specified in the Contract (or if no time is specified, within a reasonable time), the Engineer will make an adjustment for any increase in the cost or time for the performance of the Contract (excluding profit) necessarily caused by the suspension, delay, or interruption. However, no adjustment will be made for any suspension, delay, or interruption if (1) the performance would have been suspended, delayed, or interrupted by any other cause, including the fault or negligence of the Contractor, or (2) an equitable adjustment is provided for or excluded under any other provision of the Contract. If the Contractor believes that the performance of the Work is suspended, delayed, or interrupted for an unreasonable period of time and such suspension, delay, or interruption is the responsibility of the Contracting Agency, the Contractor shall immediately submit a written notice of protest to the Engineer as provided in Section 1-04.5. No adjustment shall be allowed for any costs incurred more than 10 calendar days before the date the Engineer receives the Contractor’s written notice of protest. If the Contractor contends damages have been suffered as a result of such suspension, delay, or interruption, the protest shall not be allowed unless the protest (stating the amount of damages) is asserted in writing as soon as practicable, but no later than the date of the Contractor’s signature on the Final Contract Voucher Certification. The Contractor shall keep full and complete records of the costs and additional time of such suspension, delay, or interruption and shall permit the Engineer to have access to those records and any other records as may be deemed necessary by the Engineer to assist in evaluating the protest. The Engineer will determine if an equitable adjustment in cost or time is due as provided in this section. The equitable adjustment for increase in costs, if due, shall be subject to the limitations provided in Section 1-09.4, provided that no profit of any kind will be allowed on any increase in cost necessarily caused by the suspension, delay, or interruption. Request for extensions of time will be evaluated in accordance with Section 1-08.8. The Engineer’s determination as to whether an adjustment should be made will be final as provided in Section 1-05.1. No claim by the Contractor under this clause shall be allowed unless the Contractor has followed the procedures provided in this section and in Sections 1-04.5 and 1-09.11. 2020 Standard Specifications M 41-10 Page 1-115 Prosecution and Progress 1-08 1-08.7 Maintenance During Suspension Before and during any suspension (as described in Section 1-08.6) the Contractor shall protect the Work from damage or deterioration. Suspension shall not relieve the Contractor from anything the Contract requires unless this section states otherwise. At no expense to the Contracting Agency, the Contractor shall provide through the construction area safe, smooth, and unobstructed roadways and pedestrian access routes for public use during the suspension (as required in Section 1-07.23 or the Special Provisions). This may include a temporary road, alternative pedestrian access route or detour. If the Engineer determines that the Contractor failed to pursue the Work diligently before the suspension, or failed to comply with the Contract or orders, then the Contractor shall maintain the temporary Roadway in use during suspension. In this case, the Contractor shall bear the maintenance costs. If the Contractor fails to maintain the temporary Roadway, the Contracting Agency will do the Work and deduct all resulting costs from payments due to the Contractor. If the Engineer determines that the Contractor has pursued the Work diligently before the suspension, then the Contracting Agency will maintain the temporary Roadway (and bear its cost). This Contracting Agency-provided maintenance work will include only routine maintenance of: 1. The Traveled Way, Auxiliary Lanes, Shoulders, and detour surface; 2. Roadway drainage along and under the traveled Roadway or detour; and 3. All barricades, signs, and lights needed for directing traffic through the temporary Roadway or detour in the construction area. The Contractor shall protect and maintain all other Work in areas not used by traffic. All costs associated with protecting and maintaining such Work shall be the responsibility of the Contractor. After any suspension during which the Contracting Agency has done the routine maintenance, the Contractor shall accept the traveled Roadway or detour as is when Work resumes. The Contractor shall make no claim against the Contracting Agency for the condition of the Roadway or detour. After any suspension, the Contractor shall resume all responsibilities the Contract assigns for the Work. 1-08.8 Extensions of Time The Contractor shall submit any requests for time extensions to the Engineer in writing no later than 10 working days after the delay occurs. The requests for time extension shall be limited to the effect on the critical path of the Contractor’s approved schedule attributable to the change or event giving rise to the request. Page 1-116 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress To be considered by the Engineer, the request shall be in sufficient detail (as determined by the Engineer) to enable the Engineer to ascertain the basis and amount of the time requested. The request shall include an updated schedule that supports the request and demonstrates that the change or event: (1) had a specific impact on the critical path, and except in cases of concurrent delay, was the sole cause of such impact, and (2) could not have been avoided by resequencing of the Work or by using other reasonable alternatives. If a request combined with previous extension requests, equals 20 percent or more of the original Contract time then the Contractor’s letter of request must bear consent of Surety. In evaluating any request, the Engineer will consider how well the Contractor used the time from Contract execution up to the point of the delay and the effect the delay has on any completion times included in the Special Provisions. The Engineer will evaluate and respond within 15 calendar days of receiving the request. The authorized time for Physical Completion will be extended for a period equal to the time the Engineer determines the Work was delayed because of: 1. Adverse weather causing the time requested to be unworkable, provided that the Engineer had not already declared the time to be unworkable and the Contractor has filed a written protest according to Section 1-08.5. 2. Any action, neglect, or default of the Contracting Agency, its officers, or employees, or of any other contractor employed by the Contracting Agency. 3. Fire or other casualty for which the Contractor is not responsible. 4. Strikes. 5. Any other conditions for which these Specifications permit time extensions such as: a. In Section 1-04.4 if a change increases the time to do any of the Work including unchanged Work. b. In Section 1-04.5 if increased time is part of a protest that is found to be a valid protest. c. In Section 1-04.7 if a changed condition is determined to exist that caused a delay in completing the Contract. d. In Section 1-05.3 if the Contracting Agency does not approve properly prepared and acceptable drawings within 30 calendar days. e. In Section 1-07.13 if the performance of the Work is delayed as a result of damage by others. f. In Section 1-07.17 if the removal or the relocation of any utility by forces other than the Contractor caused a delay. g. In Section 1-07.24 if a delay results from all the Right of Way necessary for the construction not being purchased and the Special Provisions does not make specific provisions regarding unpurchased Right of Way. h. In Section 1-08.6 if the performance of the Work is suspended, delayed, or interrupted for an unreasonable period of time that proves to be the responsibility of the Contracting Agency. 2020 Standard Specifications M 41-10 Page 1-117 Prosecution and Progress 1-08 i. In Section 1-09.11 if a dispute or claim also involves a delay in completing the Contract and the dispute or claim proves to be valid. j. In Section 1-09.6 for Work performed on a force account basis. 6. If the actual quantity of Work performed for a Bid item was more than the original Plan quantity and increased the duration of a critical activity. Extensions of time will be limited to only that quantity exceeding the original Plan quantity. 7. Exceptional causes not specifically identified in items 1 through 6, provided the request letter proves the Contractor had no control over the cause of the delay and could have done nothing to avoid or shorten it. Working days added to the Contract by time extensions, when time has overran, shall only apply to days on which liquidated damages or direct engineering have been charged, such as the following: If Substantial Completion has been granted prior to all of the authorized working days being used, then the number of days in the time extension will eliminate an equal number of days on which direct engineering charges have accrued. If the Substantial Completion Date is established after all of the authorized working days have been used, then the number of days in the time extension will eliminate an equal number of days on which liquidated damages or direct engineering charges have accrued. The Engineer will not allow a time extension for any cause listed above if it resulted from the Contractor’s default, collusion, action or inaction, or failure to comply with the Contract. The Contracting Agency considers the time specified in the Special Provisions as sufficient to do all the Work. For this reason, the Contracting Agency will not grant a time extension for: 1. Failure to obtain all materials and workers unless the failure was the result of exceptional causes as provided above in Subsection 7; 2. Changes, protests, increased quantities, or changed conditions (Section 1-04) that do not delay the completion of the Contract or prove to be an invalid or inappropriate time extension request; 3. Delays caused by nonapproval of drawings or plans as provided in Section 1-05.3; 4. Rejection of faulty or inappropriate equipment as provided in Section 1-05.9; 5. Correction of thickness deficiency as provided in Section 5-05.5(1). The Engineer will determine whether the time extension should be granted, the reasons for the extension, and the duration of the extension, if any. Such determination will be final as provided in Section 1-05.1. Page 1-118 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress 1-08.9 Liquidated Damages Time is of the essence of the Contract. Delays inconvenience the traveling public, obstruct traffic, interfere with and delay commerce, and increase risk to Highway users. Delays also cost tax payers undue sums of money, adding time needed for administration, engineering, inspection, and supervision. Because the Contracting Agency finds it impractical to calculate the actual cost of delays, it has adopted the following formula to calculate liquidated damages for failure to complete the physical Work of a Contract on time. Accordingly, the Contractor agrees: 1. To pay (according to the following formula) liquidated damages for each working day beyond the number of working days established for Physical Completion, and 2. To authorize the Engineer to deduct these liquidated damages from any money due or coming due to the Contractor. Liquidated Damages Formula n xXm ∑= ()() 2 1 22 1nn xxnS       − ∑−∑= S LSLXQmL −= S XUSLQ mu −= ()()() ∑ +⋅⋅⋅+== i ii2211 f PFfPFfPFfCPF if jto1i= T C15.0LD= Where: LD = liquidated damages per working day (rounded to the nearest dollar) C = original Contract amount T = original time for Physical Completion When the Contract Work has progressed to the extent that the Contracting Agency has full use and benefit of the facilities, both from the operational and safety standpoint, all the initial plantings are completed and only minor incidental Work, replacement of temporary substitute facilities, plant establishment periods, or correction or repair remains to physically complete the total Contract, the Engineer may determine the Contract Work is substantially complete. The Engineer will notify the Contractor in writing of the Substantial Completion Date. For overruns in Contract time occurring after the date so established, the formula for liquidated damages shown above will not apply. For overruns in Contract time occurring after the Substantial Completion Date, liquidated damages shall be assessed on the basis of direct engineering and related costs assignable to the project until the actual Physical Completion Date of all the Contract Work. The Contractor shall complete the remaining Work as promptly as possible. Upon request by the Engineer, the Contractor shall furnish a written schedule for completing the physical Work on the Contract. Liquidated damages will not be assessed for any days for which an extension of time is granted. No deduction or payment of liquidated damages will, in any degree, release the Contractor from further obligations and liabilities to complete the entire Contract. 2020 Standard Specifications M 41-10 Page 1-119 Prosecution and Progress 1-08 1-08.10 Termination of Contract 1-08.10(1) Termination for Default The Contracting Agency may terminate the Contract upon the occurrence of any one or more or the following events: 1. If the Contractor fails to supply sufficient skilled workers or suitable materials or equipment; 2. If the Contractor refuses or fails to prosecute the Work with such diligence as will ensure its Physical Completion within the original Physical Completion time and any extensions of time which may have been granted to the Contractor by change order or otherwise; 3. If the Contractor is adjudged bankrupt or insolvent, or makes a general assignment for the benefit of creditors, or if the Contractor or a third party files a petition to take advantage of any debtor’s act or to reorganize under the bankruptcy or similar laws concerning the Contractor, or if a trustee or receiver is appointed for the Contractor or for any of the Contractor’s property on account of the Contractor’s insolvency, and the Contractor or its successor in interest does not provide adequate assurance of future performance in accordance with the Contract within 15 calendar days of receipt of a request for assurance from the Contracting Agency; 4. If the Contractor disregards laws, ordinances, rules, codes, regulations, orders or similar requirements of any public entity having jurisdiction; 5. If the Contractor disregards the authority of the Contracting Agency; 6. If the Contractor performs Work which deviates from the Contract, and neglects or refuses to correct rejected Work; or 7. If the Contractor otherwise violates in any material way any provisions or requirements of the Contract. Once the Contracting Agency determines that sufficient cause exists to terminate the Contract, written notice shall be given to the Contractor and its Surety indicating that the Contractor is in breach of the Contract and that the Contractor is to remedy the breach within 15 calendar days after the notice is sent. In case of an emergency such as potential damage to life or property, the response time to remedy the breach after the notice may be shortened. If the remedy does not take place to the satisfaction of the Contracting Agency, the Engineer may, by serving written notice to the Contractor and Surety either: 1. Transfer the performance of the Work from the Contractor to the Surety; or 2. Terminate the Contract and at the Contracting Agency’s option prosecute it to completion by contract or otherwise. Any extra costs or damages to the Contracting Agency shall be deducted from any money due or coming due to the Contractor under the Contract. If the Engineer elects to pursue one remedy, it will not bar the Engineer from pursuing other remedies on the same or subsequent breaches. Page 1-120 2020 Standard Specifications M 41-10 1-08 Prosecution and Progress Upon receipt of a notice that the Work is being transferred to the Surety, the Surety shall enter upon the premises and take possession of all materials, tools, and appliances for the purpose of completing the Work included under the Contract and employ by contract or otherwise any person or persons satisfactory to the Engineer to finish the Work and provide the materials without termination of the Contract. Such employment shall not relieve the Surety of its obligations under the Contract and the bond. If there is a transfer to the Surety, payments on estimates covering Work subsequent to the transfer shall be made to the extent permitted under law to the Surety or its agent without any right of the Contractor to make any claim. If the Engineer terminates the Contract or provides such sufficiency of labor or materials as required to complete the Work, the Contractor shall not be entitled to receive any further payments on the Contract until all the Work contemplated by the Contract has been fully performed. The Contractor shall bear any extra expenses incurred by the Contracting Agency in completing the Work, including all increased costs for completing the Work, and all damages sustained, or which may be sustained, by the Contracting Agency by reason of such refusal, neglect, failure, or discontinuance of Work by the Contractor. If liquidated damages are provided in the Contract, the Contractor shall be liable for such liquidated damages until such reasonable time as may be required for Physical Completion of the Work. After all the Work contemplated by the Contract has been completed, the Engineer will calculate the total expenses and damages for the completed Work. If the total expenses and damages are less than any unpaid balance due the Contractor, the excess will be paid by the Contracting Agency to the Contractor. If the total expenses and damages exceed the unpaid balance, the Contractor and the Surety shall be jointly and severally liable to the Contracting Agency and shall pay the difference to the State of Washington, Department of Transportation on demand. In exercising the Contracting Agency’s right to prosecute the Physical Completion of the Work, the Contracting Agency shall have the right to exercise its sole discretion as to the manner, method, and reasonableness of the costs of completing the Work. In the event that the Contracting Agency takes Bids for remedial Work or Physical Completion of the project, the Contractor shall not be eligible for the Award of such Contracts. In the event the Contract is terminated, the termination shall not affect any rights of the Contracting Agency against the Contractor. The rights and remedies of the Contracting Agency under the Termination Clause are in addition to any other rights and remedies provided by law or under this Contract. Any retention or payment of monies to the Contractor by the Contracting Agency will not release the Contractor from liability. If a notice of termination for default has been issued and it is later determined for any reason that the Contractor was not in default, the rights and obligations of the parties shall be the same as if the notice of termination had been issued pursuant to Termination for Public Convenience in Section 1-08.10(2). This shall include termination for default because of failure to prosecute the Work, and the delay was found to be excusable under the provisions of Section 1-08.8. 2020 Standard Specifications M 41-10 Page 1-121 Prosecution and Progress 1-08 1-08.10(2) Termination for Public Convenience The Engineer may terminate the Contract in whole, or from time to time in part, whenever: 1. The Contractor is prevented from proceeding with the Work as a direct result of an Executive Order of the President with respect to the prosecution of war or in the interest of national defense; or an Executive Order of the President or Governor of the State with respect to the preservation of energy resources; 2. The Contractor is prevented from proceeding with the Work by reason of a preliminary, special, or permanent restraining order of a court of competent jurisdiction where the issuance of such restraining order is primarily caused by acts or omissions of persons or agencies other than the Contractor; or 3. The Engineer determines that such termination is in the best interests of the Contracting Agency. 1-08.10(3) Termination for Public Convenience Payment Request After receipt of Termination for Public Convenience as provided in Section 1-08.10(2), the Contractor shall submit to the Contracting Agency a request for costs associated with the termination. The request shall be prepared in accordance with the claim procedures outlined in Sections 1-09.11 and 1-09.12. The request shall be submitted promptly but in no event later than 90 calendar days from the effective date of termination. The Contractor agrees to make all records available to the extent deemed necessary by the Engineer to verify the costs in the Contractor’s payment request. 1-08.10(4) Payment for Termination for Public Convenience Whenever the Contract is terminated in accordance with Section 1-08.10(2), payment will be made in accordance with Section 1-09.5 for the actual Work performed. If the Contracting Agency and the Contractor cannot agree as to the proper amount of payment, then the matter will be resolved as outlined in Section 1-09.13 except that, if the termination occurs because of the issuance of a restraining order as provided in Section 1-08.10(2), the matter will be resolved through mandatory and binding arbitration as described in Sections 1-09.13(3)A and B, regardless of the amount of the claim. 1-08.10(5) Responsibility of the Contractor and Surety Termination of a Contract shall not relieve the Contractor of any responsibilities under the Contract for Work performed. Nor shall termination of the Contract relieve the Surety or Sureties of obligations under the Contract Bond or retainage bond for Work performed. Page 1-122 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 1-09 Measurement and Payment 1-09.1 Measurement of Quantities In measuring all acceptably completed Bid items of Work, the Engineer will: 1. Use United States standard measure; 2. Make all measurements as described in this section, unless individual Specifications require otherwise; 3. Follow methods generally recognized as conforming to good engineering practice; 4. Conform to the usual practice of the Contracting Agency by carrying measurements and computations to the proper significant figure or fraction of units for each item; and 5. Measure horizontally or vertically (unless otherwise specified). The terms listed below shall be defined as follows in all measurements under this section: “Lump Sum” (when used as an item of payment): complete payment for the Work described for that item in the Contract. “Gage” (in measurement of plates): the U.S. Standard Gage. “Gage” (in measurement of galvanized sheets used to manufacture corrugated metal pipe, metal plate pipe culverts and arches, and metal cribbing): that specified in AASHTO M 36, M 167, M 196, M 197, or M 219. “Gage” (in measurement of wire): that specified in AASHTO M 32. “Ton”: 2,000 pounds of avoirdupois weight. Items of payment that have “Lump Sum” or “Force Account” in the Bid item of Work shall have no specific unit of measurement requirement. For each basis of measurement listed below, the Engineer will use the method of measurement described. For Bid items or materials measured on the basis of: Hour – Measured for each hour that Work is actually performed. Portions of an hour will be rounded up to a half hour. Square Yard or Square Foot – The measurement shall be a calculation from the neat dimensions shown in the Plans or as altered by the Engineer. If there is an exception within the measured area where the item of Work is not performed (such as a drainage vault within a measured sidewalk) and if the exception area is greater than 9 square feet, then the area of the exception will be subtracted from the payment area calculated from the neat dimensions. Linear Foot (pipe culverts, guard rail, underdrains, etc.) – Measured parallel to the Structure’s base or foundation, unless the Plans require otherwise. 2020 Standard Specifications M 41-10 Page 1-123 Measurement and Payment 1-09 Weight – Weighed as required in Section 1-09.2. Volume (of excavation and embankment) – Measured by the average-end-area method or by the finite element analysis method utilizing digital terrain modeling techniques. All or some computations may be based on ground elevations and other data derived photogrammetrically. The Engineer may correct for curvature. Volume (in the hauling vehicle) – Measured at the point of delivery. Hauling vehicles may be of any size or type the Engineer approves provided that the body is of such shape that the actual contents may be readily and accurately determined. If the Engineer requires, the Contractor shall level loads at the delivery point to facilitate measurement. For each item listed below, the Engineer will use the method of measurement described. Structures – Measured on the neat lines shown in the Plans or as altered by the Engineer. When a complete Structure or structural unit is specified as the unit of measurement, the unit shall include all fittings and accessories. Timber – Measured by the thousand board feet (MBM) actually used in the Structure. Measurements will be based on nominal widths and thicknesses and the extreme length of each piece. Standard Manufactured Items (fence, wire, plates, rolled shapes, pipe conduit, etc., when specified) – Measured by the manufacturer’s identification of gage, unit weight, section dimension, etc. The Engineer will accept manufacturing tolerances set by each industry unless cited Specifications require more stringent tolerances. Cement – Measured by the pound, ton, or sack. A sack shall be 94 pounds. Asphalt – Measured by the gallon or ton. If measured by gallon, measurement will be made at 60 F (or will be corrected to the volume at 60 F in keeping with ASTM D1250). If shipped by rail, truck, or transport, measurement will be by net certified scale masses or certified volumes (corrected for material lost en route or not actually incorporated into the Work). No measurement will be made for: 1. Work performed or materials placed outside lines shown in the Plans or set by the Engineer; 2. Materials wasted, used, or disposed of in a manner contrary to the Contract; 3. Rejected materials (including those rejected after placement if the rejection resulted from the Contractor’s failure to comply with the Contract); 4. Hauling and disposing of rejected materials; 5. Material remaining on hand after the Work is completed, except as provided in Sections 1-09.5 and 1-09.10; or 6. Any other Work or material contrary to any Contract Provision. Page 1-124 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 1-09.2 Weighing Equipment 1-09.2(1) General Requirements for Weighing Equipment Unless specified otherwise, any Highway or bridge construction materials to be proportioned or measured and paid for by weight shall be weighed on a scale. Scales – Scales shall: 1. Be accurate to within 0.5 percent of the correct weight throughout the range of use; 2. Not include spring balances; 3. Include beams, dials, or other reliable readout equipment; 4. Be built to prevent scale parts from binding, vibrating, or being displaced and to protect all working parts from falling material, wind, and weather; and 5. Be carefully maintained, with bunkers and platforms kept clear of accumulated materials that could cause errors and with knife edges given extra care and protection. Scale Operations – “Contractor-provided scale operations” are defined as operations where a scale is set up by the Contractor specifically for the project and most, if not all, material weighed on the scale is utilized for Contract Work. In this situation, the Contractor shall provide a person to operate the project scale, write tickets, perform scale checks and prepare reports. “Commercial scale operations” include the use of established scales used to sell materials to the public on a regular basis. In addition, for the purposes of this Specification, all batch, hopper, and belt scales are considered to be commercial scales. When a commercial scale is used as the project scale, the Contractor may utilize a commercial scale operator provided it is at no additional cost to the Contracting Agency. In addition, the Contractor shall ensure that: 1. The Engineer is allowed to observe the weighing operation and check the daily scale weight record; 2. Scale verification checks are performed at the direction of the Contracting Agency (see Section 1-09.2(5)); 3. Several times each day, the scale operator records and makes certain the platform scale balances and returns to zero when the load is removed; and 4. Test results and scale weight records for each day’s hauling operations are provided to the Engineer daily. Unless otherwise approved, reporting shall utilize WSDOT Form 422-027 Scaleman’s Daily Report. 2020 Standard Specifications M 41-10 Page 1-125 Measurement and Payment 1-09 Trucks and Tickets – Each truck to be weighed shall bear a unique identification number. This number shall be legible and in plain view of the scale operator. Each vehicle operator shall obtain a weigh or load ticket from the scale operator. The Contracting Agency will provide item quantity tickets for scales that are not self-printing. The Contractor shall provide tickets for self-printing scales. All tickets shall, at a minimum, contain the following information: 1. Date of haul; 2. Contract number; 3. Contract unit Bid item; 4. Unit of measure; 5. Identification number of hauling vehicle; and 6. Weight delivered: a. Net weight in the case of batch and hopper scales. b. Gross weight, tare and net weight in the case of platform scales (tare may be omitted if a tare beam is used). c. Approximate load out weight in the case of belt conveyor scales. The vehicle operator shall deliver the ticket in legible condition to the material receiver at the material delivery point. The material delivery point is defined as the location where the material is incorporated into the permanent Work. When requested by the Engineer, the Contractor’s representative shall collect the tickets throughout the day and provide them to the Engineer’s designated receiver, not later than the end of shift, for reconciliation. Tickets for loads not verified as delivered will receive no pay. 1-09.2(2) Specific Requirements for Batching Scales Each batching scale shall be designed to support a weighing container. The arrangement shall make it convenient for the operator to remove material from the weighing container while watching readout devices. Any weighing container mounted on a platform scale shall have its center of gravity directly over the platform centerline. Batching scales used for concrete or hot mix asphalt shall not be used for batching other materials. Readout devices used for batching or hopper scales shall be marked at intervals evenly spaced throughout and shall be based on the scale’s nominal rated capacity. These intervals shall not exceed one-tenth of 1 percent of the nominal rated capacity. Before use at a new site and then at 6-month intervals, all batching and hopper scales shall be: approved under rules of the Weights and Measures Section of the Washington State Department of Agriculture, or serviced and tested with at least 10,000 pounds by an agent of its manufacturer. In either case, the Contractor shall provide the Engineer with a copy of the final test results. Page 1-126 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 1-09.2(3) Specific Requirements for Platform Scales Each platform scale shall be able to weigh the entire hauling vehicle or combination of connected vehicles at one time. No part of the vehicle or vehicle combination will be permitted off the platform as it is weighed. A tare weight shall be taken of each hauling vehicle at least once daily. Any platform scale shall be installed and maintained with the platform level and with rigid bulkheads at either end to prevent binding or shifting. The readout device shall be marked at intervals of no more than 40 pounds. Test records shall show results to the nearest 20 pounds. During weighing operations, weights shall be read and recorded to the nearest 100 pounds. Before use at a new site and then at 6-month intervals, any platform scale shall be: approved under rules of the Washington State Department of Agriculture’s Weights and Measures Section, or serviced and tested with at least 10,000 pounds by an agent of its manufacturer. In either case, the Contractor shall provide the Engineer with a copy of the final test results. 1-09.2(4) Specific Requirements for Belt Conveyor Scales The Engineer may approve conveyor-belt weighing of untreated materials if the method and device meet all general requirements for weighing equipment. The recording tape, odometer, totalizer, calibration adjustment, and clock-time imprinter shall be kept locked and the Engineer shall retain all keys. All belt-conveyor scales shall comply with the requirements for Belt-Conveyor Scales in the National Institute of Standards and Technology (NIST) Handbook No. 44, except where these Specifications modify those requirements. A static load test shall be made: each day after the belt-conveyor has run continuously for about 30 minutes, and again, immediately after the air temperature changes significantly. If the static load test reveals a need for adjustment, the Contractor shall perform a chain test. The Contractor shall make the computation of the test chain calibration, the calibration procedures and results, and related records available for the Engineer’s review. The test chain shall be clearly marked with its calibration, carried in a suitable container, and kept immediately available for testing. 1-09.2(5) Measurement Scale Verification Checks – The Engineer will verify the accuracy of each batch, hopper, or platform scale. The frequency of verification checks will be such that at least one test weekly is performed for each scale used in weighing contract items of Work. Verification checks may not be routinely conducted for weighed material, whose proposal quantity multiplied by the unit Bid price, has a value less than $20,000. The verification will consist of one of the following methods and be at the Contractor’s option: 1. Weigh a loaded truck on a separate certified platform scale designated by the Contractor, for the purpose of scale verification. 2020 Standard Specifications M 41-10 Page 1-127 Measurement and Payment 1-09 2. Weigh a vehicle that weighs at least 10,000 pounds on a separate certified scale and then check the project scale with it. 3. Establish a certified fixed load weighing at least 10,000 pounds as a check-weight. The certification shall consist of an affidavit affirming the correct weight of the fixed load. Should the scale verification check reveal a weight difference of more than 0.5 percent, a second scale verification check shall be performed immediately. If the weight differences of both comparison checks exceed the 0.5-percent limit and the scale has been overweighing, the Contractor shall immediately stop weighing and the scale shall be recertified at the Contractor’s expense. If the weight difference of both comparison checks exceed the 0.5 percent limit and the scale is underweighing, it shall be adjusted immediately. Contractor will not be compensated for any loss from underweighing. Belt Scales – To test the accuracy of a belt-conveyor scale, the Contractor shall weigh five or more payloads from sequential hauling units and compare these weights with weights of the same payloads taken on a separate certified platform scale. If the test results fluctuate, the Engineer may require more than five check loads. Conveyor weights will be based on tonnage values taken from the sealed odometer at the beginning and end of each check period. If scale verification checks shows the scale has been under weighing, it shall be adjusted immediately. The Contractor shall not be compensated for any loss from under weighing. If scale verification checks show the scale has been overweighing, its operation will cease immediately until adjusted. Minor Construction Items – If the Specifications and Plans require weight measurement for minor construction items, the Contractor may request permission to convert volume to weight. If the Engineer approves, an agreed factor may be used to make this conversion and volume may be used to calculate the corresponding weight for payment. 1-09.2(6) Payment Unless specified otherwise, the Contracting Agency will pay for no materials received by weight unless they have been weighed as required in this section or as required by another method the Engineer has approved in writing. The Contractor shall not be compensated for any loss from underweighing that is revealed by scale verification checks. If scale verification checks reveal that the scale is overweighing, then payment for all material weighed since the last valid scale verification check will be adjusted. The Contracting Agency will calculate the combined weight of all materials weighed after the last verification check showing accurate results. This combined weight will then be reduced for payment by the percentage of scale error that exceeds 0.5 percent unless the Contractor demonstrates to the satisfaction of the Engineer that the defect in the scale was present for a lesser period of time. Page 1-128 2020 Standard Specifications M 41-10 1-09 Measurement and Payment Unit Contract prices for the various pay items of the project cover all costs related to weighing and proportioning materials for payment. These costs include but are not limited to: 1. Furnishing, installing, certifying, and maintaining scales; 2. Providing a weigher to operate a Contractor-provided scale; 3. Providing a weigher to operate a commercial scale, if necessary; 4. Providing self-printing tickets, if necessary; 5. Rerouting a truck for verification weighing; 6. Assisting the Engineer with scale verification checks; 7. Any other related costs associated with meeting the requirements of this section. 1-09.3 Scope of Payment The payment provided for in the Contract shall be full payment to the Contractor for: 1. Furnishing all materials and performing all Work under the Contract (including changes in the work, materials, or Plans) in a complete and acceptable manner; 2. All risk, loss, damage, or expense of whatever character arising out of the nature or prosecution of the work; and 3. All expense incurred resulting from a suspension or discontinuance of the Work as specified under the Contract. The payment of any estimate or retained percentage shall not relieve the Contractor of the obligation to make good any defective Work or materials. Unless the Plans and Special Provisions provide otherwise, the unit Contract prices for the various Bids items shall be full payment for all labor, materials, supplies, equipment, tools, and all other things required to completely incorporate the item into the Work as though the item were to read “In Place”. If the “Payment” clause in the Specifications, for an item included in the Proposal, covers and considers all Work and material essential to that item, then the Work or materials will not be measured or paid for under any other item that may appear elsewhere in the Proposal or Specifications. Certain payment items appearing in these Specifications may be modified in the Plans and Proposal to include: 1. The words “For Structure”, “For Concrete Barrier”, “For Bridge”, etc., with the intent of clarifying specific use of the item; or 2. The words “Site (Site Designation)”, with the intent of clarifying where a specific item of Work is to be performed. Modification of payment items in this manner shall in no way change the intent of the Specifications relating to these items. 2020 Standard Specifications M 41-10 Page 1-129 Measurement and Payment 1-09 1-09.4 Equitable Adjustment The equitable adjustment provided for elsewhere in the Contract shall be determined in one or more of the following ways: 1. If the parties are able to agree, the price will be determined by using: a. Unit prices; or b. Other agreed upon prices; 2. If the parties cannot agree, the price will be determined by the Engineer using: a. Unit prices; or b. Other means to establish costs. The following limitations shall apply in determining the amount of the equitable adjustment: 1. The equipment rates shall be actual cost but shall not exceed the rates set forth in the AGC/WSDOT Equipment Rental Agreement in effect at the time the Work is performed as referred to in Section 1-09.6, and 2. To the extent any delay or failure of performance was concurrently caused by the Contracting Agency and the Contractor, the Contractor shall be entitled to a time extension for the portion of the delay or failure of performance concurrently caused, provided it make such a request pursuant to Section 1-08.8; however, the Contractor shall not be entitled to any adjustment in Contract price. 3. No claim for anticipated profits on deleted, terminated, or uncompleted Work will be allowed. 4. No claim for consequential damages of any kind will be allowed. 1-09.5 Deleted or Terminated Work The Engineer may delete Work by change order as provided in Section 1-04.4 or may terminate the Contract in whole or part as provided in Section 1-08.10(2). When the Contract is terminated in part, the partial termination shall be treated as a deletion change order for payment purposes under this section. Payment for completed items will be at unit Contract prices. When any item is deleted in whole or in part by change order or when the Contract is terminated in whole or in part, payment for deleted or terminated Work will be made as follows: 1. Payment will be made for the actual number of units of Work completed at the unit Contract prices unless the Engineer determines the unit prices are inappropriate for the Work actually performed. When that determination is made by the Engineer, payment for Work performed will be as mutually agreed. If the parties cannot agree the Engineer will determine the amount of the equitable adjustment in accordance with Section 1-09.4; Page 1-130 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 2. Payment for partially completed lump sum items will be as mutually agreed. If the parties cannot agree, the Engineer will determine the amount of the equitable adjustment in accordance with Section 1-09.4; 3. To the extent not paid for by the Contract prices for the completed units of Work, the Contracting Agency will pay as part of the equitable adjustment those direct costs necessarily and actually incurred by the Contractor in anticipation of performing the Work that has been deleted or terminated; 4. The total payment for any one item in the case of a deletion or partial termination shall not exceed the Bid price as modified by approved change orders less the estimated cost (including overhead and profit) to complete the Work and less any amount paid to the Contractor for the item; 5. The total payment where the Contract is terminated in its entirety shall not exceed the total Contract price as modified by approved change orders less those amounts paid to the Contractor before the effective date of the termination; and 6. No claim for damages of any kind or for loss of anticipated profits on deleted or terminated Work will be allowed because of the termination or change order. Contract time shall be adjusted as the parties agree. If the parties cannot agree, the Engineer will determine the equitable adjustment for Contract time. Acceptable materials ordered by the Contractor prior to the date the Work was terminated as provided in Section 1-08.10(2) or deleted as provided in Section 1-04.4 by the Engineer, will either be purchased from the Contractor by the Contracting Agency at the actual cost and shall become the property of the Contracting Agency, or the Contracting Agency will reimburse the Contractor for the actual costs connected with returning these materials to the suppliers. 1-09.6 Force Account The terms of the Contract or of a change order may call for Work or material to be paid for by force account. If so, then the objective of this Specification is to reimburse the Contractor for all costs associated with the Work, including costs of labor, small tools, supplies, equipment, specialized services, materials, applicable taxes and overhead and to include a profit commensurate with those costs. The amount to be paid shall be determined as described in this section. 1. For Labor – Labor reimbursement calculations shall be based on a “Project Labor List” (List) prepared and submitted by the Contractor and by any Subcontractor before that firm commences force account Work. Once a List is approved by the Engineer, it shall be used to calculate force account labor payment until a new List is submitted and approved. The Engineer may compare the List to payrolls and other documents and may, at any time, require the Contractor to submit a new List. The Contractor may submit a new List at any time without such a requirement. Prior payment calculations shall not be adjusted as a result of a new List. 2020 Standard Specifications M 41-10 Page 1-131 Measurement and Payment 1-09 To be approved, the List must be accurate and meet the requirements of this section. It shall include regular time and overtime rates for all employees (or work classifications) expected to participate in force account Work. The rates shall include the basic wage and fringe benefits, the current rates for Federal Insurance Compensation Act (FICA), Federal Unemployment Tax Act (FUTA) and State Unemployment Tax Act (SUTA), the company’s present rates for Medical Aid and Industrial Insurance premiums and the planned payments for travel and per diem compensation. In the event that an acceptable initial List or requested revised List is not received by the time that force account calculations are begun, the Engineer will develop a List unilaterally, utilizing the best data available, that will be used until a Contractor’s List is received and approved. Again, prior calculations, prepared using the Engineer’s List, will not be revised as a result of differences with the Contractor’s List. In addition to compensation for direct labor costs defined above, the Contracting Agency will pay Contractor 29 percent of the sum of the costs calculated for labor reimbursement to cover project overhead, general company overhead, profit, bonding, insurance required by Sections 1-07.10 and 1-07.18, Business & Occupation tax, and any other costs incurred, except paid sick leave. The Contracting Agency will pay the Contractor an additional 2 percent of the sum of the costs calculated for labor reimbursement to cover the cost of paid sick leave. This amount will include any costs of safety training and health tests, but will not include such costs for unique force account Work that is different from typical Work and which could not have been anticipated at time of Bid. 2. For Materials – The Contracting Agency will reimburse invoice cost for Contractor- supplied materials. For the purpose of this provision, “Materials” shall include those items incorporated into the Work, supplies used during the Work and items consumed. This cost shall include freight and handling charges and applicable taxes. Before Work is started, the Engineer may require the Contractor to obtain multiple quotations for the materials to be utilized and select the vendor with prices and terms most advantageous to the Contracting Agency. The Contracting Agency will provide a list of the types and quantities of Contractor- supplied materials witnessed by the Contracting Agency as being utilized in force account Work. The list will be furnished promptly after the material is incorporated, on a daily basis unless agreed otherwise. The Contractor may propose corrections to the list and will supply prices for the materials and other costs and return the list to the Contracting Agency. To support the prices, the Contractor shall attach valid copies of vendor invoices. If invoices are not available for materials from the Contractor’s stocks, the Contractor shall certify actual costs (at a reasonable level) by affidavit. The Engineer will review the prices and any Contractor-proposed corrections and, if reasonable, approve the completed list. Once approved, the prices will be utilized in the calculation of force account reimbursement for materials. If, in the case of non-invoiced materials supported by Contractor affidavit, the price appears to be unreasonable, the Engineer will determine the cost for all or part of those materials, utilizing the best data available. Page 1-132 2020 Standard Specifications M 41-10 1-09 Measurement and Payment The Contracting Agency reserves the right to provide materials. In this case, the Contractor will receive no payment for any costs, overhead, or profit arising from the value of the materials themselves. Additional costs to handle and place the Agency-furnished material shall be compensated as described in this Specification. In addition to compensation for direct materials cost, the Contracting Agency will pay the Contractor 21 percent of the sum of the costs calculated for materials reimbursement to cover project overhead, general company overhead, profit, bonding, insurance, required by Sections 1-07.10 and 1-07.18, Business & Occupation tax, and any other costs incurred. 3. For Equipment – The Contracting Agency will reimburse the Contractor for the cost of equipment utilized in the Work. The equipment provided by the Contractor shall be of modern design and in good working condition. For the purpose of this provision, “provided” shall mean that the equipment is owned (either through outright ownership or through a long-term lease) and operated by the Contractor or Subcontractor or that the equipment is rented and operated by the Contractor or Subcontractor. Equipment that is rented with operator shall not be included here, but shall be considered a service and addressed according to Subsection 4 of this provision. The amount of payment for any Contractor-owned equipment that is utilized shall be determined according to the version of the AGC/WSDOT Equipment Rental Agreement which is in effect at the time the force account is authorized. The rates listed in the Rental Rate Blue Book (as modified by the current AGC/WSDOT Equipment Rental Agreement) shall be full compensation for all fuel, oil, lubrication, ordinary repairs, maintenance, and all other costs incidental to furnishing and operating the equipment except labor for operation. Payment for rented equipment will be made on the basis of a valid invoice, covering the time period of the Work. Before Work is started, the Engineer may require the Contractor to obtain multiple quotations for the rental of equipment to be utilized and select the vendor with prices and terms most advantageous to the Contracting Agency. In the event that prior quotations are not obtained and the vendor is not a firm independent from the Contractor or Subcontractor, then after-the-fact quotations may be obtained by the Engineer from the open market in the vicinity and the lowest such quotation may be used in place of submitted invoice. In addition to the payments for Contractor-owned and rented equipment, one or more lump-sum payments may be made for small tools. The amount to be paid shall be determined as outlined in the AGC/WSDOT Equipment Rental Agreement. The Contracting Agency will add 21 percent to equipment costs to cover project overhead, general company overhead, profit, bonding, insurance, required by Sections 1-07.10 and 1-07.18, Business & Occupation tax, and any other costs incurred. This markup will be over and above those equipment costs and will not be adjusted for any equipment overhead amounts included in the Blue Book rates. Copies of the AGC/WSDOT Equipment Rental Agreement will be maintained on the Contracting Agency’s website at www.wsdot.wa.gov. 2020 Standard Specifications M 41-10 Page 1-133 Measurement and Payment 1-09 4. For Services – Compensation under force account for specialized services shall be made on the basis of an invoice from the providing entity. A “specialized service” is a work operation that is not typically done by worker classifications as defined by the Washington State Department of Labor and Industries and by the Davis Bacon Act, and therefore bills by invoice for work in road, bridge and municipal construction. Before Work is started, the Engineer may require the Contractor to obtain multiple quotations for the service to be utilized and select the provider with prices and terms most advantageous to the Contracting Agency. In the event that prior quotations are not obtained and the service invoice is submitted by a Subcontractor, then after- the-fact quotations may be obtained by the Engineer from the open market in the vicinity and the lowest such quotation may be used in place of the submitted invoice. Except as noted below, the Contracting Agency will pay the Contractor an additional 21 percent of the sum of the costs included on invoices for specialized services to cover project overhead, general company overhead, profit, bonding, insurance, required by Sections 1-07.10 and 1-07.18, Business & Occupation tax, and any other costs incurred. When a supplier of services is compensated through invoice, but acts in the manner of a Subcontractor, as described in Subsection 6 of this provision, then markup for that invoice shall be according to Subsection 6, “Contractor Markup on Subcontractors’ Work”. 5. For Mobilization – Force account mobilization is defined as the preparatory Work performed by the Contractor including procurement, loading and transportation of tools and equipment, and personal travel time (when such travel time is a contractual obligation of the Contractor or a customary payment for the Contractor to all employees). Mobilization also includes the costs incurred during demobilization. Pro-rata adjustments may be made when the mobilization applies to both force account and other Contract Work. The Contracting Agency will pay for mobilization for off-site preparatory Work for force account items provided that notice has been provided sufficiently in advance to allow the Engineer to witness the activity, if desired. Any costs experienced during mobilization activities for labor, equipment, materials or services shall be listed in those sections of the force account summary and paid accordingly. 6. For Contractor Markup on Subcontractor’s Work – When Work is performed on a force account basis by one or more approved Subcontractors, by lower-tier subcontractors or suppliers, or through invoice by firm(s) acting in the manner of a Subcontractor, the Contractor will be allowed an additional markup, from the table below, applied to the costs computed for Work done by each Subcontractor through Subsections 1, 2, 3, and 4, to compensate for all administrative costs, including project overhead, general company overhead, profit, bonding, insurance required by Sections 1-07.10 and 1-07.18, Business & Occupation tax, and any other costs incurred. Page 1-134 2020 Standard Specifications M 41-10 1-09 Measurement and Payment A firm may be considered to be acting as a Subcontractor when the Engineer observes one or more of the following characteristics: a. The person in charge of the firm’s activities takes an active role in managing the overall project, including extensive coordination, interpretation of Plans, interaction with the Contracting Agency or management of a complex and interrelated operation. b. Rented equipment is provided fueled, operated and maintained by the firm. Operators of rented equipment are supervised directly by the firm’s representative. There is little interaction between the Contractor and the employees of the firm. c. The firm appears to be holding the risk of performance and quality of the Work. d. The firm appears to be responsible for liability arising from the Work. Markups on Work Performed by Subcontractor(s): (1) On amounts paid for Work performed by each Subcontractor on each force account and calculated through Subsections 1-4, up to $25,000 12 percent (2) On amounts greater than $25,000 up to $100,000 10 percent (3) On amounts greater than $100,000 7 percent The amounts and markup rates shall be calculated separately for each Subcontractor on each force account item established. The payments provided above shall be full payment for all Work done on a force account basis. The calculated payment shall cover all expenses of every nature, kind, and description, including those listed above and any others incurred on the Work being paid through force account. Nothing in this provision shall preclude the Contractor from seeking an extension of time or time-related damages to unchanged Work arising as a result of the force account Work. The amount and costs of any Work to be paid by force account shall be computed by the Engineer, and the result shall be final as provided in Section 1-05.1. An item that has been Bid at a unit price or lump sum in the Proposal will not be paid as force account unless: 1. A change as defined in Section 1-04.4 has occurred and the provisions require a payment adjustment. 2. A Contract item paid by force account requires Work that is normally included in a lump sum Contract item. In such a case, the Work normally included in a lump sum Contract item will be paid by force account under the force account Contract item. Items which are included in the Proposal as Force Account or which are added by change order as Force Account may, by agreement of the parties at any time, be converted to agreed unit prices or lump sums applicable to the remaining Work. 2020 Standard Specifications M 41-10 Page 1-135 Measurement and Payment 1-09 1-09.7 Mobilization Mobilization consists of preconstruction expenses and the costs of preparatory Work and operations performed by the Contractor which occur before 10 percent of the total original Contract amount is earned from other Contract items. Items which are not to be included in the item of Mobilization include but are not limited to: 1. Any portion of the Work covered by the specific Contract item or incidental Work which is to be included in a Contract item or items. 2. Profit, interest on borrowed money, overhead, or management costs. 3. Any costs of mobilizing equipment for force account Work. Based on the lump sum Contract price for “Mobilization”, partial payments will be made as follows: 1. When 5 percent of the total original Contract amount is earned from other Contract items, excluding amounts paid for materials on hand, 50 percent of the amount Bid for mobilization, or 5 percent of the total original Contract amount, whichever is the least, will be paid. 2. When 10 percent of the total original Contract amount is earned from other Contract items, excluding amounts paid for materials on hand, 100 percent of the amount Bid for mobilization, or 10 percent of the total original Contract amount, whichever is the least, will be paid. 3. When the Substantial Completion Date has been established for the project, payment of any amount Bid for mobilization in excess of 10 percent of the total original Contract amount will be paid. Nothing herein shall be construed to limit or preclude partial payments otherwise provided by the Contract. 1-09.8 Payment for Material on Hand The Contracting Agency may reimburse the Contractor for materials purchased before their use in the Work if they: 1. Meet the requirements of the Plans and Specifications; 2. Are delivered to or stockpiled near the project or other Engineer-approved storage sites; and 3. Consist of: sand, gravel, surfacing materials, aggregates, reinforcing steel, bronze plates, structural steel, machinery, piling, timber and lumber (not including forms or falsework), large signs unique to the project, prestressed concrete beams or girders, or other materials the Engineer may approve. Page 1-136 2020 Standard Specifications M 41-10 1-09 Measurement and Payment The Contracting Agency may reimburse the Contractor for traffic signal controllers as follows: 1. Fifty percent when the traffic signal controller and all components are received and assembled into a complete unit at the State Materials Laboratory. 2. One hundred percent when the traffic signal controller is approved for shipment to the project by the State Materials Laboratory. The Contractor shall provide sufficient written evidence of production costs to enable the Engineer to compute the cost of Contractor-produced materials (such as sand, gravel, surfacing material, or aggregates). For other materials, the Contractor shall provide invoices from material suppliers. Each invoice shall be detailed sufficiently to enable the Engineer to determine the actual costs. Payment for materials on hand shall not exceed the total Contract cost for the Contract item. If payment is based upon an unpaid invoice, the Contractor shall provide the Engineer with a paid invoice within 60 calendar days after the Contracting Agency’s initial payment for materials on hand. If the paid invoice is not furnished in this time, any payment the Contracting Agency had made will be deducted from the next progress estimate and withheld until the paid invoice is supplied. The Contracting Agency will not pay for material on hand when the invoice cost is less than $2,000. As materials are used in the Work, credits equaling the partial payments for them will be taken on future estimates. Partial payment for materials on hand shall not constitute acceptance. Any material will be rejected if found to be faulty even if partial payment for it has been made. 1-09.9 Payments The basis of payment will be the actual quantities of Work performed according to the Contract and as specified for payment. The Contractor shall submit a breakdown of the cost of lump sum Items to enable the Engineer to determine the Work performed on a monthly basis. Lump sum item breakdowns shall be submitted prior to the first progress payment that includes payment for the Bid Item in question. A breakdown is not required for lump sum Items that include a basis for incremental payments as part of the respective Specification. Absent a lump sum breakdown, the Engineer will make a determination based on information available. The Engineer’s determination of the cost of Work shall be final. Payments will be made for Work and labor performed and materials furnished under the Contract according to the price in the Proposal unless otherwise provided. Partial payments will be made once each month, based upon partial estimates prepared by the Engineer. The determination of payments under the Contract will be final in accordance with Section 1-05.1. Unless otherwise provided, payments will be made from the Motor Vehicle Fund. 2020 Standard Specifications M 41-10 Page 1-137 Measurement and Payment 1-09 Failure to perform any of the obligations under the Contract by the Contractor may be decreed by the Contracting Agency to be adequate reason for withholding any payments until compliance is achieved. Upon completion of all Work and after final inspection (Section 1-05.11), the amount due the Contractor under the Contract will be paid based upon the final estimate made by the Engineer and presentation of a Final Contract Voucher Certification signed by the Contractor. Such voucher shall be deemed a release of all claims of the Contractor unless a claim is filed in accordance with the requirements of Section 1-09.11 and is expressly excepted from the Contractor’s certification on the Final Contract Voucher Certification. The date the Secretary signs the Final Contract Voucher Certification constitutes the final acceptance date (Section 1-05.12). If the Contractor fails, refuses, or is unable to sign and return the Final Contract Voucher Certification or any other documentation required for completion and final acceptance of the Contract, the Contracting Agency reserves the right to establish a Completion Date (for the purpose of meeting the requirements of RCW 60.28) and unilaterally accept the Contract. Unilateral final acceptance will occur only after the Contractor has been provided the opportunity, by written request from the Engineer, to voluntarily submit such documents. If voluntary compliance is not achieved, formal notification of the impending establishment of a Completion Date and unilateral final acceptance will be provided by certified letter from the Secretary to the Contractor, which will provide 30 calendar days for the Contractor to submit the necessary documents. The 30 calendar day period will begin on the date the certified letter is received by the Contractor. The date the Secretary unilaterally signs the Final Contract Voucher Certification shall constitute the Completion Date and the final acceptance date (Section 1-05.12). The reservation by the Contracting Agency to unilaterally accept the Contract will apply to Contracts that are Physically Completed in accordance with Section 1-08.5, or for Contracts that are terminated in accordance with Section 1-08.10. Unilateral final acceptance of the Contract by the Contracting Agency does not in any way relieve the Contractor of their responsibility to comply with all Federal, State, tribal, or local laws, ordinances, and regulations that affect the Work under the Contract. Payment to the Contractor of partial estimates, final estimates, and retained percentages shall be subject to controlling laws. 1-09.9(1) Retainage Pursuant to RCW 60.28, a sum of 5 percent of the monies earned by the Contractor will be retained from progress estimates. Such retainage shall be used as a trust fund for the protection and payment (1) to the State with respect to taxes imposed pursuant to Title 82 RCW, and (2) the claims of any person arising under the Contract. Monies retained under the provisions of RCW 60.28 shall, at the option of the Contractor, be: 1. Retained in a fund by the Contracting Agency; or Page 1-138 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 2. Deposited by the Contracting Agency in an escrow (interest-bearing) account in a bank, mutual saving bank, or savings and loan association (interest on monies so retained shall be paid to the Contractor). Deposits are to be in the name of the Contracting Agency and are not to be allowed to be withdrawn without the Contracting Agency’s written authorization. The Contracting Agency will issue a check representing the sum of the monies reserved, payable to the bank or trust company. Such check shall be converted into bonds and securities chosen by the Contractor as the interest accrues. At the time the Contract is executed the Contractor shall designate the option desired. The Contractor in choosing option (2) agrees to assume full responsibility to pay all costs that may accrue from escrow services, brokerage charges or both, and further agrees to assume all risks in connection with the investment of the retained percentages in securities. The Contracting Agency may also, at its option, accept a bond in lieu of retainage. Release of the retainage will be made 60 days following the Completion Date (pursuant to RCW 39.12, and RCW 60.28) provided the following conditions are met: 1. On Contracts totaling more than $35,000, a release has been obtained from the Washington State Department of Revenue. 2. Affidavits of Wages Paid for the Contractor and all Subcontractors are on file with the Contracting Agency (RCW 39.12.040). 3. A certificate of Payment of Contributions Penalties and Interest on Public Works Contract is received from the Washington State Employment Security Department. 4. Washington State Department of Labor and Industries (in accordance with Section 1-07.10) shows the Contractor is current with payments of industrial insurance and medical aid premiums. 5. All claims, as provided by law, filed against the retainage have been resolved. In the event claims are filed and provided the conditions of 1, 2, 3, and 4 are met, the Contractor will be paid such retained percentage less an amount sufficient to pay any such claims together with a sum determined by the Contracting Agency sufficient to pay the cost of foreclosing on claims and to cover attorney’s fees. 1-09.10 Payment for Surplus Processed Materials After the Contract is completed, the Contractor will be reimbursed actual production costs for surplus processed material produced by the Contractor from Contracting Agency-provided sources if its value is $3,000 or more (determined by actual production costs). The quantity of surplus material eligible for reimbursement of production costs shall be the quantity produced (but an amount not greater than 110 percent of Plan quantity or as specified by the Engineer), less the actual quantity used. For Hot Mix Asphalt, the Plan quantity and quantity used will be adjusted for the quantity of Asphalt and quantity of RAP or other materials incorporated into the mix. The Contracting Agency will determine the actual amount of surplus material for reimbursement. 2020 Standard Specifications M 41-10 Page 1-139 Measurement and Payment 1-09 The Contractor shall not dispose of any surplus material without permission of the Engineer. Surplus material shall remain the property of the Contracting Agency without reimbursement to the Contractor if it is not eligible for reimbursement. 1-09.11 Disputes and Claims When protests occur during a Contract, the Contractor shall pursue resolution through the Engineer. The Contractor shall follow the procedures outlined in Section 1-04.5. If the negotiations using the procedures outlined in Section 1-04.5 fail to provide satisfactory resolution of protests, then the Contractor shall provide the Engineer with written notification that the Contractor will continue to pursue the dispute in accordance with the provisions of Section 1-09.11. The written notification shall be provided within 7 calendar days after receipt of the Engineer’s written determination that the Contractor’s protest is invalid pursuant to Section 1-04.5. The Contractor’s written notice of dispute shall indicate whether the Contractor prefers to resolve the dispute through the use of a Disputes Review Board as outlined in Section 1-09.11(1), or to submit a formal claim directly to the Contracting Agency pursuant to Section 1-09.11(2). If a Disputes Review Board is requested by the Contractor, the Contracting Agency will notify the Contractor in writing whether the use of a Disputes Review Board is agreed upon within 7 calendar days after receiving the Contractors written notice of dispute. If both parties to the dispute agree, then the dispute will be referred to a Disputes Review Board according to Section 1-09.11(1). If the parties do not mutually agree to establish a Disputes Review Board then none shall be used, and the Contractors shall submit a formal claim directly to the Contracting Agency as outlined in Section 1-09.11(2), Claims. In spite of any protest or dispute, the Contractor shall proceed promptly with the Work as the Engineer orders. 1-09.11(1) Disputes Review Board In order to assist in the resolution of disputes arising out of the Work of this project, the Contract provides for the establishment of a Disputes Review Board, hereinafter called the “Board”. The Board is created when negotiations using the procedures outlined in Section 1-04.5 fail to provide a satisfactory resolution and the Contracting Agency and Contractor mutually agree to use a Board as part of the disputes resolution process prior to the Contractor filing a formal claim pursuant to Section 1-09.11(2). The Board will consider disputes referred to it and furnish recommendations to the Contracting Agency and Contractor to assist in the resolution of the differences between them. The purpose of the Board response to such issues is to provide nonbinding findings and recommendations designed to expose the disputing parties to an independent view of the dispute. The Board members will be especially knowledgeable in the type of construction involved in the Project and shall discharge their responsibilities impartially and independently considering the facts and conditions related to the matters under consideration and the provisions of the Contract. Page 1-140 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 1-09.11(1)A Disputes Review Board Membership The Board shall consist of one member selected by the Contracting Agency and one member selected by the Contractor, with these two members to select the third member. The first two members shall be mutually acceptable to both the Contracting Agency and the Contractor. If one or both of the two members selected are not acceptable to the Contracting Agency or Contractor, another selection shall be made. The Contracting Agency and Contractor shall each select their respective Board member and negotiate an agreement, separate and apart from this Contract, with their respective Board member within 14 calendar days after the parties have agreed to establish a Board, as outlined in Section 1-09.11(1). The agreements with these two Board members shall contain language imposing the “Scope of Work” and “Suggested Administrative Procedures” for Disputes Review Boards available at www.wsdot.wa.gov/business/consulting. These negotiated agreements shall also include clauses that require the respective selected members to immediately pursue selection of a third member. The goal is to obtain a third Board member who will complement the first two by furnishing a needed expertise, which will facilitate the Board’s operations. In case a member of the Board needs to be replaced, the replacement member will be appointed in the same manner as the replaced member was appointed. The appointment of a replacement Board member will begin promptly upon determination of the need for replacement and shall be completed within 30 calendar days. Service of a Board member may be terminated at any time with not less than 30 calendar days notice as follows: 1. The Contracting Agency may terminate service of the Contracting Agency appointed member. 2. The Contractor may terminate service of the Contractor appointed member. 3. The third member’s services may be terminated by agreement of the other two members. 4. By resignation of the member. Termination of a member will be followed by appointment of a substitute as specified above. No member shall have a financial interest in the Contract, except for payments for services on the Board. The Contracting Agency-selected member and the Contractor- selected member shall not have been employed by the party who selected them within a period of 1 year; except that, service as a member of other Disputes Review Boards on other contracts will not preclude a member from serving on the Board for this Contract. 2020 Standard Specifications M 41-10 Page 1-141 Measurement and Payment 1-09 Compensation for the Board members, and the expenses of operation of the Board, shall be shared by the Contracting Agency and Contractor in accordance with the following: 1. The Contracting Agency will compensate directly the wages and travel expense for its selected member. 2. The Contractor shall compensate directly the wages and travel expense for its selected member. 3. The Contracting Agency and Contractor shall share equally in the third member’s wages and travel expense, and all of the operating expenses of the Board. These equally shared expenses shall be billed to and paid by the Contracting Agency. The Contractor’s share will be deducted from monies due or coming due the Contractor. 4. The Contracting Agency, through the Engineer, will provide administrative services, such as conference facilities and secretarial services, to the Board and the Contracting Agency will bear the costs for this service. The Contracting Agency and Contractor shall indemnify and hold harmless the Board Members from and against all claims, damages, losses, and expenses, including but not limited to, attorney’s fees arising out of and resulting from the actions and recommendations of the Board. 1-09.11(1)B Disputes Review Board Procedures The Board, the Contracting Agency, and the Contractor shall develop by agreement the Board’s rules of operation and procedures to be followed for the Project. In developing the agreement, the parties shall take into consideration their respective duties and responsibilities set forth in the “Scope of Work” section of their agreements. The parties may also consider the “Suggested Administrative Procedures” for the Board’s operation included in their agreements. These Procedures express, in general terms, the policy for the creation and operation of the Board. No dispute shall be referred to the Board unless the Contractor has complied with the requirements of Sections 1-04.5 and 1-09.11 and the parties have mutually agreed to refer the dispute to the Board in an attempt to resolve the dispute prior to the Contractor filing a claim according to Section 1-09.11(2). If the dispute is referred to the Board, then the Board will consider the matter in dispute and provide recommendations concerning: 1. The interpretation of the Contract. 2. Entitlement to additional compensation or time for performance. 3. The amount of additional compensation or time for performance following a recommendation of entitlement by the Board provided that; (1) the parties were not able to reach a resolution as to the amount of the equitable adjustment or time; (2) the Engineer has made a unilateral determination of the amount of compensation for time; and (3) the Contractor has protested the Engineer’s unilateral determination. 4. Other subjects mutually agreed by the Contracting Agency and Contractor to be a Board issue. Page 1-142 2020 Standard Specifications M 41-10 1-09 Measurement and Payment Once the Board is established, the dispute resolution process shall be as follows: 1. Board hearing dates will be scheduled by agreement of the parties. 2. The Contractor and the Contracting Agency shall each be afforded an opportunity to be heard by the Board and to offer evidence. Either party furnishing any written evidence or documentation to the Board must furnish copies of such information to the other party a minimum of 15 calendar days prior to the date the Board sets to convene the hearing for the dispute. Either party shall produce such additional evidence as the Board may deem necessary to an understanding and determination of the dispute and furnish copies to the other party. 3. After the hearing is concluded, the Board shall meet in private and reach a conclusion supported by two or more members. Its findings and recommendations, together with its reasons shall then be submitted as a written report to both parties. The recommendations shall be based on the pertinent Contract Provisions and facts and circumstances involved in the dispute. The Contract shall be interpreted and construed in accordance with the laws of the State of Washington. The Board shall make every effort to reach a unanimous decision. If this proves impossible, the dissenting member may prepare a minority report. 4. Within 30 calendar days of receiving the Board recommendations, both the Contracting Agency and the Contractor shall respond to the other in writing signifying that the dispute is either resolved or remains unresolved. Although both parties should place weight upon the Board recommendations, the recommendations are not binding. In the event the Board’s recommendations do not lead to resolution of the dispute, all Board records and written recommendations, including any minority reports, will be admissible as evidence in any subsequent litigation. If the Board’s assistance does not resolve the dispute, the Contractor must file a claim according to Section 1-09.11(2) before seeking any form of judicial relief. 1-09.11(2) Claims If the Contractor claims that additional payment is due and the Contractor has pursued and exhausted all the means provided in Sections 1-04.5 and 1-09.11(1) to resolve a dispute, including the use of a Disputes Review Board if one was established, the Contractor may file a claim as provided in this section. The Contractor agrees to waive any claim for additional payment if the written notifications provided in Section 1-04.5 are not given, or if the Engineer is not afforded reasonable access by the Contractor to complete records of actual cost and additional time incurred as required by Section 1-04.5, or if a claim is not filed as provided in this section. The fact that the Contractor has provided a proper notification, provided a properly filed claim, or provided the Engineer access to records of actual cost, shall not in any way be construed as proving or substantiating the validity of the claim. If the claim, after consideration by the Engineer, is found to have merit, the Engineer will make an equitable adjustment either in the amount of costs to be paid or in the time required for the Work, or both. If the Engineer finds the claim to be without merit, no adjustment will be made. 2020 Standard Specifications M 41-10 Page 1-143 Measurement and Payment 1-09 All claims filed by the Contractor shall be in writing and in sufficient detail to enable the Engineer to ascertain the basis and amount of the claim. All claims shall be submitted to the Engineer as provided in Section 1-05.15. As a minimum, the following information must accompany each claim submitted: 1. A detailed factual statement of the claim for additional compensation and time, if any, providing all necessary dates, locations, and items of Work affected by the claim. 2. The date on which facts arose which gave rise to the claim. 3. The name of each Contracting Agency individual, official, or employee involved in or knowledgeable about the claim. 4. The specific provisions of the Contract which support the claim and a statement of the reasons why such provisions support the claim. 5. If the claim relates to a decision of the Engineer which the Contract leaves to the Engineer’s discretion or as to which the Contract provides that the Engineer’s decision is final, the Contractor shall set out in detail all facts supporting its position relating to the decision of the Engineer. 6. The identification of any documents and the substance of any oral communications that support the claim. 7. Copies of any identified documents, other than Contracting Agency documents and documents previously furnished to the Contracting Agency by the Contractor, that support the claim (manuals which are standard to the industry, used by the Contractor, may be included by reference). 8. If an extension of time is sought: a. The specific days and dates for which it is sought, b. The specific reasons the Contractor believes a time extension should be granted, c. The specific provisions of Section 1-08.8 under which it is sought, and d. The Contractor’s analysis of its progress schedule to demonstrate the reason for a time extension. 9. If additional compensation is sought, the exact amount sought and a breakdown of that amount into the following categories: a. Labor; b. Materials; c. Direct equipment. The actual cost for each piece of equipment for which a claim is made or in the absence of actual cost, the rates established by the AGC/ WSDOT Equipment Rental Agreement which was in effect when the Work was performed. In no case shall the amounts claimed for each piece of equipment exceed the rates established by that Equipment Rental Agreement even if the actual cost for such equipment is higher. The Contracting Agency may audit the Contractor’s cost records as provided in Section 1-09.12 to determine actual Page 1-144 2020 Standard Specifications M 41-10 1-09 Measurement and Payment equipment cost. The following information shall be provided for each piece of equipment: (1) Detailed description (e.g., Motor Grader Diesel Powered Caterpillar 12 “G”, Tractor Crawler ROPS & Dozer Included Diesel); (2) The hours of use or standby; and (3) The specific day and dates of use or standby; d. Job overhead; e. Overhead (general and administrative); f. Subcontractor’s claims (in the same level of detail as specified herein is required for any Subcontractor’s claims); and g. Other categories as specified by the Contractor or the Contracting Agency. 10. A notarized statement shall be submitted to the Engineer containing the following language: Under the penalty of law for perjury or falsification, the undersigned, ____________________________, ______________________________    (name)           (title) of _________________________________________________________    (company) hereby certifies that the claim for extra compensation and time, if any, made herein for Work on this Contract is a true statement of the actual costs incurred and time sought, and is fully documented and supported under the Contract between the parties. Dated __________________________/s/__________________________ Subscribed and sworn before me this ___________ day of ____________ ___________________________________________________________ Notary Public My Commission Expires:______________________________________ It will be the responsibility of the Contractor to keep full and complete records of the costs and additional time incurred for any alleged claim. The Contractor shall permit the Engineer to have access to those records and any other records as may be required by the Engineer to determine the facts or contentions involved in the claim. The Contractor shall retain those records for a period of not less than three years after final acceptance. 2020 Standard Specifications M 41-10 Page 1-145 Measurement and Payment 1-09 The Contractor shall pursue administrative resolution of any claim with the Engineer or the designee of the Engineer. Failure to submit with the Final Contract Voucher Certification such information and details as described in this section for any claim shall operate as a waiver of the claims by the Contractor as provided in Section 1-09.9. Provided that the Contractor is in full compliance with all the provisions of this section and after the formal claim document has been submitted, the Contracting Agency will respond, in writing, to the Contractor as follows: 1. Within 45 calendar days from the date the claim is received by the Contracting Agency if the claim amount is less than $100,000; 2. Within 90 calendar days from the date the claim is received by the Contracting Agency if the claim amount is equal to or greater than $100,000; or 3. If the above restraints are unreasonable due to the complexity of the claim under consideration, the Contractor will be notified within 15 calendar days from the date the claim is received by the Contracting Agency as to the amount of time which will be necessary for the Contracting Agency to prepare its response. Full compliance by the Contractor with the provisions of this section is a contractual condition precedent to the Contractor’s right to seek judicial relief. 1-09.11(3) Time Limitation and Jurisdiction For the convenience of the parties to the Contract it is mutually agreed by the parties that any claims or causes of action which the Contractor has against the State of Washington arising from the Contract shall be brought within 180 calendar days from the date of final acceptance (Section 1-05.12) of the Contract by the State of Washington; and it is further agreed that any such claims or causes of action shall be brought only in the Superior Court of Thurston County. The parties understand and agree that the Contractor’s failure to bring suit within the time period provided, shall be a complete bar to any such claims or causes of action. It is further mutually agreed by the parties that when any claims or causes of action which the Contractor asserts against the State of Washington arising from the Contract are filed with the State or initiated in court, the Contractor shall permit the State to have timely access to any records deemed necessary by the State to assist in evaluating the claims or action. 1-09.12 Audits 1-09.12(1) General The Contractor’s wage, payroll, and cost records on this Contract shall be open to inspection or audit by representatives of the Contracting Agency during the life of the Contract and for a period of not less than 3 years after the date of final acceptance of the Contract. The Contractor shall retain these records for that period. The Contractor shall also guarantee that the wage, payroll, and cost records of all Subcontractors and all lower tier Subcontractors shall be retained and open to similar inspection or Page 1-146 2020 Standard Specifications M 41-10 1-09 Measurement and Payment audit for the same period of time. The audit may be performed by employees of the Contracting Agency or by an auditor under contract with the Contracting Agency. The Contractor, Subcontractors, or lower tier subcontractors shall provide adequate facilities, acceptable to the Engineer, for the audit during normal business hours. The Contractor, Subcontractors, or lower tier subcontractors shall make a good faith effort to cooperate with the auditors. If an audit is to be commenced more than 60 calendar days after the final acceptance date of the Contract, the Contractor will be given 20 calendar days notice of the time when the audit is to begin. If any litigation, claim, or audit arising out of, in connection with, or related to this Contract is initiated, the wage, payroll, and cost records shall be retained until such litigation, claim, or audit involving the records is completed. 1-09.12(2) Claims All claims filed against the Contracting Agency shall be subject to audit at any time following the filing of the claim. Failure of the Contractor, Subcontractors, or lower tier subcontractors to maintain and retain sufficient records to allow the auditors to verify all or a portion of the claim or to permit the auditor access to the books and records of the Contractor, Subcontractors, or lower tier subcontractors shall constitute a waiver of a claim and shall bar any recovery thereunder. 1-09.12(3) Required Documents for Audits As a minimum, the auditors shall have available to them the following documents: 1. Daily time sheets and supervisor’s daily reports. 2. Collective Bargaining Agreements. 3. Insurance, welfare, and benefits records. 4. Payroll registers. 5. Earnings records. 6. Payroll tax forms. 7. Material invoices and requisitions. 8. Material cost distribution worksheet. 9. Equipment records (list of company equipment, rates, etc.). 10. Vendors’, rental agencies’, Subcontractors’, and lower tier subcontractors’ invoices. 11. Contracts between the Contractor and each of its Subcontractors, and all lower-tier subcontractor contracts and supplier contracts. 12. Subcontractors’ and lower tier subcontractors’ payment certificates. 13. Canceled checks (payroll and vendors). 14. Job cost reports, including monthly totals. 15. Job payroll ledger. 16. General ledger. 2020 Standard Specifications M 41-10 Page 1-147 Measurement and Payment 1-09 17. Cash disbursements journal. 18. Financial statements for all years reflecting the operations on this Contract. In addition, the Contracting Agency may require, if it deems appropriate, additional financial statements for 3 years preceding execution of the Contract and 3 years following final acceptance of the Contract. 19. Depreciation records on all company equipment whether these records are maintained by the company involved, its accountant, or others. 20. If a source other than depreciation records is used to develop costs for the Contractor’s internal purposes in establishing the actual cost of owning and operating equipment, all such other source documents. 21. All documents which relate to each and every claim together with all documents which support the amount of damages as to each claim. 22. Worksheets or software used to prepare the claim establishing the cost components for items of the claim including but not limited to labor, benefits and insurance, materials, equipment, Subcontractors, all documents which establish the time periods, individuals involved, the hours for the individuals, and the rates for the individuals. 23. Worksheets, software, and all other documents used by the Contractor to prepare its Bid. An audit may be performed by employees of the Contracting Agency or a representative of the Contracting Agency. The Contractor and its Subcontractors shall provide adequate facilities acceptable to the Contracting Agency for the audit during normal business hours. The Contractor and all Subcontractors shall cooperate with the Contracting Agency’s auditors. 1-09.13 Claims Resolution 1-09.13(1) General Prior to seeking claim resolution through nonbinding alternative dispute resolution processes, binding arbitration, or litigation, the Contractor shall proceed under the administrative procedures in Sections 1-04.5 and 1-09.11, and any Special Provision provided in the Contract for resolution of disputes. The provisions of these sections must be complied with in full, as a condition precedent to the Contractor’s right to seek claim resolution through any nonbinding alternative dispute resolution process, binding arbitration or litigation. 1-09.13(2) Nonbinding Alternative Disputes Resolution (ADR) Nonbinding ADR processes are encouraged and available upon mutual agreement of the Contractor and the Contracting Agency for all claims submitted in accordance with Section 1-09.11, provided that: 1. All the administrative remedies provided for in the Contract have been exhausted; Page 1-148 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 2. The Contracting Agency has been given the time and opportunity to respond to the Contractor as provided in Section 1-09.11(2); and 3. The Contracting Agency has determined that it has sufficient information concerning the Contractor’s claims to participate in a nonbinding ADR process. The Contracting Agency and the Contractor mutually agree that the cost of the nonbinding ADR process shall be shared equally by both parties with each party bearing its own preparation costs. The type of nonbinding ADR process shall be agreed upon by the parties and shall be conducted within the State of Washington at a location mutually acceptable to the parties. The Contractor agrees that the participation in a nonbinding ADR process does not in any way waive the requirement that binding arbitration or litigation proceedings must commence within 180 calendar days of final acceptance of the Contract, the same as any other claim or causes of action as provided in Section 1-09.11(3). 1-09.13(3) Claims $250,000 or Less The Contractor and the Contracting Agency mutually agree that those claims which total $250,000 or less, submitted in accordance with Section 1-09.11 and not resolved by nonbinding ADR processes, shall be resolved through mandatory and binding arbitration as described herein. 1-09.13(3)A Administration of Arbitration Arbitration shall be as agreed by the parties or, if the parties cannot agree, arbitration shall be administered through the American Arbitration Association (AAA) using the following arbitration methods: 1. The current version of the Construction Industry Arbitration Rules and Mediation Fast Track Procedures shall be used for claims with an amount less than $75,000. 2. The current version of the Construction Industry Arbitration Rules and Mediation Regular Track Procedures shall be used for claims with an amount equal to or greater than $75,000 and less than $250,000. The Contracting Agency and the Contractor mutually agree the venue of any arbitration hearing shall be within the State of Washington and any such hearing shall be conducted within the State of Washington. The Contracting Agency and the Contractor mutually agree to be bound by the decision of the arbitrator, and judgment upon the award rendered by the arbitrator may be entered in the Superior Court of Thurston County. The decision of the arbitrator and the specific basis for the decision shall be in writing. The arbitrator shall use the Contract as a basis for decisions. 2020 Standard Specifications M 41-10 Page 1-149 Measurement and Payment 1-09 1-09.13(3)B Procedures to Pursue Arbitration If the dispute cannot be resolved through administrative procedures provided in Sections 1-04.5 and 1-09.11, and any Special Provision provided in the Contract for resolution of disputes or through a mutually agreed upon nonbinding ADR process, the Contractor shall advise the Engineer, in writing, that mandatory and binding arbitration is desired. The parties may agree on an arbitration process, or, if the parties cannot agree a demand for arbitration shall be filed by the Contractor, in accordance with the AAA rules, with the Contracting Agency, and with the AAA. Selection of the arbitrator and the administration of the arbitration shall proceed in accordance with AAA rules using arbitrators from the list developed by the AAA, except that: for claims under $25,000 using the Northwest Region Expedited Commercial Arbitration Rules, arbitration selection shall proceed pursuant to Section 55 of the Expedited Procedure of the Construction Industry Arbitration Rules. Arbitration shall proceed utilizing the appropriate rule of the AAA as determined by the dollar amount of the claim as provided in Section 1-09.13(3)A. Unresolved disputes which do not involve delays or impacts to unchanged Work may be brought to binding arbitration prior to Physical Completion of the project, provided that: 1. All the administrative remedies provided for in the Contract have been exhausted; 2. The dispute has been pursued to the claim status as provided in Section 1-09.11(2); and 3. The Contractor certifies in writing that claims for delays or impacts to the Work will not result from the dispute. Unless the Contracting Agency and the Contractor agree otherwise, all other unresolved claims (disputes which have been pursued to the claim status) which arise from a Contract must be brought in a single arbitration hearing and only after Physical Completion of the Contract. The total of those unresolved claims cannot be greater than $250,000 to be eligible for arbitration. In addition, the Contractor agrees arbitration proceedings must commence, by filing of the aforementioned demand for arbitration, within 180 calendar days of final acceptance of the contract, the same as any other claim or causes of action as provided in Section 1-09.11(3). The scope and extent of discovery shall be determined by the arbitrator in accordance with AAA rules. In addition, each party for claims greater than $25,000 shall serve upon the other party a “statement of proof”. The statement of proof shall be served, with a copy to the AAA, no less than 20 calendar days prior to the arbitration hearing and shall include: 1. The identity, current business address, and residential address of each witness who will testify at the hearing; 2. The identity of a witness as an expert if an expert witness is to be called, a statement as to the subject matter and the substance of the facts and opinions on which the expert is expected to testify, a summary of the grounds for each opinion, and a resume of the expert’s qualifications; and Page 1-150 2020 Standard Specifications M 41-10 1-09 Measurement and Payment 3. A list of each document that the party intends to offer in evidence at the arbitration hearing. Either party may request from the other party a copy of any document listed. If such a request is made, a copy of the document shall be provided within 5 calendar days from the date the request is received. The arbitrator may permit a party to call a witness or offer a document not shown or included in the statement of proof only upon a showing of good cause. 1-09.13(4) Claims in Excess of $250,000 The Contractor and the Contracting Agency mutually agree that those claims in excess of $250,000, submitted in accordance with Section 1-09.11 and not resolved by nonbinding ADR processes, shall be resolved through litigation unless the parties mutually agree to resolve the claim through binding arbitration. 2020 Standard Specifications M 41-10 Page 1-151 Temporary Traffic Control 1-10 1-10 Temporary Traffic Control 1-10.1 General Temporary traffic control refers to the control of all types of traffic, including vehicles, bicyclists, and pedestrians (including pedestrians with disabilities). The Contractor, utilizing contractor labor and contractor-provided equipment and materials (except when such labor, equipment, or materials are to be provided by the Contracting Agency as specifically identified herein), shall plan, manage, supervise, and perform all temporary traffic control activities needed to support the Work of the Contract. 1-10.1(1) Materials Materials shall meet the requirements of the following Sections: Stop/Slow Paddles 9-35.1 Construction Signs 9-35.2 Wood Sign Posts 9-35.3 Sequential Arrow Signs 9-35.4 Portable Changeable Message Signs 9-35.5 Barricades 9-35.6 Traffic Safety Drums 9-35.7 Traffic Cones 9-35.9 Tubular Markers 9-35.10 Warning Lights and Flashers 9-35.11 Transportable Attenuator 9-35.12 Tall Channelizing Devices 9-35.13 Portable Temporary Traffic Control Signal 9-35.14 1-10.1(2) Description The Contractor shall provide flaggers and all other personnel required for labor for traffic control activities that are not otherwise specified as being furnished by the Contracting Agency. The Contractor shall perform all procedures necessary to support the Contract Work. Unless otherwise permitted by the Contract or approved by the Engineer, the Contractor shall keep all existing pedestrian routes and access points (including sidewalks, paths, and crosswalks) open and clear at all times. The Contractor shall keep lanes, on-ramps, and off-ramps, open to traffic at all times except when Work requires closures. Ramps shall not be closed on consecutive interchanges at the same time, unless approved by the Engineer. Lanes and ramps shall be closed for the minimum time required to complete the Work. When paving hot mix asphalt the Contractor may apply water to the pavement to shorten the time required before reopening to traffic. Page 1-152 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control The Contractor shall provide signs and other traffic control devices not otherwise specified as being furnished by the Contracting Agency. The Contractor shall erect and maintain all construction signs, warning signs, detour signs, and other traffic control devices necessary to warn and protect the public at all times from injury or damage as a result of the Contractor’s operations, which may occur on or adjacent to Highways, roads, streets, sidewalks, or paths. No Work shall be done on or adjacent to any Traveled Way until all necessary signs and traffic control devices are in place. The traffic control resources and activities described shall be used for the safety of the public, of the Contractor’s employees, and of the Contracting Agency’s personnel and to facilitate the movement of the traveling public. Traffic control resources and activities may be used for the separation or merging of public and construction traffic when such use is in accordance with a specific approved traffic control plan. Upon failure of the Contractor to immediately provide flaggers; erect, maintain, and remove signs; or provide, erect, maintain, and remove other traffic control devices when ordered to do so by the Engineer, the Contracting Agency may, without further notice to the Contractor or the Surety, perform any of the above and deduct all of the costs from the Contractor’s payments. The Contractor shall be responsible for providing adequate labor, sufficient signs, and other traffic control devices, and for performing traffic control procedures needed for the protection of the Work and the public at all times regardless of whether or not the labor, devices or procedures have been ordered by the Engineer, furnished by the Contracting Agency, or paid for by the Contracting Agency. Wherever possible when performing Contract Work, the Contractor’s equipment shall follow normal and legal traffic movements. The Contractor’s ingress and egress of the Work area shall be accomplished with as little disruption to traffic as possible. Traffic control devices shall be removed by picking up the devices in a reverse sequence to that used for installation. This may require moving backwards through the work zone. When located behind barrier or at other locations shown on approved traffic control plans, equipment may operate in a direction opposite to adjacent traffic. The Contractor is advised that the Contracting Agency may have entered into operating agreements with one or more law enforcement organizations for cooperative activities. Under such agreements, at the sole discretion of the Contracting Agency, law enforcement personnel may enter the work zone for enforcement purposes and may participate in the Contractor’s traffic control activities. The responsibility under the Contract for all traffic control resides with the Contractor and any such participation by law enforcement personnel in Contractor traffic control activities will be referenced in the Special Provisions or will be preceded by an agreement and, if appropriate, a cost adjustment. Nothing in this Contract is intended to create an entitlement, on the part of the Contractor, to the services or participation of the law enforcement organization. 2020 Standard Specifications M 41-10 Page 1-153 Temporary Traffic Control 1-10 1-10.2 Traffic Control Management 1-10.2(1) General It is the Contractor’s responsibility to plan, conduct, and safely perform the Work. The Contractor shall manage temporary traffic control with his or her own staff. Traffic control management responsibilities shall be formally assigned to one or more company supervisors who are actively involved in the planning and management of field Contract activities. The Contractor shall provide the Engineer with a copy of the formal assignment. The duties of traffic control management may not be subcontracted. The Contractor shall designate an individual or individuals to perform the duties of the primary Traffic Control Supervisor (TCS). The designation shall also identify an alternate TCS who can assume the duties of the primary TCS in the event of that person’s inability to perform. The TCS shall be responsible for safe implementation of approved Traffic Control Plans provided by the Contractor. The primary and alternate TCS shall be certified by one of the organizations listed in the Special Provisions. Possession of a current Washington State TCS card and flagging card by the primary and alternate TCS is mandatory. A traffic control management assignment and a TCS designation are required on all projects that will utilize traffic control. The Contractor shall maintain 24-hour telephone numbers at which the Contractor’s assigned traffic control management personnel and the TCS can be contacted and be available upon the Engineer’s request at other than normal working hours. These persons shall have the resources, ability and authority to expeditiously correct any deficiency in the traffic control system. 1-10.2(1)A Traffic Control Management The responsibilities of the Contractor’s traffic control management personnel shall include: 1. Overseeing and approving the actions of the Traffic Control Supervisor (TCS) to ensure that proper safety and traffic control measures are implemented and consistent with the specific requirements created by the Contractor’s work zones and the Contract. Some form of oversight shall be in place and effective even when the traffic control management personnel are not present at the jobsite. 2. Providing the Contractor’s designated TCS with approved Traffic Control Plans (TCPs) which are compatible with the Work operations and traffic control for which they will be implemented. Having the latest adopted edition of the Manual on Uniform Traffic Control Devices for Streets and Highways (MUTCD), including the Washington State Modifications to the MUTCD M 24-01 the most current edition of the Public Rights-of-Way Accessibility Guidelines (PROWAG), which can be downloaded from the United States Access Board website at www.access-board.gov/prowac under Revised Draft Guidelines (2005), and applicable standards and Specifications available at all times on the project. Page 1-154 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control 3. Discussing proposed traffic control measures and coordinating implementation of the Contractor-adopted traffic control plan(s) with the Engineer. 4. Coordinating all traffic control operations, including those of Subcontractors and suppliers, with each other and with any adjacent construction or maintenance operations. 5. Coordinating the project’s activities (such as ramp closures, road closures, and lane closures) with appropriate police, fire control agencies, city or county engineering, medical emergency agencies, school districts, and transit companies. 6. Overseeing all requirements of the Contract that contribute to the convenience, safety, and orderly movement of vehicular and pedestrian traffic. 7. Reviewing the TCS’s diaries daily and being aware of field traffic control operations. 8. Being present on-site a sufficient amount of time to adequately satisfy the above- listed responsibilities. Failure to carry out any of the above-listed responsibilities shall be a failure to comply with the Contract and may result in a suspension of Work as described in Section 1-08.6. 1-10.2(1)B Traffic Control Supervisor A Traffic Control Supervisor (TCS) shall be present on the project whenever flagging or other traffic control labor is being utilized or less frequently, as authorized by the Engineer. The TCS shall personally perform all the duties of the TCS. During nonwork periods, the TCS shall be available to the job site within a 45-minute time period after notification by the Engineer. The TCS’s duties shall include: 1. Having a current set of approved traffic control plans (TCPs), applicable Contract Provisions as provided by the Contractor, the latest adopted edition of the MUTCD, including the Washington State Modifications to the MUTCD, the book Quality Guidelines for Temporary Work Zone Traffic Control Devices, the most current edition of the PROWAG, and applicable standards and Specifications. 2. Inspecting traffic control devices and nighttime lighting for proper location, installation, message, cleanliness, and effect on the traveling public. Traffic control devices shall be inspected at least once per hour during working hours except that Class A signs need to be checked once a week and nighttime lighting need to be checked only once a shift. Traffic control devices left in place for 24 hours or more shall also be inspected once during the nonworking hours when they are initially set up (during daylight or darkness, whichever is opposite of the working hours). The TCS shall correct, or arrange to have corrected, any deficiencies noted during these inspections. 2020 Standard Specifications M 41-10 Page 1-155 Temporary Traffic Control 1-10 3. Preparing a daily traffic control diary on each day that traffic control is performed using WSDOT Form 421-040A and 421-040B, and submitting them to the Engineer no later than the end of the next working day. The Contractor may use alternate forms if approved by the Engineer. Diary entries shall include, but not be limited to: a. Time of day when signs and traffic control devices are installed and removed, b. Location and condition of signs and traffic control devices, c. Revisions to the traffic control plan, d. Lighting utilized at night, and e. Observations of traffic conditions. 4. Making minor revisions to the traffic control plan to accommodate site conditions provided that the original intent of the traffic control plan is maintained and the revision has the concurrence of both the Contractor and the Engineer. 5. Attending traffic control coordinating meetings or coordination activities as necessary for full understanding and effective performance. 6. Ensuring that all needed traffic control devices and equipment are available and in good working condition prior to the need to install or utilize them. 7. Ensuring that all pedestrian routes or access points, existing or temporary, are kept clear and free of obstructions and that all temporary pedestrian routes or access points are detectable and accessible to persons with disabilities as provided for in the approved Plans. The TCS may perform the Work described in Section 1-10.3(1)A Flaggers or in Section 1-10.3(1)B Other Traffic Control Labor and be compensated under those Bid items, provided that the duties of the TCS are accomplished. 1-10.2(2) Traffic Control Plans The traffic control plan or plans appearing in the Contract documents show a method of handling vehicle, bicycle, and pedestrian traffic. All construction signs, flaggers, and other traffic control devices are shown on the traffic control plan(s) except for emergency situations. If the Contractor proposes adding the use of flaggers to a plan, this will constitute a modification requiring approval by the Engineer. The modified plans shall show locations for all the required advance warning signs and a safe, protected location for the flagging station. If flagging is to be performed during hours of darkness, the plan shall include appropriate illumination for the flagging station. When the Contractor’s chosen method of performing the Work in the Contract requires some form of temporary traffic control, for vehicles, bicyclists, or pedestrians, the Contractor shall either: (1) submit a Type 1 Working Drawing designating and adopting, in writing, the traffic control plan or plans from the Contract documents that support that method; or (2) submit a Type 2 Working Drawing consisting of the Contractor’s plan that modifies, supplements or replaces a plan from the Contract documents. Any Contractor- proposed modification, supplement or replacement shall show the necessary construction signs, flaggers, and other traffic control devices required to support the Work. Any Page 1-156 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control Contractor-proposed traffic control plan shall conform to the established standards for plan development as shown in the MUTCD, Part 6 and the most current edition of the PROWAG. The Contractor shall be solely responsible for submitting any proposed traffic control plan or modification, obtaining the Engineer’s acceptance and providing copies of the accepted Traffic Control Plans to the Traffic Control Supervisor. 1-10.2(3) Conformance to Established Standards Flagging, signs, and all other traffic control devices and procedures furnished or provided shall conform to the standards established in the latest WSDOT adopted edition of the MUTCD, published by the U.S. Department of Transportation and the Washington State Modifications to the MUTCD, and the most current edition of the Public Rights-of-Way Accessibility Guidelines (PROWAG). Judgment of the quality of devices furnished will be based upon Quality Guidelines for Temporary Traffic Control Devices, published by the American Traffic Safety Services Association. Copies of the MUTCD and Quality Guidelines for Temporary Control Devices may be purchased from the American Traffic Safety Services Association, 15 Riverside Parkway, Suite 100, Fredericksburg, VA 22406-1022. The Washington State Modifications to the MUTCD may be obtained from the Department of Transportation, Olympia, WA 98504. The most current edition of the Public Rights-of-Way Accessibility Guidelines (PROWAG) can be accessed at https://www.access-board.gov/ guidelines-and-standards/streets-sidewalks/public-rights-of-way/proposed-rights-of- way-guidelines. In addition to the standards of the MUTCD described above, the Contracting Agency has crashworthiness requirements for most work zone devices. The National Cooperative Highway Research Project (NCHRP) Report 350 and the AASHTO Manual for Assessing Safety Hardware (MASH) have established requirements for crash testing. Work zone devices are divided into four categories. Each of those categories is described below: Category 1 includes those items that are small and lightweight, channelizing, and delineating devices that have been in common use for many years and are known to be crashworthy by crash testing of similar devices or years of demonstrable safe performance. These include cones, tubular markers, flexible delineator posts, and plastic drums. All Category 1 devices used on the project shall meet the requirements of NCHRP 350 or MASH as certified by the manufacturer of the device. Category 2 includes devices that are not expected to produce significant vehicular velocity change, but may otherwise be hazardous. Examples of this class are barricades, portable sign supports and signs. All Category 2 devices shall meet the requirements of NCHRP 350 or MASH. For the purpose of definition, a sign support and sign shall be considered a single unit. A new sign may be purchased for an existing sign support and the entire unit will be defined as “existing equipment”. Category 3 is for hardware expected to cause significant velocity changes or other potentially harmful reactions to impacting vehicles. Barriers, fixed sign supports, crash cushions, transportable attenuators and other work zone devices not meeting the definitions of Category 1 or 2 are examples from this category. Many Category 3 devices are defined in the design of the project. Where this is the case, 2020 Standard Specifications M 41-10 Page 1-157 Temporary Traffic Control 1-10 NCHRP 350 or MASH requirements have been incorporated into the design and the Contractor complies with the requirements by constructing devices according to the Plans and Specifications. Where the device is a product chosen by the Contractor, the device chosen must be compliant with the requirements of NCHRP 350 or MASH. Category 4 includes portable or trailer-mounted devices such as arrow displays, temporary traffic signals, area lighting supports, and portable changeable message signs. Crash testing is not required for these devices. The condition of signs and traffic control devices shall be acceptable or marginal as defined in the book Quality Guidelines for Temporary Traffic Control Devices, and will be accepted based on a visual inspection by the Engineer. The Engineer’s decision on the condition of a sign or traffic control device shall be final. A sign or traffic control device determined to be unacceptable shall be removed from the project and replaced within 12 hours of notification. 1-10.3 Traffic Control Labor, Procedures, and Devices 1-10.3(1) Traffic Control Labor The Contractor shall furnish all personnel for flagging, for the execution of all procedures related to temporary traffic control and for the setup, maintenance and removal of all temporary traffic control devices and construction signs necessary to control vehicular, bicycle, and pedestrian traffic during construction operations. Vests and other high-visibility apparel shall be in conformance with Section 1-07.8. 1-10.3(1)A Flaggers Flaggers shall be posted where shown on approved Traffic Control Plans or where directed by the Engineer. All flaggers shall possess a current flagging card issued by the State of Washington, Oregon, Montana, or Idaho. The flagging card shall be immediately available and shown to the Contracting Agency upon request. Flagging stations shall be shown on Traffic Control Plans at locations where construction operations require stopping or diverting public traffic. Flagging stations shall be staffed only when flagging is required. This staffing may be continuous or intermittent, depending on the nature of the construction activity. Whenever a flagger is not required to stop or divert traffic, the flagger shall move away from the flagging station to a safer location. During hours of darkness, flagging stations shall be illuminated in a manner that insures that flaggers can easily be seen but that does not cause glare to the traveling public. Flagger station illumination shall meet the requirements of the MUTCD and these Specifications. The Contractor shall provide portable lighting equipment capable of sufficiently illuminating a flagger and their station without creating glare for oncoming motorists, yet will meet the mobility requirements of the operation. The lighting stations shall be located on the same side of the roadway as the flagger and aimed either parallel or perpendicular Page 1-158 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control to the traveled lanes to minimize glare. The lighting devices shall be located 5 to 10 feet from the edge of the travel lane with a mounting height of 15 to 25 feet above the ground. The flagger should be visible and discernable as a flagger from a distance of 1,000 feet. Flaggers shall be equipped with portable two-way radios, with a range suitable for the project. The radios shall be capable of having direct contact with project management (foremen, superintendents, etc.). The Contractor shall furnish Stop/Slow paddles conforming to the requirements of Section 9-35.1 for all flagging operations. 1-10.3(1)B Other Traffic Control Labor In addition to flagging duties, the Contractor shall provide personnel for all other traffic control procedures required by the construction operations and for the labor to install, maintain and remove any traffic control devices shown on Traffic Control Plans. 1-10.3(2) Traffic Control Procedures 1-10.3(2)A One-Way Traffic Control The project Work may require that traffic be maintained on a portion of the Roadway during the progress of the Work using one-way traffic control. If this is the case, the Contractor’s operation shall be confined to one-half the Roadway, permitting traffic on the other half. If shown on an approved traffic control plan or directed by the Engineer, one-way traffic control, in accordance with the MUTCD, shall be provided and shall also conform to the following requirements: In any one-way traffic control configuration, side roads and approaches will be closed or controlled by a flagger or by appropriate approved signing. A side road flagger will coordinate with end flaggers where there is line of sight and with the pilot car where the end flaggers cannot be seen. Queues of vehicles will be allowed to take turns passing through the work zone in the single open lane. When one-way traffic control is in effect, Contractor vehicles shall not use the open traffic lane except while following the same rules and routes required of the public traffic. As conditions permit, the Contractor shall, at the end of each day, leave the Work area in such condition that it can be traveled without damage to the Work, without danger to traffic, and without one-way traffic control. If, in the opinion of the Engineer, one-way traffic control cannot be dispensed with after working hours, then the operation will be continued throughout the non-working hours. 2020 Standard Specifications M 41-10 Page 1-159 Temporary Traffic Control 1-10 1-10.3(2)B Rolling Slowdown Rolling slowdown traffic control operations are not to be used for routine Work that can be addressed by standard lane or shoulder closure traffic control. When a short-term roadway closure is needed for an infrequent, nonrepetitive Work operation such as a sign bridge removal or utility wire crossing, the Contractor may implement a rolling slowdown on a multilane roadway, as part of an accepted traffic control plan. The Contractor shall submit Type 2 Working Drawings consisting of a traffic control plan detailing the expected delay time, interchange ramp control, and rolling slowdown distance. A portable changeable message sign shall be placed ahead of the starting point of the traffic control to warn traffic of the slowdown. The sign shall be placed far enough ahead of the Work to avoid any expected backup of vehicles. A rolling slowdown shall use traffic control vehicles with flashing amber lights. At least one traffic control vehicle will be used for every two lanes to be slowed, plus a control vehicle will serve as a following (chase) vehicle for traffic ahead of the blockade. The traffic control vehicles shall enter the roadway and form a moving blockade to reduce traffic speeds and create a clear area ahead of the blockade in which to accomplish the Work without a total stoppage of traffic. The location where the traffic control vehicles shall begin the slowdown and the speed at which the moving blockade will be allowed to travel will be calculated to accommodate the estimated time needed for closure. The chase control vehicle shall follow the slowest vehicle ahead of the blockade. When the chase vehicle passes, the Contractor may begin the Work operation. In the event that the Work operation is not completed when the moving blockade reaches the site, all Work except that necessary to clear the Roadway shall cease immediately and the Roadway shall be cleared and reopened as soon as possible. All ramps and entrances to the Roadway between the moving blockade and Work operation shall be temporarily closed using flaggers. Radio communications between the Work operation and the moving blockade shall be established and utilized to adjust the speed of the blockade to accommodate the closure time needed. 1-10.3(2)C Lane Closure Setup/Takedown Where allowed by the Contract and where shown on approved traffic control plans or directed by the Engineer, the Contractor shall set up traffic control measures to close one or more lanes of a multi-lane facility. When this is to occur, the following sequence shall be followed: 1. If the Plans show a portable changeable message sign, it shall be established in advance of the operation, far enough back to provide warning of both the operation and any queue of traffic that has formed during the operation. 2. Advance warning signs are set up on the Shoulder of the Roadway opposite the lane to be closed. 3. Advance warning signs are set up on the same Shoulder as the lane to be closed. Page 1-160 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control 4. A transportable attenuator, with arrow board, is moved into place at the beginning of the closure taper. 5. Channelization devices are placed to mark the taper and the length of the closure as shown on the traffic control plan. Once the lane is closed, the transportable attenuator/arrow board combination shall be replaced with an arrow board without attenuator. If additional lanes are to be closed, this shall be done in sequence with previous lane closures using the same sequence of activities. A transportable attenuator with arrow board is required during the process of closing each additional lane and is to be replaced with an arrow board without attenuator after the lane is closed. Each closed lane shall be marked with a separate arrow board at all times. Channelization devices shall not be moved by traffic control personnel across an open lane of traffic. If an existing setup or staging of traffic control devices require crossing an open lane of traffic, the traffic control devices shall be taken down completely and then set up in the new configuration. Traffic control for lane closures shall be removed in the reverse order of its installation. 1-10.3(2)D Mobile Operations Where construction operations are such that movement along the length of a Roadway is continuous or near-continuous to the extent that a stationary traffic control layout will not be effective, the Contractor may implement a moving, or mobile, traffic control scheme. Such moving control shall always be conducted in the same direction as the adjacent traffic. Where shown on an approved traffic control plan or where directed by the Engineer, mobile traffic control shall consist of portable equipment, moving with the operation. A portable changeable message sign shall be established in advance of the operation, far enough back to provide warning of both the operation and of any queue of traffic that has formed during the operation. The advance sign shall be continuously moved to stay near the back of the queue at all times. A transportable attenuator, with arrow board, shall be positioned and maintained at a fixed distance upstream of the Work. A shadow vehicle, with transportable attenuator shall be positioned and maintained immediately upstream of the Work. 1-10.3(2)E Patrol and Maintain Traffic Control Measures At all times, when temporary traffic control measures are in place, the Contractor shall provide for patrolling and maintaining these measures. The Work shall consist of resetting errant devices, assuring visibility of all devices, cleaning and repairing where necessary, providing maintenance for all equipment, including replacing batteries and light bulbs as well as keeping motorized and electronic items functioning, and adjusting the location of devices to respond to actual conditions, such as queue length, unanticipated traffic conflicts and other areas where planned traffic control has proven ineffective. 2020 Standard Specifications M 41-10 Page 1-161 Temporary Traffic Control 1-10 This Work shall be performed by the Contractor, either by or under the direction of the Traffic Control Supervisor. Personnel, with vehicles if necessary, shall be dispatched so that all traffic control can be reviewed at least once per hour during working hours and at least once during each non-working day. 1-10.3(3) Traffic Control Devices Traffic control devices, including signs, furnished or provided shall conform to the standards established in the latest WSDOT-adopted edition of the Manual on Uniform Traffic Control Devices for Streets and Highways (MUTCD) published by the U.S. Department of Transportation and the Washington State Modifications to the MUTCD. Requirements for pedestrian traffic control devices are addressed in the MUTCD. 1-10.3(3)A Construction Signs All construction signs required by approved traffic control plans, as well as any other appropriate signs directed by the Engineer shall be furnished by the Contractor. The Contractor shall provide the posts or supports and erect and maintain the signs in a clean, neat, and presentable condition until the need for them has ended. Post mounted signs shall be installed as shown in the Standard Plans. When the need for construction signs has ended, the Contractor, upon approval of the Engineer, shall remove all signs, posts, and supports from the project and they shall remain the property of the Contractor. No passing zones on the existing Roadway that are marked with paint striping and which striping is to be obliterated by construction operations shall be replaced by “Do Not Pass” and “Pass With Care” signs. The Contractor shall provide and install the posts and signs. The signs shall be maintained by the Contractor until they are removed or until the Contract is Physically Completed. When the project includes striping by the Contractor, the signs and posts shall be removed by the Contractor when the no passing zones are reestablished by striping. The signs and posts will become the property of the Contractor. When the Contractor is not responsible for striping and when the striping by others is not completed when the project is Physically Completed, the posts and signs shall be left in place and shall become the property of the Contracting Agency. All existing signs, new permanent signs installed under this Contract, and construction signs installed under this Contract that are inappropriate for the traffic configuration at a given time shall be removed or completely covered in accordance with Section 8-21.3(3). Construction signs will be divided into two classes. Class A construction signs are those signs that remain in service throughout the construction or during a major phase of the Work. They are mounted on posts, existing fixed Structures, or substantial supports of a semi-permanent nature. Class A signs will be designated as such on the approved Traffic Control Plan. “Do Not Pass” and “Pass With Care” signs are classified as Class A construction signs. Sign and support installation for Class A signs shall be in accordance with the Contract Plans or the Standard Plans. Class B construction signs are those signs that are placed and removed daily, or are used for short durations which may extend for 1 to 3 days. They are mounted on portable or temporary mountings. Tripod-mounted signs in place more than 3 days in any one location, unless approved by the Engineer, shall be required to be post-mounted and shall be classified as Class A construction signs. Page 1-162 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control Where it is necessary to add weight to signs for stability, sand bags or other similar ballast may be used, but the top of ballast shall not be more than 4 inches above the Roadway surface, and shall not interfere with the breakaway features of the device. The Contractor shall follow the manufacturer’s recommendations for sign ballasting. Signs, posts, or supports that are lost, stolen, damaged, destroyed, or which the Engineer deems to be unacceptable while their use is required on the project shall be replaced by the Contractor. 1-10.3(3)B Sequential Arrow Signs Where shown on an approved traffic control plan or where ordered by the Engineer, the Contractor shall provide, operate and maintain sequential arrow signs. A sequential arrow sign is required for all lane closure tapers on a multilane facility. A separate sequential arrow sign shall be used for each closed lane. The arrow sign shall not be used to laterally shift traffic. When used in the caution mode, the four corner mode shall be used. 1-10.3(3)C Portable Changeable Message Sign Where shown on an approved traffic control plan or where ordered by the Engineer, the Contractor shall provide, operate, and maintain portable changeable message signs (PCMS). A PCMS shall be placed behind a barrier or guardrail whenever possible, but shall at a minimum provide 4 feet of lateral clearance to edge of travelled lane and be delineated by channelization devices. The Contractor shall remove the PCMS from the clear zone when not in use unless protected by barrier or guardrail. 1-10.3(3)D Barricades Where shown on an approved traffic control plan or where ordered by the Engineer, the Contractor shall provide, install and maintain barricades. Barricades shall be kept in good repair and shall be removed immediately when, in the opinion of the Engineer, they are no longer functioning as designed. Where it is necessary to add weight to barricades for stability, sand bags or other similar ballast may be used, but the height shall not be more than 4 inches above the Roadway surface and shall not interfere with the breakaway features of the device. The Contractor shall follow the manufacturer’s recommendation for sign ballasting. 1-10.3(3)E Traffic Safety Drums Where shown on an approved Traffic Control Plan, or where ordered by the Engineer, the Contractor shall provide, install, and maintain traffic safety drums. Used drums may be utilized, provided all drums used on the project are of essentially the same configuration and the devices conform to Section 1-10.2(3). The drums shall be designed to resist overturning by means of a weighted lower unit that will separate from the drum when impacted by a vehicle. 2020 Standard Specifications M 41-10 Page 1-163 Temporary Traffic Control 1-10 Drums shall be regularly maintained to ensure that they are clean and that the drum and reflective material are in good condition. If the Engineer determines that a drum has been damaged beyond usefulness, or provides inadequate reflectivity, a replacement drum shall be furnished. When the Engineer determines that the drums are no longer required, they shall be removed from the project and shall remain the property of the Contractor. 1-10.3(3)F Vacant 1-10.3(3)G Traffic Cones and Tall Channelizing Devices Where shown on an approved traffic control plan or where ordered by the Engineer, the Contractor shall provide, install and maintain traffic cones or tall channelizing devices. Cones and tall channelizing devices shall be kept in good repair and shall be removed immediately when directed by the Engineer. Where wind or moving traffic frequently displaces cones or tall channelizing devices, an effective method of stabilizing them, such as stacking two together at each location, shall be employed, or heavier weighted bases may be necessary. 1-10.3(3)H Tubular Markers Where shown on an approved traffic control plan or where ordered by the Engineer, the Contractor shall provide, install, and maintain tubular markers. Tubular markers shall be kept in good repair and shall be removed immediately when directed by the Engineer. Tubular markers are secondary devices and are not to be used as substitutes for cones or other delineation devices without an approved traffic control plan. Where the Traffic Control Plan shows pavement-mounted tubular markers, the adhesive used to fasten the base to the pavement shall be suitable for the purpose, as approved by the Engineer. During the removal of pavement-mounted tubular markers, care shall be taken to avoid damage to the existing pavement. Any such damage shall be repaired by the Contractor at no cost to the Contracting Agency. 1-10.3(3)I Warning Lights and Flashers Where shown attached to traffic control devices on an approved traffic control plan or where ordered by the Engineer, the Contractor shall provide and maintain flashing warning lights. Lights attached to advance warning signs shall be Type B, high-intensity. Lights attached to traffic safety drums, barricades or other signs shall be Type C, steady- burning low intensity or, where attention is to be directed to a specific device, Type A, flashing low-intensity units. 1-10.3(3)J Transportable Attenuator Where shown on an approved traffic control plan or where ordered by the Engineer, the Contractor shall provide, operate, and maintain transportable impact attenuators consistent with the requirements of Section 9-35.12. These attenuators shall be available, on-site, for the entire duration of their projected use. Page 1-164 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control The transportable attenuator shall be positioned to separate and protect construction work zone activities from normal traffic flow. During use, the attenuator shall be in the full down-and-locked position. For stationary operations, the host vehicle’s parking brake shall be set. A transportable attenuator may be used in lieu of a temporary impact attenuator when approved by the Engineer as part of a stage traffic control shift to protect an object such as blunt barrier end or bridge pier column that is located within the work zone clear zone. This use of a transportable attenuator is restricted to a maximum of 3 days or approved extension by the Engineer. 1-10.3(3)K Portable Temporary Traffic Control Signal Where shown on an approved traffic control plan, the Contractor shall provide, operate, maintain, and remove a portable temporary traffic control signal system to provide alternating one-lane traffic operations on a two-way facility. A portable temporary traffic control signal system shall be defined as two traffic control units that operate together. The system shall be trailer-mounted, fully self-contained, and designed so that it can be easily transported and deployed at different locations. The Contractor shall submit a Type 2 Working Drawing consisting of the manufacturer’s specifications for the portable temporary traffic control signal. A manufacturer’s representative is required to demonstrate the capabilities of the temporary portable signal prior to approval and provide training to contractor personnel as necessary. Remote manual control of the portable traffic control signal by the Traffic Control Supervisor (TCS) or a qualified operator may be allowed if necessitated by Work area or traffic conditions and as allowed by the Engineer. Maximum length between signal heads shall be 1,500 feet unless otherwise shown on the Plans or ordered by the Engineer in accordance with Section 1-04.4. The Engineer or designee will inspect the signal system at initial installation/operation and approve the signal timing. Final approval will be based on the results of the operational inspection. The Traffic Control Supervisor shall monitor and ensure that the Portable Temporary Traffic Control Signal is fully operational and maintained as specified by the manufacturer. This Work may include cleaning and replacing lamps and other routine maintenance as needed. If repairs or adjustments are required the Contractor shall respond immediately and provide flagger traffic control, if the Roadway cannot be safely reopened to two-way traffic, until such time that repairs can be made. The Contractor shall either repair the signal or replace with a backup unit within 24 hours. The Engineer will monitor the traffic, signal operation and order adjustments as needed based on traffic conditions. Timing adjustments require the approval of the Engineer. 2020 Standard Specifications M 41-10 Page 1-165 Temporary Traffic Control 1-10 As shown on the traffic control plan, temporary stop bars and “STOP HERE ON RED” Signs (R10-6) shall be provided at the location traffic is expected to stop during the red display. The stop bar locations shall be illuminated at night. The illumination shall be the responsibility of the Contractor and shall be adjusted to ensure minimal glare to motorists. When not in operation, remove signal heads from the view of traffic or cover signal heads with bags made of non-ripping material specifically designed for covering signal heads. Do not use trash bags of any type. Remove, cover, fold, or turn all inappropriate signs so that they are not readable by oncoming traffic. The Contractor shall provide and install all field wiring to make a complete and operational portable traffic control signal and shall maintain the system throughout the life of the Contract. Portable temporary traffic signals shall not be installed within 300 feet of at-grade railroad crossing, or if driveways or Roadway access points are located between the portable temporary traffic control signals. 1-10.4 Measurement 1-10.4(1) Lump Sum Bid for Project (No Unit Items) When the Bid Proposal contains the item “Project Temporary Traffic Control”, there will be no measurement of unit items for Work defined by Section 1-10 except as described in Section 1-10.4(3). Also, except as described in Section 1-10.4(3), all of Sections 1-10.4(2) and 1-10.5(2) are deleted. 1-10.4(2) Item Bids With Lump Sum for Incidentals When the Bid Proposal does not contain the item “Project Temporary Traffic Control”, Sections 1-10.4(1) and 1-10.5(1) are deleted and the Bid Proposal will contain some or all of the following items, measured as noted. “Flaggers” will be measured by the hour. Hours will be measured for each flagging station, shown on an approved Traffic Control Plan, when that station is staffed in accordance with Section 1-10.3(1)A. When a flagging station is staffed on an intermittent basis, no deduction will be made in measured hours provided that the person staffing the station is in a standby mode and is not performing other duties. “Other Traffic Control Labor” will be measured by the hour. Time spent on activities other than those described herein will not be measured under this item. The hours of one person will be measured for each patrol route that the Contractor performs the Work described under Section 1-10.3(2)E, Patrol and Maintain Traffic Control Measures, regardless of the actual number of persons per route. Hours will be measured for each person engaged in any one of the following activities: • Operating a pilot vehicle during one-way piloted traffic control. • Operating a traffic control vehicle or a chase vehicle during a rolling slowdown operation. Page 1-166 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control • Operating a vehicle or placing/removing traffic control devices during the setup or takedown of a lane closure. Performing preliminary Work to prepare for placing and removing these devices. • Operating any of the moving traffic control equipment, or adjusting signing during a mobile operation as described in Section 1-10.3(2)D. • Placing and removing Class B construction signs. Performing preliminary Work to prepare for placing and removing these signs. • Relocation of Portable Changeable Message Signs within the project limits. • Installing and removing Barricades, Traffic Safety Drums, Cones, Tubular Markers and Warning Lights and Flashers to carry out approved Traffic Control Plan(s). Performing preliminary Work to prepare for installing these devices. “Construction Signs, Class A” will be measured by the square foot of panel area for each sign designated on an approved Traffic Control Plan as Class A or for each construction sign installed as ordered by the Engineer and designated as Class A at the time of the order. Class A signs may be used in more than one location and will be measured for each new installation. Class B construction signs will not be measured. Sign posts or supports will not be measured. “Sequential Arrow Sign” will be measured by the hour for the time that each sign is operating as shown on an approved Traffic Control Plan. “Portable Changeable Message Sign” will be measured by the hour for the time that each sign is operating as shown on an approved Traffic Control Plan. “Transportable Attenuator” will be measured per each one time only for each host vehicle with mounted or attached impact attenuator used on the project. The final pay quantity shall be the maximum number of transportable attenuators in place at any one time. “Operation of Transportable Attenuator” will be measured by the hour for each transportable attenuator manned and operated. Manned and operated shall be when the transportable attenuator has an operator and is required to move, in operating position, with the construction operation or when moving the transportable attenuator from one position to another on the project. 1-10.4(3) Reinstating Unit Items With Lump Sum Traffic Control The Contract Provisions may establish the project as lump sum, in accordance with Section 1-10.4(1) and also include one or more of the items included above in Section 1-10.4(2). When that occurs, the corresponding measurement provision in Section 1-10.4(2) is not deleted and the Work under that item will be measured as specified. 1-10.4(4) Owner-Provided Resources The Contract Provisions may call for specific items of labor, materials, or equipment, noted in Section 1-10 as the responsibility of the Contractor, to be supplied by the Contracting Agency. When this occurs, there will be no adjustment in measurement of unit quantities. 2020 Standard Specifications M 41-10 Page 1-167 Temporary Traffic Control 1-10 1-10.5 Payment 1-10.5(1) Lump Sum Bid for Project (No Unit Items) “Project Temporary Traffic Control”, lump sum. The lump sum Contract payment shall be full compensation for all costs incurred by the Contractor in performing the Contract Work defined in Section 1-10 except for costs compensated by Bid Proposal items inserted through Contract Provisions as described in Section 1-10.4(3). 1-10.5(2) Item Bids With Lump Sum for Incidentals “Traffic Control Supervisor”, lump sum. The lump sum Contract payment shall be full compensation for all costs incurred by the Contractor in performing the Work defined in Section 1-10.2(1)B. “Pedestrian Traffic Control”, lump sum. The lump sum Contract payment shall be full compensation for all costs incurred by the Contractor in performing the Work for pedestrian traffic control defined in Section 1-10. “Flaggers”, per hour. The unit Contract price, when applied to the number of units measured for this item in accordance with Section 1-10.4(2), shall be full compensation for all costs incurred by the Contractor in performing the Work defined in Section 1-10.3(1)A. “Other Traffic Control Labor”, per hour. The unit Contract price, when applied to the number of units measured for this item in accordance with Section 1-10.4(2), shall be full compensation for all labor costs incurred by the Contractor in performing the Work specified for this item in Section 1-10.4(2). “Construction Signs Class A”, per square foot. The unit Contract price, when applied to the number of units measured for this item in accordance with Section 1-10.4(2), shall be full compensation for all costs incurred by the Contractor in performing the Work described in Section 1-10.3(3)A. In the event that “Do Not Pass” and “Pass With Care” signs must be left in place, a change order, as described in Section 1-04.4, will be required. When the Bid Proposal contains the item “Sign Covering”, then covering those signs indicated in the Contract will be measured and paid according to Section 8-21. “Sequential Arrow Sign”, per hour. The unit Contract price, when applied to the number of units measured for this item in accordance with Section 1-10.4(2), shall be full compensation for all costs incurred by the Contractor in performing the Work described in Section 1-10.3(3)B. “Portable Changeable Message Sign”, per hour. Page 1-168 2020 Standard Specifications M 41-10 1-10 Temporary Traffic Control The unit Contract price, when applied to the number of units measured for this item in accordance with Section 1-10.4(2), shall be full compensation for all costs incurred by the Contractor in performing the Work for procuring all portable changeable message signs required for the project and for transporting these signs to and from the project. “Transportable Attenuator”, per each. The unit Contract price, when applied to the number of units measured for this item in accordance with Section 1-10.4(2), shall be full compensation for all costs incurred by the Contractor in performing the Work described in Section 1-10.3(3)J except for costs compensated separately under the items “Operation of Transportable Attenuator” and “Repair Transportable Attenuator”. “Operation of Transportable Attenuator”, per hour. The unit Contract price, when applied to the number of units measured for this item in accordance with Section 1-10.4(2), shall be full compensation for all costs incurred by the Contractor in performing the Work for operating transportable attenuators on the project. “Repair Transportable Attenuator”, by force account. All costs of repairing or replacing transportable attenuators that are damaged by the motoring public while in use as shown on an approved Traffic Control Plan will be paid for by force account as specified in Section 1-09.6. To provide a common Proposal for all Bidders, the Contracting Agency has estimated the amount of force account for “Repair Transportable Attenuator” and has entered the amount in the Proposal to become a part of the total Bid by the Contractor. Transportable attenuators damaged due to the Contractor’s operation or damaged in any manner when not in use shall be repaired or replaced by the Contractor at no expense to the Contracting Agency. “Other Temporary Traffic Control”, lump sum. The lump sum Contract payment shall be full compensation for all costs incurred by the Contractor in performing the Work defined in Section 1-10, and which costs are not compensated by one of the above-listed items. “Portable Temporary Traffic Control Signal”, lump sum. The lump sum Contract payment shall be full compensation for all costs incurred by the Contractor in performing the Work as described in Section 1-10.3(3)K, including all costs for traffic control during manual control, adjustment, malfunction, or failure of the portable traffic control signals and during replacement of failed or malfunctioning signals. 1-10.5(3) Reinstating Unit Items With Lump Sum Traffic Control The Contract Provisions may establish the project as lump sum, in accordance with Section 1-10.4(1) and also reinstate the measurement of one or more of the items described in Section 1-10.4(2). When that occurs, the corresponding payment provision in Section 1-10.5(2) is not deleted and the Work under that item will be paid as specified. 2020 Standard Specifications M 41-10 Page 2-1 Division 2 Earthwork 2-01 Clearing, Grubbing, and Roadside Cleanup 2-01.1 Description The Contractor shall clear, grub, and clean up those areas staked or described in the Special Provisions. This Work includes protecting from harm all trees, bushes, shrubs, or other objects selected to remain. “Clearing” means removing and disposing of all unwanted material from the surface, such as trees, brush, down timber, or other natural material. “Grubbing” means removing and disposing of all unwanted vegetative matter from underground, such as sod, stumps, roots, buried logs, or other debris. “Roadside cleanup”, whether inside or outside the staked area, means Work done to give the roadside an attractive, finished appearance. “Debris” means all unusable natural material produced by clearing, grubbing, or roadside cleanup. 2-01.2 Disposal of Usable Material and Debris The Contractor shall meet all requirements of state, county, and municipal regulations regarding health, safety, and public welfare in the disposal of all usable material and debris. The Contractor shall dispose of all debris by one or more of the disposal methods described below. 2-01.2(1) Disposal Method No. 1 – Open Burning The open burning of residue resulting from land clearing is restricted by Chapter 173-425 of the Washington Administrative Code (WAC). No commercial open burning shall be conducted without authorization from the Washington State Department of Ecology or the appropriate local air pollution control authority. All burning operations shall be strictly in accordance with these authorizations. 2-01.2(2) Disposal Method No. 2 – Waste Site Debris shall be hauled to a waste site obtained and provided by the Contractor in accordance with Section 2-03.3(7)C. Page 2-2 2020 Standard Specifications M 41-10 2-01 Clearing, Grubbing, and Roadside Cleanup 2-01.2(3) Disposal Method No. 3 – Chipping Wood chips may be disposed of on-site in accordance with the following: 1. Chips shall be no larger than 6 square inches and no thicker than ½ inch. 2. Chips shall be disposed outside of sensitive areas, and in areas that aren’t in conflict with permanent Work. 3. Chips shall not be incorporated into the embankment but may be spread on slopes where feasible at depths no greater than 2 inches. 4. Chips shall be tractor-walked into the ground. 2-01.3 Construction Requirements 2-01.3(1) Clearing The Contractor shall: 1. Fell trees only within the area to be cleared. 2. Close-cut parallel to the slope of the ground all stumps to be left in the cleared area outside the slope stakes. 3. Follow these requirements for all stumps that will be buried deeper than 5 feet from the top, side, or end surface of the embankment or any structure and are in a location that will not be terraced as described in Section 2-03.3(14): a. Close-cut stumps under 18 inches in diameter. b. Trim stumps that exceed 18 inches in diameter to no more than 12 inches above original ground level. 4. Leave standing any trees or native growth indicated by the Engineer. 5. Trim all trees to be left standing to the height specified by the Engineer, neatly cutting all limbs close to the tree trunk. 6. Thin clumps of native growth as the Engineer may direct. 7. Protect, by fencing if necessary, all trees or native growth from any damage caused by construction operations. 2-01.3(2) Grubbing The Contractor shall: 1. Grub deep enough to remove all stumps, large roots, buried logs, and other vegetative material. 2. Grub all areas: a. Indicated by the Engineer or by the Special Provisions. b. To be excavated, including area staked for slope treatment. c. Where subdrainage trenches will be dug, unsuitable material removed, or Structures built. 2020 Standard Specifications M 41-10 Page 2-3 Clearing, Grubbing, and Roadside Cleanup 2-01 d. In which hillsides or existing embankments will be terraced as described in Section 2-03.3(14). e. Upon which embankments will be placed, except stumps may be close-cut or trimmed as allowed in Section 2-01.3(1) item 3. A Contract may include grubbing without mentioning clearing or roadside cleanup. In that case, the Contractor shall remove and dispose of all upturned stumps and roots of windfalls that lie within the cleared area of the Right of Way, even though they are outside the area staked for grubbing. Such Work shall be incidental to other Work covered by the Contract. 2-01.3(3) Vacant 2-01.3(4) Roadside Cleanup Roadside cleanup, as ordered by the Engineer, consists of Work not otherwise provided for in the Contract. Such Work may include: 1. Removing trees, snags, down timber, upturned stumps, large rocks and boulders, and other unsightly matter outside the areas staked for clearing or grubbing. 2. Thinning trees or brush. 3. Filling holes, and smoothing and contouring the ground. 4. Shaping the ends of cuts and fills to fit adjacent terrain and to enhance the area’s appearance. 5. Obliterating abandoned roads and reshaping the areas to blend naturally with surroundings. Methods and equipment used in roadside cleanup shall be approved by the Engineer. 2-01.4 Measurement When clearing and grubbing is paid per acre, the following areas will be excluded from measurement: 1. Any area along an existing Highway that requires no Work. 2. Any gap that requires no Work, provided the gap is at least 50 feet long when measured parallel to the center line and contains at least 2,500 square feet. Isolated areas of less than 2,500 square feet that require Work lying between areas excluded from measurement will be counted as having 2,500 square feet. If these isolated areas occur intermittently, the final measurement shall not exceed the total area containing the several isolated areas when measured as continuous. Clearing and grubbing may be combined in the Proposal. If the Proposal calls for such combined Work to be measured “per acre”, the measurement methods described above will apply. If the Proposal designates such combined Work as “lump sum”, the Contracting Agency will not base payment on any unit of measurement. Page 2-4 2020 Standard Specifications M 41-10 2-01 Clearing, Grubbing, and Roadside Cleanup 2-01.5 Payment Payment will be made for the following Bid items when they are included in the Proposal: “Clearing and Grubbing”, per acre or lump sum. The unit Contract price per acre or lump sum for “Clearing and Grubbing” shall be full pay for all Work described in this section except “Roadside Cleanup”. “Roadside Cleanup”, by force account as provided in Section 1-09.6. To provide a common Proposal for all Bidders, the Contracting Agency has entered an amount in the Proposal to become a part of the Contractor’s total Bid. 2020 Standard Specifications M 41-10 Page 2-5 Removal of Structures and Obstructions 2-02 2-02 Removal of Structures and Obstructions 2-02.1 Description The Work described in this section includes removing and disposing of, or salvaging, materials named in the Special Provisions or identified by the Engineer. The Work also includes the backfilling of trenches, holes, or pits that result from such removal. 2-02.2 Vacant 2-02.3 Construction Requirements With certain exceptions, the Contractor shall raze, remove, and dispose of all buildings and foundations, Structures, fences, and other obstructions that lie wholly or partially within the Right of Way. The exceptions are utility-owned equipment and any other items the Contracting Agency may direct the Contractor to leave intact. When salvageable material is to remain Contracting Agency property, the Special Provisions will identify the material and describe how the Contractor shall remove it and where it will be stored. Any material not named in the Special Provisions as Contracting Agency property will become the property of the Contractor and shall be removed from the project. The Contractor may dispose of waste material in Contracting Agency-owned sites if the Special Provisions or the Engineer permits it. Otherwise, the Contractor shall arrange to dispose of waste at no expense to the Contracting Agency and the disposal shall meet the requirements of Section 2-03.3(7)C. 2-02.3(1) Removal of Foundations When removing foundations the Contractor shall: 1. Remove foundations to a depth of at least 5 feet below finished ground elevation or Subgrade elevation, whichever is lower. 2. Break up basement floors to promote drainage. 3. Fill basements or other cavities left by the removal of Structures. The fill shall match the level of surrounding ground. Fill within the slopes of the Roadbed shall be compacted to meet the requirements of Section 2-03.3(14)C, Method B. 2-02.3(2) Removal of Bridges, Box Culverts, and Other Drainage Structures When salvaging any steel or wooden bridge that will remain Contracting Agency property, the Contractor shall prevent unnecessary damage to the material. Steel members shall be match-marked. Unless otherwise directed, the Contractor shall remove foundations of existing Structures to a point 2 feet below: the finished ground elevation, the adjacent ground elevation, or the natural stream bottom. If a foundation lies wholly or partially on the site of a new Structure, it shall be removed to a level that accommodates building the new Structure. Page 2-6 2020 Standard Specifications M 41-10 2-02 Removal of Structures and Obstructions Any blasting shall be subject to the Engineer’s approval. The Contractor must complete all blasting before the placement of new Work. 2-02.3(2)A Bridge and Structure Removal 2-02.3(2)A1 Bridge Demolition Plan Submittal The Contractor shall submit a Type 2E Working Drawing consisting of a bridge demolition plan, showing the method of removing the existing bridge(s), or portions of bridges, as specified. The bridge demolition plan shall show all equipment, sequence of operations, and details required to complete the work, including containment, collection, and disposal of all debris. The plan shall include a crane foundation stability analysis and crane load calculations, including all dead load and rigging for the Work. The plan shall detail the containment, collection, and disposal of all debris. The plan shall show all stages of demolition. When the bridge removal work includes removal of a truss or other steel span, and when the Contractor’s removal method involves use of a crane or cranes to pick, lift, and remove the truss or steel span, the Contractor shall confirm the dead load weight prior to beginning the removal operation. The operation of confirming the dead load shall be performed at both ends of the span or at all existing support locations, and shall ensure that the span is broken free of its support bearings. The Contractor’s method of confirming the dead load, whether by hydraulic jacks or other means, shall be included in the Contractor’s bridge demolition plan submittal. Verification of dead load may be waived with Engineer’s concurrence if the calculated lifting weight is less than 20 tons and is less than half the safe working load of the selected crane. When the bridge removal work involves removing portions of existing concrete without replacement, the methods and tools used to achieve the smooth surface and profile specified in Section 2-02.3(2)A2 shall be included in the Contractor’s bridge demolition plan submittal. 2-02.3(2)A2 Removing Portions of Existing Concrete Care shall be taken in removing concrete to prevent overbreakage or damage to portions of the existing Structure which are to remain. Before concrete removal begins, a saw cut shall be made into the surface of the concrete at the perimeter of the removal limits. The saw cut shall be ¾-inch deep when the steel reinforcement is to remain, and may be deeper when the steel reinforcement is removed with the concrete. Concrete shall be completely removed (exposing the deformed surface of the bar) from existing steel reinforcing bars which extend from the existing members and are specified to remain. Steel reinforcing bars that are not designated to remain shall be cut a minimum of 1-inch behind the final surface. The void left by removal of the steel reinforcing bar shall be filled with mortar conforming to Section 9-20.4(2). The mortar shall match the color of the existing concrete surface as nearly as practicable. 2020 Standard Specifications M 41-10 Page 2-7 Removal of Structures and Obstructions 2-02 The Contractor shall roughen, clean, and saturate existing concrete surfaces, against which fresh concrete will be placed, in accordance with Section 6-02.3(12)B. When a portion of existing concrete is to be removed without replacement, concrete shall be removed to a clean line with a smooth surface of less than 1/16 inch profile. 2-02.3(2)A3 Use of Explosives for Bridge Demolition Explosives shall not be used for bridge demolition, except as specifically allowed by the Special Provisions. 2-02.3(3) Removal of Pavement, Sidewalks, Curbs, and Gutters In removing pavement, sidewalks, curbs, and gutters, the Contractor shall: 1. Haul broken-up pieces into the Roadway embankment or to some off-project site. 2. Material that is to be incorporated into the embankment shall be broken into pieces not exceeding 18 inches in any dimension, and no part of any piece shall be within 3 feet of the top, side, or end surface of the embankment or any Structure. 3. Make a vertical full depth saw cut between any existing pavement, sidewalk, curb, or gutter that is to remain and the portion to be removed. For concrete pavement removal, a second vertical full depth relief saw cut offset 12 to 18 inches from and parallel to the initial saw cut is also required, unless the Engineer allows otherwise. For removal of bituminous pavement, asphalt planing equipment may be used in lieu of sawcutting provided that a clean vertical edge remains. 4. Replace at no expense to the Contracting Agency any existing pavement designated to remain that is damaged during the removal of other pavement. 2-02.4 Vacant 2-02.5 Payment Payment shall be made for the following Bid item when it is included in the Proposal: “Removal of Structures and Obstructions”, lump sum. If pavements, sidewalks, curbs, or gutters lie within an excavation area, their removal will be paid for as part of the quantity removed in excavation. “Removing Existing Bridge___”, lump sum. “Removing Existing Structure___”, lump sum. “Removing Portion of Existing Bridge___”, lump sum. “Removing Portion of Existing Structure___”, lump sum. Page 2-8 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment 2-03 Roadway Excavation and Embankment 2-03.1 Description The Work described in this section, regardless of the nature or type of the materials encountered, includes excavating and grading the Roadway, excavating in borrow pits, excavating below grade, excavating channels and ditches, removing slide material, and disposing of all excavated material. These activities may be performed in making cuts, embankments, slopes, Roadway ditches, approaches, parking areas, Highway-driveway intersections, and in completing related Work. The Work includes the removal of pavement, sidewalks, curbs and gutters as described in Section 2-02 when these items lie within an excavation area. The Work excludes these items if they are designated as pay items in the Contract: 1. Haul. 2. Excavation for Structures and ditches. 3. Removal of unsuitable materials. The Plans may divide the project into separate areas (Roadway Excavation, Area A, Roadway Excavation, Area B, etc.). Such division does not imply any classification of materials in the areas. The boundaries of the areas shall not be changed regardless of how similar or dissimilar the materials are from one area to another. All Work described here must reasonably conform to the alignment, grade, and cross-sections shown in the Plans or established by the Engineer. 2-03.2 Vacant 2-03.3 Construction Requirements 2-03.3(1) Widening of Cuts If routine cuts do not supply enough material to form the embankment, the Contractor shall obtain more material from areas inside or outside the Right of Way and/or from widening one or both sides of existing cuts as determined by the Engineer. The Contractor shall dress the sides of the cuts to any slopes the Engineer may require. If the Contractor has dressed a cut before the Engineer determines to widen it, the Contracting Agency will pay for the resloping as provided in Section 1-04.4. In addition, material obtained from areas beyond the cuts shown in the Plans that result in additional haul will be paid by the Contracting Agency as provided in Section 1-04.4. 2020 Standard Specifications M 41-10 Page 2-9 Roadway Excavation and Embankment 2-03 2-03.3(2) Rock Cuts 1. Preserving Rock Below Subgrade – The Contractor shall take care not to break down, loosen, or damage the rock under the Subgrade line, except as provided by Section 2-03.3(3). Normally cuts will be made from the top, lift by lift, to protect the rock bench that will remain. The Contractor shall be responsible for methods used and for any damage caused to the Roadbed, regardless of any previous approvals by the Engineer. 2. Scaling and Dressing – To leave rock cuts in a safe, stable condition, the Contractor shall scale and dress them, removing all loose fragments and rocks not firmly fastened to the rock slope. The Contractor shall also remove any overhanging rock the Engineer sees as a hazard to Roadway users. If the Engineer requires it, the Contractor shall remove loose fragments and rocks lying outside the slope stakes. Payment for such extra Work shall be by force account as provided in Section 1-09.6. The Contracting Agency will pay for loading and hauling these materials at the unit Contract prices that apply or as provided in Section 1-04.4. 3. Drilling and Blasting – Not less than 2 weeks prior to commencing drilling and blasting operations or at any time the Contractor proposes to change the drilling and blasting methods, the Contractor shall submit a Type 2 Working Drawing consisting of a blasting plan. The blasting plan shall contain the full details of the drilling and blasting patterns and controls the Contractor proposes to use for both the controlled and production blasting. The blasting plan submittal is required for all blasting operations and shall contain at least the following information: a. Station limits of proposed shot. b. Plan and section views of proposed drill pattern including free face, burden, blast hole spacing, blast hole diameter, blast hole angles, lift height, and subdrill depth. c. Loading diagram showing type and amount of explosives, primers, initiators, and location and depth of stemming. d. Initiation sequence of blast holes including delay times and delay system. e. Manufacturer’s data sheets for all explosives, primers, and initiators to be employed. Review of the blasting plan by the Engineer shall not relieve the Contractor of the responsibility for the accuracy and adequacy of the plan when implemented in the field. 4. Controlled Blasting – When blasting to establish slopes 0.5:1 or steeper, and more than 10 feet high, the Contractor shall use controlled blasting. The Engineer may require the Contractor to use controlled blasting to form the faces of other slopes, even if the slopes could be formed by nonblasting methods. Page 2-10 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment Controlled blasting refers to the controlled use of explosives and blasting accessories in carefully spaced and aligned drill holes to provide a free surface or shear plane in the rock along the specified backslope. Controlled blasting techniques covered by this Specification include presplitting and cushion blasting. In addition to the blasting plan submittal, when using controlled blasting the Contractor shall: a. Prior to commencing full-scale blasting operations, the Contractor shall demonstrate the adequacy of the proposed blast plan by drilling, blasting, and excavating short test sections, up to 100 feet in length, to determine which combination of method, hole spacing, and charge works best. When field conditions warrant, the Contractor may be ordered to use test section lengths less than 100 feet. Unless otherwise allowed by the Engineer, the Contractor shall begin the tests with the controlled blast holes spaced 30 inches apart, then adjust if needed, until the Engineer accepts the spacing to be used for full-scale blasting operations. b. The Contractor shall completely remove all overburden, soil, and loose or decomposed rock along the top of the excavation for a distance of at least 30 feet beyond the end of the production hole drilling limits, or to the end of the cut, before drilling the presplitting holes. c. The controlled blast holes shall be not less than 2½ inches nor more than 3 inches in diameter. d. The Contractor shall control drilling operations by the use of the proper equipment and technique to ensure that no hole deviates from the plane of the planned slope by more than 9 inches either parallel or normal to the slope. Drill holes exceeding these limits will not be paid for unless satisfactory slopes are being obtained. e. Controlled blast holes shall extend a minimum of 30 feet beyond the limits of the production holes to be detonated, or to the end of the cut as applicable. f. The length of controlled blast holes for any individual lift shall not exceed 20 feet unless the Contractor can demonstrate to the Engineer the ability to stay within the above tolerances and produce a uniform slope. If greater than 5 percent of the presplit holes are misaligned in any one lift, the Contractor shall reduce the height of the lifts until the 9-inch alignment tolerance is met. Upon satisfactory demonstration, the length of holes may be increased to a maximum of 60 feet with written acceptance of the Engineer. g. When the cut height requires more than one lift, a maximum 2-foot offset between lifts will be permitted to allow for drill equipment clearances. The Contractor shall begin the controlled blast hole drilling at a point that will allow for necessary offsets and shall adjust, at the start of lower lifts, to compensate for any drift that may have occurred in the upper lifts. 2020 Standard Specifications M 41-10 Page 2-11 Roadway Excavation and Embankment 2-03 h. Before placing charges, the Contractor shall determine that the hole is free of obstructions for its entire depth. All necessary precautions shall be exercised so that the placing of the charges will not cause caving of material from the walls of the holes. i. The maximum diameter of explosives used in presplit holes shall not be greater than ½ the diameter of the presplit hole. j. Only standard explosives manufactured especially for controlled blasting shall be used in controlled blast holes, unless otherwise allowed by the Engineer. Bulk ammonium nitrate and fuel oil (ANFO) shall not be loaded in the presplit holes. k. If fractional portions of standard explosive cartridges are used, they shall be firmly affixed to the detonating cord in a manner that the cartridges will not slip down the detonating cord nor bridge across the hole. Spacing of fractional cartridges along the length of the detonating cord shall not exceed 30 inches center to center and shall be adjusted to give the desired results. l. Continuous column cartridge type of explosives used with detonating cord shall be assembled and affixed to the detonating cord in accordance with the explosive manufacturer’s instructions, a copy of which shall be submitted as a Type 1 Working Drawing. m. The bottom charge of a presplit hole may be larger than the line charges but shall not be large enough to cause overbreak. The top charge of the presplitting hole shall be placed far enough below the collar, and reduced sufficiently, to avoid overbreaking and heaving. n. The upper portion of all presplit holes, from the top most charge to the hole collar, shall be stemmed. Stemming materials shall be sand or other dry angular material, all of which passes a ⅜-inch sieve. o. If presplitting is specified, the detonation of these holes shall be fired first. p. If cushion blasting is specified, the detonation of these holes shall be fired last on an instantaneous delay after all other blasting has taken place in the excavation. q. Production blast holes shall not be drilled closer than 6 feet to the controlled blast line, unless otherwise allowed by the Engineer. The bottom of the production holes shall not be lower than the bottom of the controlled blast holes. Production holes shall not exceed 6 inches in diameter, unless otherwise allowed by the Engineer. Detonation of production holes shall be on a delay sequence toward a free face. r. The use of horizontal blast holes for either production or controlled blasting is prohibited. Page 2-12 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment 2-03.3(3) Excavation Below Subgrade Rock Excavation – When the Contractor finds rock or other hard material at the Subgrade elevation, it shall be excavated the full width of the Roadbed to at least 6 inches below Subgrade, then backfilled with rock fragments, gravel, or other free-draining material not more than 4 inches in diameter. If the Contractor uses a Subgrade trimmer, the backfill shall be rock, gravel, or other free-draining material not more than 2 inches in diameter. The Contractor shall save the finer free-draining material from excavations or borrow pits to use in backfilling the top 6 inches of the Subgrade. All such material shall be approved by the Engineer. Sub excavation – At any time, the Engineer may order excavation below Subgrade to remove soft and uncompactible material. The replacement material shall be free-draining and granular, or other materials as determined by the Engineer. Draining Rock Pockets – If blasting below Subgrade leaves a rock pocket that will not drain, the Contractor shall dig a trench from the pocket bottom to the roadside ditch, then backfill both the pocket and the trench with rock fragments, gravel, or other material approved by the Engineer, at no expense to the Contracting Agency. Compaction – If the density of the natural earth under any area of the Roadway is less than that required in Section 2-03.3(14)C, Method B, the Engineer may order the Contractor to perform any or all of the following: 1. Scarify the earth to a depth of 6 inches. 2. Aerate or water. 3. Compact the scarified area to the required density. 4. Excavate to a specific depth. 5. Backfill the excavated area in layers, using the previously excavated material or other material. 6. Compact each layer to meet the compaction requirements for embankments. 2-03.3(4) Sluicing The Contractor shall not excavate by sluicing unless the Special Provisions specifically call for it. 2-03.3(5) Slope Treatment The tops of all Roadway cut slopes, except solid rock cuts, shall be rounded in accordance with the Standard Plans. Unless otherwise noted in the Plans or Special Provisions, Class A slope treatment shall be utilized. If a layer of earth covers a rock cut, the slope shall be rounded above the rock as if it were an earth slope. 2020 Standard Specifications M 41-10 Page 2-13 Roadway Excavation and Embankment 2-03 When the Contractor removes stumps or any embedded material from the rounded area, the void shall be backfilled and stabilized to prevent erosion. All Work required to complete slope treatment, including excavation, haul, and slope rounding, shall be included in the unit Bid price for Roadway excavation. 2-03.3(6) Deposit of Rock for the Contracting Agency’s Use At the Engineer’s direction, the Contractor shall deposit excavated rock at the roadside or elsewhere. If this requires the Contractor to use material that would otherwise have gone into an embankment, the Contracting Agency will pay for the extra cubic yards of excavation needed to complete the embankment. Any such rock deposit shall be Contracting Agency property. The Contractor shall be responsible for safekeeping the deposit until the Contracting Agency has removed it or until the Contract is completed. 2-03.3(7) Disposal of Surplus Material 2-03.3(7)A General The Contractor shall haul all excavation to the nearest embankment unless the Engineer declares the hauling distance to be too great. If excavation yields more material than needed for nearby embankments, the Contractor shall dispose of the excess in keeping with the Special Provisions or as the Engineer directs. 2-03.3(7)B Haul When the Contract includes a payment item for haul, the Contracting Agency will pay as follows for hauling excess excavation to a disposal site: 1. If the Contracting Agency provides a site, but the Contractor chooses to haul elsewhere, the Contracting Agency will pay for the actual distance up to but not exceeding the distance that would have been necessary using the Contracting Agency site. 2. If the Contracting Agency does not provide a site, the Contracting Agency will pay for the actual distance up to but not exceeding the distance necessary to haul to a site 1 mile from the project limits. 2-03.3(7)C Contractor-Provided Disposal Site If the Contracting Agency provides no waste site, but requires disposal of excess excavation or other materials, the Contractor shall arrange for disposal at no expense to the Contracting Agency, except as provided in Section 2-03.3(7)B, item 2. The Contractor shall acquire all permits and approvals required for the use of the disposal sites before any waste is hauled off the project. The Contractor shall submit a Type 1 Working Drawing consisting of copies of the permits and approvals for any disposal sites to be used. The cost of any such permits and approvals shall be included in the Bid prices for other Work. Page 2-14 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment Disposal of excess material within a wetland area will not be allowed without a Section 404 permit issued by the U.S. Corps of Engineers and approval by the local agency with jurisdiction over the wetlands. The Contractor shall protect, indemnify, and save harmless the Contracting Agency from any damages that may arise from the Contractor’s activities in making these arrangements. Such indemnity shall be in accordance with RCW 4.24.115 as amended by CH. 305, Laws of 1986. Any action required to satisfy any permit and/or any approval requirements in a Contractor-provided disposal site shall be performed by the Contractor at no additional expense to the Contracting Agency. Reclamation of a Contractor-supplied waste site must conform to the requirements of Section 3-03. 2-03.3(8) Wasting Material If, against the Engineer’s orders, the Contractor wastes material needed for the embankment, it shall be replaced at no expense to the Contracting Agency with material the Engineer approves. 2-03.3(9) Roadway Ditches At each transition from cut to fill, the Contractor shall divert any Roadway ditch away from the embankment in natural ground. Ditches shall never permit water to flow into or upon embankment material. 2-03.3(10) Selected Material When the Contract or the Engineer calls for it, selected material shall be used for finishing the top part of the Subgrade, for structural or other backfill, or for other purposes. Unless the Special Provisions specify otherwise, the Engineer may identify as “selected” any material excavated within the right-of-way, including the excavation of local borrow. Direct Hauling – If it is practical, the Contractor shall haul selected material immediately from excavation to its final place on the Roadbed. The Contracting Agency will pay for such Work at the unit Contract prices for excavating, hauling, watering, and compacting. Delayed Excavation – If it is impractical to haul selected material to its final place at once, the Contractor shall delay excavation until the placement will be workable. The Contracting Agency will not pay extra for delayed excavation. Stockpiling – The Engineer may allow the Contractor to stockpile selected materials if delaying the excavation will hamper grading or force impractical movements of equipment. In this case, the Engineer will direct where and when the Contractor shall excavate, stockpile, haul, and place the selected materials. Sections 2-03.4 and 2-03.5 describe how the Contracting Agency will measure and pay for excavating and hauling these stockpiled selected materials. The neat line volume of material removed will provide the basis for measuring material taken from the stockpile. 2020 Standard Specifications M 41-10 Page 2-15 Roadway Excavation and Embankment 2-03 2-03.3(11) Slides If a slide occurs on a finished slope before final acceptance of the Work, the Contractor shall remove or replace the slide material. The Contractor shall also refinish the slope to the condition and with the materials required by the Engineer. The Contracting Agency will pay for the excavation at the unit Contract price and for resloping on a force account basis. The Engineer may authorize payment for the excavation by agreed price or force account if: 1. The slide material cannot be measured accurately, or 2. Excavation of slide material requires equipment not available on the project. If the Contractor undercuts or destroys a slope, or has failed to implement erosion control devices as shown in the Contract or in the TESC plan, it shall be resloped to the original alignment or to a new one established by the Engineer at no expense to the Contracting Agency. 2-03.3(12) Overbreak Overbreak includes that part of any material excavated, displaced, or loosened outside the staked or reestablished slope or grade. Such material is considered overbreak whether its movement resulted from blasting, from the character of the material itself, or from any other cause. Overbreak, however, does not include material from slides as described in Section 2-03.3(11). If the Engineer does not approve use of the overbreak, the Contractor shall remove, haul, and dispose of it at no expense to the Contracting Agency. In this case, the Contractor shall follow the procedure for handling surplus described in Section 2-03.3(7). If the Engineer approves, the Contractor may use overbreak: 1. To complete an embankment when the excavated material unexpectedly falls short of the amount required. The Contracting Agency will pay the Roadway excavation Contract price for the volume of material the overbreak replaces, and will pay the Contract price for haul. However, no payment will be made if overbreak is used when other material is available within the neat lines of the Roadway prism. 2. To replace borrow excavation originally planned for an embankment. The Contracting Agency will pay for overbreak used this way at the unit Contract price for Roadway or borrow excavation, whichever costs less. The Engineer will include haul to be paid as in the original Proposal in comparing the costs under the two payment methods. 2-03.3(13) Borrow Borrow is the excavation of material outside the Roadway prism or outside the limits of any other excavation area required by the Contract. Before any borrow site can be used, it must be measured and approved by the Engineer. Any material excavated from a borrow site before the site is measured will not be paid for. The widening of Roadway cuts and ditches will be considered Roadway excavation, not borrow. Page 2-16 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment If the Contract documents designate borrow sources, the Contractor may utilize those sources or may obtain borrow from other sites. If borrow is obtained from a Contractor- provided site, there will be no additional cost to the Contracting Agency beyond the Contract unit price for the excavated borrow material. There will be no payment for aeration of the borrowed material from a Contractor-provided site, even if the Contract contains an item for aeration and even if the Contract documents designate borrow sources. If neither the Plans nor the Special Provisions name a source for borrow, the Contractor shall provide a source at no expense to the Contracting Agency. The Contractor shall reclaim all borrow sites, Contracting Agency-owned, Contracting Agency-supplied, or obtained by the Contractor, in keeping with Section 3-03. 2-03.3(14) Embankment Construction The Contracting Agency classifies embankment construction as: 1. Rock Embankment – In which the material in all or any part of an embankment contains 25 percent or more, by volume, gravel or stone 4 inches or more in diameter. Section 2-03.3(14)A. 2. Earth Embankment – Made of any material other than that used in rock embankment. Section 2-03.3(14)B. Unstable Base – If the Engineer believes the natural earth base will impair an embankment or make it unstable, the Contractor shall stabilize or remove and dispose of the base material in keeping with this section or Section 2-03.3(14)E. Hillside Terraces – The Contractor shall terrace the original ground or embankment when the slope of the surface is 2H:1V or steeper unless otherwise directed by the Engineer. The face of each terrace shall be a minimum of 1 foot and a maximum of 5 feet in height and shall be vertical or near vertical as required to remain stable during material placement and compaction. The bench of the terrace shall slope outward to drain and shall not be inclined steeper than 0.05 foot per foot. Terraces damaged during work shall be reestablished. The Engineer may order the Contractor to place gravel backfill, pipe drains or both to drain any seepage. All costs for building terraces shall be included in the prices for other Work. Soft Base – On wet or swampy ground, the Contractor shall haul and spread embankment material by methods that will disturb the base as little as possible. If the Engineer approves, the Contractor may place the lower part of the fill by dumping and spreading successive loads to form a uniform layer just thick enough to support equipment used to place and compact upper layers. 2020 Standard Specifications M 41-10 Page 2-17 Roadway Excavation and Embankment 2-03 Normally the Contractor shall not increase the planned depth of the embankment over a soft base merely to permit the use of heavier equipment. But if the Contractor proves that the planned depth will not support light hauling vehicles, the Engineer may approve a deeper fill. The Contractor shall not claim extra pay if these restrictions require the use of lighter equipment or different construction methods than originally planned for use on the soft base. 2-03.3(14)A Rock Embankment Construction The Contractor shall build rock embankments in horizontal layers. No layer shall be deeper than 18 inches unless the rocks in the fill material average more than 18 inches in diameter. The Contractor shall separate and distribute the larger pieces of rock and fill the spaces between them with smaller rocks and earth. With the Engineer’s approval, the Contractor may dispose of rocks larger than the average size instead of placing them in the embankment. Compacting – The Contractor shall use a 50-ton compression roller or a vibratory roller having a dynamic force of at least 40,000 pounds impact per vibration and at least 1,000 vibrations per minute. In either case, the roller shall make one full coverage for each 6 inches, or any fraction of 6 inches, of lift depth. When lift depth is 18 inches or less, the Contractor may use a 10-ton compression roller or a vibratory roller having a dynamic force of at least 30,000-pounds impact per vibration and at least 1,000 vibrations per minute. In either case, the roller shall make four full coverages for each 6 inches, or any fraction of 6 inches, of lift depth. Rollers must exert reasonably even pressure over the area covered. The Contractor shall limit the speed of compression rollers to no more than 4 mph, and the speed of vibratory rollers to no more than 1½ mph. If possible, the Contractor shall compact the material even further by routing empty and loaded hauling equipment evenly over the entire width of the embankment. When the Engineer believes rolling to be physically impractical, rolling may be omitted on part or all of a layer. Should excessive moisture threaten the stability of the embankment the Engineer may order the Contractor to alter the operation. This may include alternating layers of wet and dry materials, drying materials before placing, or halting Work in the problem areas. In this case the Contracting Agency will not increase payment, but will pay the unit Contract prices for the pay items that apply. Top Layer – The Contractor shall build each rock embankment up to 6 inches below Subgrade. The top 6-inch layer of embankment shall be of rock, gravel, or other free- draining material that does not exceed 4 inches in diameter. When the Plans require use of a Subgrade trimmer, these materials in the top layer may not exceed 2 inches in diameter. Page 2-18 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment When practical, and as approved by the Engineer, the Contractor shall save the finer free-draining material from excavations or borrow pits for use in topping rock fills. If selected materials suitable for topping are available, the Contracting Agency will pay for them as described in Section 2-03.3(10). If such materials are not available on site, the Contracting Agency will pay for imported materials by including them in the unit Contract price for gravel borrow or borrow excavation, each including haul. If the Proposal does not include these items, the Contracting Agency will pay as provided in Section 1-04.4. 2-03.3(14)B Earth Embankment Construction The Contractor shall place earth embankments in horizontal layers of uniform thickness. These layers shall run full width from the top to the bottom of the embankment. Slopes shall be compacted to the required density as part of embankment compaction. During grading operations, the Contractor shall shape the surfaces of embankments and excavations to uniform cross-sections and eliminate all ruts and low places that could hold water. The Contractor shall raise the center of an embankment above the sides. When the surface of an embankment intersects a side hill, the surface shall be sloped away at a rate not to exceed 20:1. 2-03.3(14)C Compacting Earth Embankments This section describes three methods (A, B, and C) for building earth embankments. The Contractor shall use Method B unless the Special Provisions require another method. Method A – Each embankment shall be made of layers no more than 2 feet thick. The Contractor shall compact each layer by routing loaded haul equipment over its entire width. If the Engineer approves, the Contractor may use end dumping to begin placing a side hill fill too narrow for hauling equipment. When the fill is wide enough, the remaining layers shall be compacted by the loaded hauling equipment. Method B – The top 2 feet of each embankment shall be compacted to 95 percent of the maximum density as determined by the compaction control tests described in Section 2-03.3(14)D. All material below the 2-foot level shall be compacted to 90 percent of the same maximum density. In the top 2 feet, horizontal layers shall not exceed 4 inches in depth before compaction. No layer below the top 2 feet shall exceed 8 inches in depth before compaction. The Contractor shall use compacting equipment approved by the Engineer. Method C – Each layer of the entire embankment shall be compacted to 95 percent of the maximum density as determined by the compaction control tests described in Section 2-03.3(14)D. In the top 2 feet, horizontal layers shall not exceed 4 inches in depth before compaction. No layer below the top 2 feet shall exceed 8 inches in depth before compaction. The Contractor shall use compacting equipment approved by the Engineer. 2020 Standard Specifications M 41-10 Page 2-19 Roadway Excavation and Embankment 2-03 Under Methods B or C, the Engineer may permit the Contractor to increase layer thickness up to 18 inches before compaction, provided: 1. The layer is more than 2 feet below the top of the embankment, 2. An approved vibratory roller is used, and 3. The required density is obtained throughout the full depth and width of each layer. Whatever the method used, any embankment inaccessible to large compacting equipment shall be compacted with small mechanical or vibratory compactors. Moisture Content – The Contractor shall adjust moisture content during compaction to produce a firm, stable and unyielding embankment. The embankment shall be free from pumping and rutting due to excessive moisture and is the Contractor’s responsibility to manage and adjust as necessary. The Contracting Agency will consider all costs for drying embankment material to be incidental to other Work, including excessive moisture due to inclement weather. If, however, the Contract includes an aeration item, the Contracting Agency will pay for such Work as specified in Sections 2-03.4 and 2-03.5. The Contractor shall repair, at no expense to the Contracting Agency, any partial or complete embankment that loses stability because of continued hauling across it. Evidence of lost stability includes pumping, rutting or lateral displacement of embankment. The Contractor shall also alter hauling equipment or procedures to prevent further damage. 2-03.3(14)D Compaction and Moisture Control Tests Maximum density and optimum moisture content shall be determined by one of the following methods: 1. Materials with less than 30 percent by weight retained on the No. 4 sieve shall be determined using FOP for AASHTO T 99 Method A. 2. Materials with 30 percent or more by weight retained on the No. 4 sieve and less than 30 percent retained on the ¾-inch sieve shall be determined by WSDOT T 606 or FOP for AASHTO T 180 Method D. The determination of which test procedure to use will be made solely by the Contracting Agency. 3. Materials with 30 percent or more retained on the ¾-inch sieve shall be determined by WSDOT T 606. In place density will be determined using Test Methods FOP for AASHTO T 310 and WSDOT SOP 615. Page 2-20 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment 2-03.3(14)E Unsuitable Foundation Excavation When the Contract or the Engineer requires it, the Contractor shall excavate unstable natural ground before building any embankment over it. This unstable material may include peat, muck, swampland, buried logs and stumps, or other material not fit for an embankment base. The Contractor shall excavate such material to the boundaries set by the Engineer. The Work will not be considered unsuitable foundation excavation if the materials: 1. Came from the Roadway cut, ditch, or channel-change prisms. 2. Resulted from Structure excavation Class A or B. 3. Are covered in Section 2-03.3(3). If the Contract provides no Bid item for unsuitable foundation excavation, the Contracting Agency will pay as provided in Section 1-04.4. 2-03.3(14)F Vacant 2-03.3(14)G Backfilling When water fills an area after the removal of soft or unstable materials, the Contractor shall, if possible, drain the site so that any backfill may be compacted. If drainage is not possible, the Contractor shall use granular material for backfilling in water, including areas where blasting has displaced the soft material. The Special Provisions may require other backfilling methods. The costs of pumping or digging temporary drainage ditches shall be incidental to and included in other items of Work that apply. 2-03.3(14)H Prefabricated Vertical Drains The Contractor shall furnish all necessary labor, equipment and materials, and perform all operations necessary for the installation of prefabricated vertical drains in accordance with the details shown in the Plans and with the requirements of these Specifications. The prefabricated drain shall consist of a continuous plastic drainage core wrapped in a nonwoven geotextile material as specified in the Contract. The drains shall be free of defects, rips, holes, or flaws. During shipment and storage, the drain shall be wrapped in a heavy-duty protective covering. The storage area shall protect the drain material from sunlight, mud, dirt, dust, debris, and detrimental substances. Manufacturer certification shall be provided for all drain materials delivered to the project. Vertical drains shall be staked by the Contractor and constructed prior to embankment construction. Prior to installation of vertical drains, a sand drainage blanket shall be placed on the ground surface for use as a working platform. This platform shall have a minimum depth of 2 feet and shall consist of uncompacted material meeting the requirements of Section 9-03.13(1). 2020 Standard Specifications M 41-10 Page 2-21 Roadway Excavation and Embankment 2-03 Vertical drains shall be installed with equipment that will cause a minimum of subsoil disturbance. A mandrel or sleeve shall be advanced through the subsoil using vibratory, constant load, or constant rate of advance methods. The mandrel shall have a maximum cross-sectional area of 14 square inches, shall protect the prefabricated drain material from tears, cuts, and abrasions during installation, and shall be provided with an “anchor” plate or rod. The “anchor” plate or rod shall provide sufficient strength to prevent the soil from entering the bottom during installation and shall anchor the bottom of the drain at the required depth when the mandrel is removed. Use of falling weight impact hammers or jetting will not be allowed within the compressible subsoil to be drained. The prefabricated drains shall be installed vertically from the working surface to the required elevations and in a sequence that will not require equipment to travel over previously installed drains. The Contractor shall provide the Engineer with a suitable means of verifying the plumbness of the equipment and determining the depth of the drain at any time. The equipment shall not deviate more than 0.25 inches per foot from vertical. Splices or connections in the prefabricated drain material shall be done in a professional manner to ensure continuity of the wick material. The prefabricated drain shall be cut to leave at least 6 inches protruding above the working platform at each drain location. Where obstructions are encountered which cannot be penetrated the Contractor shall abandon the hole. A maximum of two attempts shall be made to install a new drain within 18 inches of the obstructed hole. Drains that otherwise deviate from the Plan location by more than 6 inches, or that are damaged or improperly installed, will be rejected. Installation of the drains should consider and be coordinated with the geotechnical instrumentation shown in the Plans. Special care shall be taken when installing drains near instrumentation already in place. Replacement of instrumentation damaged by the Contractor will be the responsibility of the Contractor. The Contractor shall demonstrate that the equipment, method, and materials produce a satisfactory installation in accordance with these Specifications. For this purpose, the Contractor shall be required to install trial drains at different locations within the Work area. The Contractor shall submit a Type 2 Working Drawing consisting of details of the sequence and method of installation. The submittal shall, at a minimum, contain the dimensions and length of mandrel, a detailed description of the proposed method(s) for overcoming obstructions, and the proposed method(s) for splicing drains. Approval by the Engineer will not relieve the Contractor of the responsibility to install prefabricated vertical drains in accordance with the Plans, Special Provisions, and these Specifications. If, at any time, the Engineer considers the method of installation does not produce a satisfactory drain, the Contractor shall alter the method and equipment as necessary. Page 2-22 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment 2-03.3(14)I Embankments at Bridge and Trestle Ends This Work consists of filling around the ends of trestles and bridges, the area defined in Section 1-01.3. The Contractor shall begin and complete this Work as soon as possible after each bridge is completed or when the Engineer requires. The Contractor shall select fill material from the excavation sources elsewhere on the project. Bridge Approach Embankments shall be compacted to at least 95 percent of the maximum density as determined by the tests described in Section 2-03.3(14)D. In any embankment area where piles will be installed, the Contractor shall remove all solid material, rocks, broken concrete, etc., larger than 3 inches across that would interfere with pile driving. To prevent the bridge from being distorted or displaced, the Contractor shall place backfill evenly around all sides and parts of the Structure. The Contractor shall not backfill any abutment prior to placing the Superstructure. After the Superstructure is in place, use of small compactors may be required to compact the backfill around the Structure. Embankments and backfill behind the abutments shall be brought up in layers and compacted concurrently. The difference in backfill height against each abutment shall not exceed 2 feet unless otherwise allowed by the Engineer. The Contractor may request to place the abutment backfill (either full or partial height) prior to placement of the Superstructure by submitting Type 2E Working Drawings consisting of calculations confirming that the abutment is stable, both for overturning and sliding, without the Superstructure in place. The stability calculations shall assume a loading of 30 lbs/ft3 equivalent fluid pressure and include at least a 2-foot surcharge for the backfill placement equipment. If the abutment backfill is allowed to be placed prior to completion of the Superstructure, the Contractor shall bear any added cost that results from the change. The Contractor shall build the embankment under the bridge to the dimensions shown in the Standard Plans or detailed in the Plans. Cost related to all Work described in this section shall be incidental to other Work and included in the unit Contract prices that apply. 2-03.3(14)J Gravel Borrow Including Haul When required by the Plans or the Engineer, the Contractor shall use gravel borrow meeting the requirements of Section 9-03.14(1) to: 1. Build structural embankments. 2. Backfill excavation of unsuitable foundation material above the ground water table. 3. Backfill below-grade excavation above the ground water table. 4. Construct mechanically stabilized earth walls. 5. Construct reinforced soil slopes. Gravel borrow shall be compacted according to Sections 2-03.3(14)C and 2-03.3(14)D. 2020 Standard Specifications M 41-10 Page 2-23 Roadway Excavation and Embankment 2-03 2-03.3(14)K Select or Common Borrow Including Haul When required by the Plans or the Engineer, the Contractor shall use select borrow meeting the requirements of Section 9-03.14(2), or common borrow meeting the requirements of Section 9-03.14(3) to: 1. Build embankments. 2. Backfill excavation of unsuitable foundation material above the ground water table. 3. Backfill below-grade excavation above the ground water table. Where specified, select borrow may be used for constructing reinforced slopes. Select borrow and common borrow shall be compacted according to Sections 2-03.3(14)C and 2-03.3(14)D. 2-03.3(14)L Embankment Widening for Guardrail Embankments widened for the installation of beam guardrail shall be terraced in accordance with the requirements for hillside terraces in Section 2-03.3(14). Compaction shall be in accordance with Method A, as specified in Section 2-03.3(14)C. Guardrail posts shall not be installed until the embankment widening is completed and compacted. 2-03.3(14)M Excavation of Channels and Ditches Channel Excavation includes open excavations 8 feet wide or more at the bottom, but excludes channels that are part of the Roadway. Ditch Excavation includes open excavations less than 8 feet wide at the bottom, but excludes ditches that are part of the Roadway. Before excavating channels or ditches, the Contractor shall clear and grub the area in accordance with Section 2-01. 2-03.3(15) Aeration The Contracting Agency may include aeration as a Contract item if material from test holes in excavation or borrow sites is too wet to compact properly. Even if the Contract includes such an item, the Contractor shall make every effort to reduce the need for aeration. The Contractor shall do so by using methods known to be effective in building embankments with wet materials. Such methods include open ditching to drain excavation areas or alternating layers of wet and dry materials. These and similar methods will be incidental to excavation and their costs shall be included in the unit Contract price for Roadway excavation, for borrow excavation (including haul), and for haul. If aeration is not a Contract item, its cost shall be incidental to and included in the excavation and embankment items. Page 2-24 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment Aeration Equipment – The Engineer may direct the Contractor to use aeration equipment in these areas: Roadway excavation, borrow sites, or embankments. The Contracting Agency does not guarantee the moisture-reducing effectiveness of any single type of equipment. The Engineer may, however, require the use of any type that will best aerate a given area. If the Contractor uses any of the following types of equipment, it shall meet these minimum requirements: 1. Heavy-Duty Power Grader – This machine shall have a moldboard measuring 12 feet long, 24 inches high, and ¾ inch thick. Each grader shall carry its maximum number of standard scarifier-rippers or discs. 2. Heavy-Duty Gang Plow – It shall have at least five 16-inch bottoms. Its tractor shall be able to move no less than 1½ mph while plowing at least 9 inches deep through fairly wet material. 3. Heavy-Duty Tandem Discs – This machine shall cut a swath at least 8 feet wide with discs no less than 28 inches in diameter. Its tractor shall be able to turn fairly wet material at least 6 inches deep while moving at 2 mph or more. 4. Heavy-Duty Self-Propelled, Rotary Pulverizer – This machine shall have paddles attached to a transverse shaft. It shall travel 1½ mph or more while aerating a swath at least 6 feet wide to a depth of 6 inches. The Contractor shall not use any aerating equipment listed above in tandem nor use any of this equipment to carry out other Bid items of Work while aerating. The Engineer may halt aerating Work when weather conditions prevent satisfactory results. 2-03.3(16) End Slopes The Engineer will determine when and where to build end slopes, whether these occur at the beginning or end of a project, at the borders of excavation or embankments, at bridge ends, or elsewhere. The Contractor shall build end slopes not detailed in the Plans to the line and grade designated by the Engineer regardless of centerline limits shown in the Plans. All Work to complete and maintain these end slopes shall be considered as Work to be performed under the Contract. 2-03.3(17) Snow Removal If snow deep enough to interfere with the Work covers a cut or an embankment, the Contractor shall remove and deposit it outside the slope stakes. Snow removal must be done at least 100 feet ahead of excavation and embankment Work. The Contractor shall remove snow at no expense to the Contracting Agency. 2020 Standard Specifications M 41-10 Page 2-25 Roadway Excavation and Embankment 2-03 2-03.3(18) Stepped Slope Construction When the Plans or the Engineer requires it, the Contractor shall shape slopes cut in soft rock to a stepped pattern conforming closely to the typical cross-section in the Plans. Stepped slopes shall meet these requirements: 1. Each step shall be 1 to 2 feet high. 2. The horizontal depth of each step will depend on its relationship to the staked slope ratio. The approximate midpoint of each horizontal tread shall occur on the staked slope line. 3. The treads shall be approximately level in all directions. 4. The ends of the steps shall be blended into the natural ground, with loose material removed from transitional areas. 5. If the Contractor cannot rip a rock outcropping within a cut, the steps shall be blended into the rock. 6. Large rocks and material that may fall into the ditch line or onto the Roadway shall be removed, but scaling is not required. The compaction and seeding requirements of Section 8-01.3(2) shall not apply to stepped slope construction. The Contracting Agency will measure stepped slope excavation by the area defined by the staked slope line. The unit Contract price per cubic yard for Roadway or borrow excavation shall be full pay for all labor and equipment required to build stepped slopes. 2-03.3(19) Removal of Pavement, Sidewalks, Curbs, and Gutters The requirements of Section 2-02.3(3) shall also apply when pavements, sidewalks, curbs, and gutters lie within an excavation. 2-03.4 Measurement Roadway excavation, channel excavation, ditch excavation, unsuitable foundation excavation, and common borrow items will be measured by the cubic yard. All excavated material will be measured in the position it occupied before the excavation was performed. An original ground measurement will be taken using cross-section or digital terrain modeling survey techniques. For Roadway excavation, channel excavation, and ditch excavation items, the original ground will be compared with the planned finished section shown in the Plans. Slope/ground intercept points defining the limits of the measurement will be as staked. For unsuitable foundation excavation and common borrow items, the original ground will be compared with a survey of the excavation area taken after the Work is completed. When the Contracting Agency requires excavated material to be stockpiled, re-excavated and moved again, a second measurement will be made, adding quantity for the same item used in the original excavation. The second measurement will be a comparison of the original cross-section of the stockpile with a cross-section of the stockpile area after the second excavation is completed. Page 2-26 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment If the excavation item does not include Haul, then the measurement provisions of Section 2-04 shall apply. Gravel borrow and select borrow will be measured by the cubic yard or ton. Measurement by cubic yard will be made in the hauling vehicle. Sand drainage blanket will be measured by the ton with deductions made for the weight of moisture above 8 percent. Embankment compaction (Methods B and C in Section 2-03.3(14)C) will be measured by the cubic yard. An original ground measurement will be taken using cross-section or digital terrain modeling survey techniques. Quantities will be determined based on a comparison of the original ground measurement with the finished embankment section as staked. No allowance will be made for material that settles. No deduction will be taken for other items constructed within the embankment (bridge abutments, piers, columns, backfill, pipes, etc.). The Contracting Agency will exclude from compaction measurement material that is wasted or placed under water and not compacted in layers as provided by Sections 2-03.3(14)A and 2-03.3(14)C. In cuts, where excavation has been made below the planned Subgrade elevation, and in fills where excavation has been made below original ground, compaction will be measured by the cubic yard in the cross-section of compacted backfill material. When material below grade in cuts or in original ground beneath fills is scarified and recompacted, embankment compaction will be measured by its compacted depth, up to a maximum of 6 inches. There is no specific unit of measure and no measurement will be made for method A compaction as described in Section 2-03.3(14)C. Controlled blasting of rock face will be measured by the linear foot of hole drilled. Holes will be measured from the top of the rock surface to the elevation of the Roadway ditch or to a bench elevation set by the Engineer. Quantities shown in the Plans are based on 30-inch hole spacing. Actual quantities will depend on field conditions and results from test sections. Prefabricated vertical drains will be measured by the linear foot. Trial drains will be measured and included in the payment quantity for the prefabricated vertical drains. The drains will be measured from the top of the working platform to the bottom of each hole. 2-03.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Roadway Excavation”, per cubic yard. “Roadway Excavation Incl. Haul”, per cubic yard. “Roadway Excavation – Area ____”, per cubic yard. “Roadway Excavation Incl. Haul – Area ____”, per cubic yard. “Channel Excavation”, per cubic yard. “Channel Excavation Incl. Haul”, per cubic yard. 2020 Standard Specifications M 41-10 Page 2-27 Roadway Excavation and Embankment 2-03 “Ditch Excavation”, per cubic yard. “Ditch Excavation Incl. Haul”, per cubic yard. The unit Contract price per cubic yard for “Roadway Excavation”, “Roadway Excavation Incl. Haul”, “Roadway Excavation – Area __”, “Roadway Excavation Incl. Haul – Area ___”, “Channel Excavation”, “Channel Excavation Incl. Haul”, “Ditch Excavation”, and “Ditch Excavation Incl. Haul” shall be full compensation for all costs incurred for excavating, loading, placing, or otherwise disposing of the material. For “Haul”, the unit Contract price as provided in Section 2-04 shall apply, except when the pay item is shown as including Haul. In that case the unit Contract price per cubic yard shall include “Haul”. When a bid item is not included in the proposal for channel excavation or ditch excavation, all costs shall be included in roadway excavation. When the Engineer orders Work according to Section 2-03.3(3), unit Contract prices shall apply unless the Work differs materially from the excavation above Subgrade, then payment will be in accordance with Section 1-04.4. “Unsuitable Foundation Excavation”, per cubic yard. “Unsuitable Foundation Excavation Incl. Haul”, per cubic yard. The unit Contract price per cubic yard for “Unsuitable Foundation Excavation” and “Unsuitable Foundation Excavation Incl. Haul” shall be full payment for all costs incurred for excavating, loading, and disposing of the material. For “Haul”, the unit Contract price as provided in Section 2-04 shall apply, except when the Bid item is shown as including Haul. In that case, the unit Contract price per cubic yard shall include “Haul”. “Common Borrow Incl. Haul”, per cubic yard. The unit Contract price per cubic yard for “Common Borrow Incl. Haul” shall be full compensation for all costs incurred for excavating, loading, hauling, placing, or otherwise disposing of the material. The unit Contract price includes removing, disposing of, wasting, or stockpiling any material in the borrow site that does not meet the Specifications for “Common Borrow”. “Select Borrow Incl. Haul”, per ton. “Select Borrow Incl. Haul”, per cubic yard. “Gravel Borrow Incl. Haul”, per ton. “Gravel Borrow Incl. Haul”, per cubic yard. “Sand Drainage Blanket”, per ton. The unit Contract price per ton or cubic yard for “Select Borrow Incl. Haul”, “Gravel Borrow Incl. Haul” and “Sand Drainage Blanket” shall be full compensation for all costs incurred for excavating, loading, hauling, and placing the material unless otherwise specified in the Proposal. “Embankment Compaction”, per cubic yard. Page 2-28 2020 Standard Specifications M 41-10 2-03 Roadway Excavation and Embankment The unit Contract price per cubic yard for “Embankment Compaction” shall be full compensation for all costs incurred for all material, labor, tools, equipment, and incidentals required. When embankments are constructed using Method A compaction, payment for embankment compaction will not be made as a separate item. All costs for embankment compaction shall be included in other Bid items involved. If the Bid item “Embankment Compaction” is not provided in the Proposal, compensation for costs incurred to perform the Work described in Section 2-03.3(14), Embankment Construction, shall be included in payment for other items of Work in the Contract. “Aeration”, by force account. “Aeration” will be paid for by force account as specified in Section 1-09.6. The payment for aeration and other related unit Contract prices shall be full compensation for all costs incurred to perform the Work described in Section 2-03.3(15). Should the Contractor fail to seal an aerated area prior to inclement weather, additional aeration to restore the area to its previous condition shall be at the Contractor’s expense. For the purpose of providing a common Proposal for all Bidders, the Contracting Agency has entered an amount in the Proposal to become a part of the total Bid by the Contractor. “Controlled Blasting of Rock Face”, per linear foot. The unit Contract price per linear foot for “Controlled Blasting of Rock Face” shall be full compensation for all costs incurred to perform the Work described in Section 2-03.3(2). Measurement and payment for Roadway excavation and haul related to blasting shall be as provided under those items in this section and shall include the volume of material excavated from the benches or setbacks approved for drilling separate lifts. “Prefabricated Vertical Drain”, per linear foot. The unit Contract price per linear foot shall be full compensation for all costs incurred to perform the Work, including trial drains, as described in Section 2-03.3(14)H. 2020 Standard Specifications M 41-10 Page 2-29 Haul 2-04 2-04 Haul 2-04.1 Description This Work consists of transporting excavated material from its original site to its final place in the Work. The balance points shown in the Plans are only approximate. The Engineer may change the balance points to help equalize quantities of materials or to dispose of surpluses. When the Plans require hauling, the Contractor shall not substitute wasting or borrowing. The Contracting Agency will not pay extra for cross-hauling unless the Engineer so orders. 2-04.2 Vacant 2-04.3 Vacant 2-04.4 Measurement The Contracting Agency will measure haul in units of haul where one unit equals 100-cubic yards of excavated material hauled 100 feet. Excavated material will be measured in its original position. The Engineer will provide a copy of the location mass diagram upon request. Haul On Right of Way – To compute units of haul, the Contracting Agency will measure haul distance parallel to the centerline (or base line) of the Highway. Lateral distance (cross-hauling) will not be measured. Quantities to be measured in this way include: (1) material from the Roadway prism or prisms; (2) borrow from widened cuts; (3) waste deposited in the Right of Way or alongside it; and (4) material from Auxiliary Lanes – Frontage Roads, speed change lanes, paralleling and loop ramps, cross roads, and other lanes that supplement through- traffic movements. If the Plans show more than one centerline or base line (as in a multi-lane Highway), the Plans or Special Provisions will describe the line by which haul will be computed. Waste Haul Off Right of Way – The Contracting Agency will measure the cross-section and length of any waste embankment to calculate waste quantities. If the Plans or Special Provisions do not specify a haul route, the Contracting Agency will compute haul along the long axis of the waste embankment, thence along a line running perpendicular to the Highway center line, starting at the center line and ending at the nearest end of the waste embankment. However, when a route is specified, haul distance will be measured along that route. If the Contractor chooses to use a route shorter than that computed or specified, the Contracting Agency will base payment on the length of the route actually used. Page 2-30 2020 Standard Specifications M 41-10 2-04 Haul 2-04.5 Payment Payment will be made for the following Bid item when it is included in the Proposal: “Haul”, per unit. 2020 Standard Specifications M 41-10 Page 2-31 2-05 Vacant Vacant 2-05 Page 2-32 2020 Standard Specifications M 41-10 2-06 Subgrade Preparation 2-06 Subgrade Preparation 2-06.1 Description This Work consists of preparing graded Roadbed for surfacing or surfaced Roadbed for paving. 2-06.2 Vacant 2-06.3 Construction Requirements 2-06.3(1) Subgrade for Surfacing In preparing the Roadbed for surfacing, the Contractor shall: 1. Remove from the Roadbed, immediately before placing surfacing materials, all brush, weeds, vegetation, grass, and other debris. 2. Dispose of all debris as the Engineer directs. 3. Drain water from all low spots or ruts. 4. Shape the entire Subgrade to a uniform surface running reasonably true to the line, grade, and cross-section as staked. 5. If necessary, the Contractor shall process the Subgrade in cut areas to remove materials too coarse for mechanical trimming and recompaction. 6. Compact the Subgrade to a depth of 6 inches. Compaction shall achieve 95 percent of the maximum density determined under the tests described in Section 2-03.3(14)D. If the underlying material is too soft to permit proper compaction of the Subgrade, the Contractor shall loosen, aerate (or excavate and remove), and compact the Subgrade until the top layer can be compacted as required. 7. Remove excess material that does not drift to low spots during grading and shaping. The Contractor shall dispose of this excess by placing it where the Subgrade lacks material or by wasting it, as the Engineer directs. 8. Add materials as the Engineer directs where the Subgrade needs more to bring it up to grade. The Contractor shall water and compact these added materials as needed to produce a true finished Subgrade. If the Contract requires a trimming machine, it shall: 1. Maintain the grade and transverse slopes automatically through sensors that respond to reference lines on both edges of each Roadway. 2. Create a smooth, uniform surface free from chatter and ripples. 2020 Standard Specifications M 41-10 Page 2-33 Subgrade Preparation 2-06 2-06.3(2) Subgrade for Pavement Before any paving is placed, the Contractor shall bring the Subgrade to the required line, grade, and cross-section. The Contractor shall compact the Subgrade to a depth of 6 inches to 95 percent of maximum density as determined by the compaction control tests for granular materials. The compacted area shall be wide enough to let paving machines operate without visible distortion of surfacing material. The Contractor shall maintain the Subgrade in the required condition until the pavement is placed. The Contractor may remove material just before paving if the Plans require thicker areas of pavement. 2-06.4 Vacant 2-06.5 Measurement and Payment 2-06.5(1) Subgrade Constructed Under Same Contract Surfacing or Treated Base – If the Contractor builds a Subgrade for surfacing or treated base, the Contracting Agency will consider Subgrade preparation as part of the construction Work. In this case, measurement and payment will conform to Section 2-03. Such payment shall be the full price for all Subgrade preparation Work. Pavement – If the Contractor builds a Subgrade for pavement, the Contracting Agency will follow the criteria in Section 5-04 (for HMA pavement) or Section 5-05 (for cement concrete pavement) to measure and pay for materials used to prepare the Subgrade. The Contracting Agency will measure and pay for water as specified in Section 2-07. 2-06.5(2) Subgrade Not Constructed Under Same Contract When the Contractor prepares an existing Subgrade for surfacing (one not built under the present Contract), the Contracting Agency will measure and pay for the Work by these criteria: 1. Final Conditioning – All the following Work on the Subgrade shall be included in other Contract Bid items: clearing vegetation and other debris, draining water, smoothing to prepare for staking, grading, shaping, and compacting to a 6-inch depth to final line, grade, and cross-section. 2. Excess Materials – If the Contractor must dispose of excess materials during grading and shaping, the Contracting Agency will measure and pay for the Work as Roadway excavation. If the Contract includes no pay item for Roadway excavation, the Contracting Agency will measure and pay as provided in Section 1-04.4. 3. Added Materials – If the Subgrade requires more materials, the Contracting Agency will pay the unit Contract price for each kind of material the Contractor provides. The unit Contract price shall be full pay for furnishing, placing, and compacting the materials. When unit Contract prices do not apply, the Contracting Agency will measure and pay for the Work as provided in Section 1-04.4. Page 2-34 2020 Standard Specifications M 41-10 2-06 Subgrade Preparation 4. Excavation and Backfill – If the Engineer orders the Contractor to excavate unstable spots in the Subgrade, the Contracting Agency will measure and pay for the Work as Roadway excavation. If the Contract does not include Roadway excavation as a pay item, payment will be by agreed price or force account. The Contracting Agency will pay unit Contract prices for suitable backfill material when included in the Contract and will pay as provided in Section 1-04.4 when not included. 5. Subgrade Protection – No payment shall be made for protecting the Subgrade. 2020 Standard Specifications M 41-10 Page 2-35 Watering 2-07 2-07 Watering 2-07.1 Description This Work consists of furnishing, hauling, and applying water for compacting embankments, constructing Subgrade, placing of crushed surfacing, dust control, and as the Engineer requires. 2-07.2 Vacant 2-07.3 Construction Requirements The Contractor shall apply water by means of tank trucks equipped with spray bars. Spray controls shall ensure that the water flows evenly and in the amounts required by the Engineer. The Engineer may direct that the Contractor apply water at night or early in the morning to reduce evaporation losses. 2-07.4 Measurement Water will be measured by the gallon using tanks or tank trucks of known capacity or by meters approved by the Engineer. The Contractor shall supply and install any meters at no expense to the Contracting Agency. 2-07.5 Payment Payment will be made for the following Bid item when it is included in the Proposal: “Water”, per M gal. The unit Contract price per M gallon for “Water” shall be full pay for all labor, materials, tools, and equipment necessary to furnish, haul, and apply the water. When the Contract does not include water as a pay item, providing and applying the water shall be incidental to construction. All costs shall be included in the other Contract pay items. Page 2-36 2020 Standard Specifications M 41-10 2-08 Vacant 2-08 Vacant 2020 Standard Specifications M 41-10 Page 2-37 Structure Excavation 2-09 2-09 Structure Excavation 2-09.1 Description Structure excavation consists of excavating and disposing of all natural material or man-made objects that must be removed to make way for bridge foundations, retaining walls, culverts, trenches for pipelines, conduits, and other Structures as shown in the Plans. This Work also includes, unless the Contract provides otherwise, removing whole or partial Structures, grubbing Structure sites that would not otherwise be grubbed, building and later removing shoring, cofferdams, or caissons, pumping or draining excavated areas, protecting excavated materials from the weather, and placing and compacting backfill. 2-09.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Fine Aggregate for Concrete 9-03.1(2) Admixture for Concrete 9-23.6 Fly Ash 9-23.9 Ground Granulated Blast Furnace Slag 9-23.10 Water 9-25 2-09.3 Construction Requirements 2-09.3(1) General Requirements All Structure excavation, trenching, and shoring shall be performed in strict compliance with WAC 296-155 as well as all other applicable local, Contracting Agency, and Federal laws and regulations. 2-09.3(1)A Staking, Cross-Sectioning, and Inspecting The Contractor shall not begin excavating until after the stakes have been set to locate and/or outline the Structure and taken cross-sections to determine how much material to remove. The Engineer will occasionally inspect material taken from and material remaining in the excavation. 2-09.3(1)B Depth of Excavation The Contractor shall excavate foundation pits to the depth the Plans require, or to any revised depth ordered by the Engineer. Page 2-38 2020 Standard Specifications M 41-10 2-09 Structure Excavation 2-09.3(1)C Removal of Unstable Base Material When the material at the bottom of an excavation is not stable enough to support the Structure, the Contractor shall excavate below grade and replace the unstable material with gravel backfill. Gravel backfill shall meet the requirements of Section 9-03.12. It shall be placed in layers not more than 6 inches thick with each layer compacted to 95 percent of the maximum density determined by the Compaction Control Test, Section 2-03.3(14)D. 2-09.3(1)D Disposal of Excavated Material The Engineer may direct the Contractor to dispose of excavated material in embankments, backfills, or remove it from the site. All costs for disposing of excavated material within the project limits shall be included in the unit Contract price for Structure excavation, Class A or B. If, however, the Contractor must load and haul the material to a disposal site, the Contracting Agency will pay as provided in Section 1-04.4 for loading and hauling. The Contracting Agency will not pay for handling at the disposal site. Any such disposal shall meet the requirements of Section 2-03.3(7)C. If the Contract includes Structure excavation, Class A or B, including haul, the unit Contract price shall include all costs for loading and hauling the material the full required distance. 2-09.3(1)E Backfilling The backfilling of openings dug for Structures shall be a necessary part of and incidental to the excavation. Unless the Engineer directs otherwise, backfill material shall be nonclay material containing no pieces more than 3 inches across, no frozen lumps, and no wood or other foreign material. When specified in the Contract or when approved by the Engineer, the Contractor shall supply controlled density fill as backfill material. Alternative Sources. When material from Structure excavation is unsuitable for use as backfill, the Engineer may require the Contractor to: 1. Use other material covered by the Contract if such substitution involves Work that does not differ materially from what would otherwise have been required, 2. Substitute selected material in accordance with Section 2-03.3(10), 3. Use Controlled Density Fill (CDF) also known as Controlled Low Strength Material (CLSM)), or 4. Obtain material elsewhere. Material obtained elsewhere will be paid for in accordance with Section 1-04.4. 2020 Standard Specifications M 41-10 Page 2-39 Structure Excavation 2-09 Controlled Density Fill (CDF) or Controlled Low-Strength Material (CLSM) – CDF is a self compacting, cementitious, flowable material requiring no subsequent vibration or tamping to achieve consolidation. The Contractor shall provide a mix design in writing to the Engineer on WSDOT Form 350-040 and utilize ACI 229 as a guide to develop the CDF mix design. No CDF shall be placed until the Engineer has reviewed the mix design. CDF shall be designed to have a minimum 28-day strength of 50 psi and a maximum 28- day strength not to exceed 300 psi. The CDF consistency shall be flowable (approximate slump 3 to 10 inches). The following testing methods shall be used by the Contractor to develop the CDF mix design: 28-day compressive strength – ASTM D4832; Unit weight, yield, and air content – ASTM D6023; Slump – FOP for AASHTO T 119. The water/cement ratio shall be calculated on the total weight of cementitious material. Cementitious materials are those listed in Section 5-05.2. Admixtures used in CDF shall meet the requirements of Section 9-23.6, Admixtures for Concrete, and foaming agents, if used, shall meet the requirements of ASTM C869. Admixtures shall be used in accordance with the manufacturer’s recommendations and non-chloride accelerating admixtures may be used to accelerate the hardening of CDF. CDF shall meet the requirement of Section 6-02.3(5)C and shall be accepted based on a Certificate of Compliance. The producer shall provide a Certificate of Compliance for each truckload of CDF in accordance with Section 6-02.3(5)B. Stockpiling – The Engineer may require the Contractor to selectively remove and stockpile any usable material excavated for a Structure. If this material meets the requirements for gravel backfill for walls it may replace gravel as wall or abutment backfill. If the Contractor stockpiles excavated material for use as backfill, it shall be protected with plastic sheeting or by some other method from contamination and weather damage. If the material becomes too wet or contaminated in the stockpile, the Contractor shall dispose of and replace it with an equal amount of suitable material, all at no expense to the Contracting Agency. All costs for storing, protecting, rehandling, and placing stockpiled material shall be included in the unit Contract price for Structure excavation, Class A or B. Compaction – Backfill from Structure excavation shall be placed and compacted in keeping with the following requirements: 1. Backfill supporting Roadbed, Roadway embankments, or Structures, including backfill providing lateral support for noise barrier wall foundations, luminaire poles, traffic signal standards, and roadside and overhead sign Structure foundations shall be placed in horizontal layers no more than 6 inches thick with each layer compacted to 95 percent of the maximum density determined by the Compaction Control Test according to Section 2-03.3(14)D. Page 2-40 2020 Standard Specifications M 41-10 2-09 Structure Excavation 2. Gravel backfill for drains shall be placed in horizontal layers no more than 12 inches thick, with each layer compacted by at least three passes of a vibratory compactor approved by the Engineer. 3. All other structure excavation backfill shall be placed in layers no more than 2 feet thick (loose), with each layer tamped and graded so that final settling will leave the backfill flush with surrounding ground. 4. Compaction of controlled density fill will not be required. Timing – Backfill shall not be placed against any concrete Structure until the concrete has attained 90 percent of its design strength and a minimum age of 14 days, except that reinforced concrete retaining walls 15 feet in height or less may be backfilled after the wall has attained 90 percent of its design compressive strength and curing requirements of Section 6-02.3(11) are met. Footings and columns may be backfilled as soon as forms have been removed, so long as the backfill is brought up evenly on all sides. The Engineer may order the Contractor to use lean concrete in backfilling around piers and in front of abutments and walls. The Contracting Agency will pay for such backfilling as provided in Section 1-04.4. If water prevents the Contractor from properly placing and compacting backfill, it shall be removed by pumping or other means. All costs not defined in this section that relate to providing, placing, and compacting backfill shall be at the Contractor’s expense. 2-09.3(1)F Items to Remain If the Contractor damages or removes pavement or anything else meant to remain outside the excavation area, it shall be repaired or replaced at no expense to the Contracting Agency. 2-09.3(2) Classification of Structure Excavation 1. Class A – Structure excavation required for bridge and retaining wall footings, precast reinforced concrete three sided structure footings, geosynthetic retaining walls, structural earth walls, sign structure footings, pile or drilled shaft caps, seals, wingwall footings, precast reinforced concrete box culverts, precast reinforced concrete split box culverts, detention vaults, and noise barrier wall footings shall be classified as Structure excavation Class A. If the excavation requires a cofferdam, structural shoring, or extra excavation, the work outside the neat lines of the Structure excavation Class A shall be classified as shoring or extra excavation Class A. 2. Class B – All other Structure excavation shall be Class B. If this excavation requires cofferdams, shoring, or extra excavation, the work outside the neat lines of the Structure excavation Class B shall be classified as shoring or extra excavation Class B. 2020 Standard Specifications M 41-10 Page 2-41 Structure Excavation 2-09 2-09.3(3) Construction Requirements, Structure Excavation, Class A 2-09.3(3)A Preservation of Channel When foundations or Substructures are to be built in or next to running streams, the Contractor shall: 1. Excavate inside cofferdams, caissons, or sheet piling unless dredging or open pit excavation is permitted. 2. Backfill foundations placed inside cofferdams and behind sheet piling prior to removing cofferdams or sheet piling. This backfill shall be level with the original streambed and shall prevent scouring. 3. Remove any excavation material that may have been deposited in or near the stream so that the watercourse is free from obstruction. 4. Maintain water depth and horizontal clearances required for traffic to pass on navigable streams, furnishing any channel signals or lights required during construction. 5. Place riprap around the outside of cofferdams, as specified, to repair local scour. 2-09.3(3)B Excavation Using Open Pits – Extra Excavation The Contractor may dig open pits or perform extra excavation without shoring or cofferdams, if: 1. Footings can be placed in dry material away from running water. 2. The integrity of the completed Structure and its surroundings is not reduced. 3. Worker safety is ensured as required by law. 4. The excavation does not disturb the existing pavement or any other adjacent structural elements. If a slide occurs in an open pit, the Contractor shall remove the slide material. If the slide disturbs an area over which a Highway will be built, the Contractor shall backfill and compact the site to the original ground line as approved by the Engineer. If the slide damages an existing facility such as a Roadway or Structure, the Contractor shall repair the damage caused by the slide. The Contractor shall pay all costs related to removing slide material and restoring the slide area, including the repair of any pavement or structural elements damaged by the slide. The Contractor shall drain or pump any water from the pit, taking care not to stir up or soften the bottom. If equipment in the pit or inadequate water removal makes the foundation material unstable, the Contractor shall, at no expense to the Contracting Agency, remove and replace it with material acceptable to the Engineer. When the Engineer believes ground water flow may impair a concrete footing, the Contractor shall place under it a layer of gravel at least 6 inches thick. Before placing the gravel, the Contractor shall excavate to whatever grade the Engineer requires. This provision shall not apply to the building of concrete seals. Page 2-42 2020 Standard Specifications M 41-10 2-09 Structure Excavation The Contractor may omit forms when the earthen sides of a footing excavation will stand vertically. In this case, the Contractor may excavate to the neat line dimensions of the footing and pour concrete against the undisturbed earth. If the hole is larger than neat line dimensions, the Contractor shall bear the cost of the extra concrete. For open temporary cuts, the following requirements shall be met: 1. No vehicular or construction traffic, or construction surcharge loads will be allowed within a distance of 5 feet from the top of the cut. 2. Exposed soil along the slope shall be protected from surface erosion. 3. Construction activities shall be scheduled so that the length of time the temporary cut is left open is reduced to the extent practical. 4. Surface water shall be diverted away from the excavation. The excavation height (Ht) shall be calculated within a vertical plane as the difference between the lowest elevation in the excavation and the highest elevation of the ground surface immediately adjacent to the excavation. Pavement thickness and other surface treatments existing at the time of the excavation shall be included in the height calculation. Submittals and Design Requirements Excavations 4-feet and less in height do not require design and submittals. The Contractor shall provide a safe work environment and shall execute the work in a manner that does not damage adjacent pavements, utilities, or structures. If the Engineer determines the Contractor’s work may potentially affect adjacent traffic, pavements, utilities, or structures, the Engineer may request a Type 1 Working Drawing from the Contractor. The Contractor shall explain in the Type 1 Working Drawing how the Engineer’s concerns will be addressed, why infrastructure will not be damaged by the work, and how worker safety will be preserved. For excavations that have soil types and slope geometries defined in WAC 296-155 part N and are between 4-feet and 20-feet in height, the Contractor shall submit Type 2 Working Drawings. Required submittal elements include, at a minimum, the following: 1. A plan view showing the limits of the excavation and its relationship to traffic, structures, utilities and other pertinent project elements. If the stability of the excavation requires no-load zones or equipment setback distances, those shall be shown on the plan view. 2. A typical or controlling cross section showing the proposed excavation, original ground line, and locations of traffic, existing structures, utilities, site constraints, surcharge loads, or other conditions that could affect the stability of the slope. If the stability of the excavation requires no-load zones or equipment setback distances, those shall be shown in cross section. 3. A summary clearly describing subsurface conditions, soil type for WAC 296-155 part N, and groundwater conditions, sequencing considerations, and governing assumptions. 2020 Standard Specifications M 41-10 Page 2-43 Structure Excavation 2-09 Where WAC 296-155 part N requires an engineer’s design, the Contractor shall submit Type 2E Working Drawings. Required submittal elements include, at a minimum, the three items above and the following additional items: 4. Supporting calculations for the design of the excavation, the soil and material properties selected for design, and the justification for the selection for those properties, in accordance with the WSDOT Geotechnical Design Manual M 46-03. 5. Safety factors, or load and resistance factors used, and justification for their selection, in accordance with the WSDOT Geotechnical Design Manual M 46-03, and referenced AASHTO design manuals. 6. A monitoring plan to evaluate the excavation performance throughout its design life 7. Any supplemental subsurface explorations made by the Contractor to meet the requirements for geotechnical design of excavation slopes, in accordance with the WSDOT Geotechnical Design Manual M 46-03. 2-09.3(3)C Preparation for Placing Foundations When a foundation will rest on rock, excavation shall penetrate it at least 1 foot, or more if the Plans require, to form a key for the footing. The Contractor shall cut the bottom of the excavation to a firm surface, level, stepped, or serrated as the Engineer directs, and remove all loose material. For an arch abutment, the back face shall be trimmed to true lines so that concrete can be poured against undisturbed material. If concrete will rest on any excavated surface other than solid rock, the Contractor shall not disturb the bottom of the excavation. The Contractor shall also remove all loose or soft material just before pouring the concrete. Upon completing any foundation excavation, the Contractor shall notify the Engineer. No concrete or other permanent part of the Structure may be placed until the Engineer has given permission to proceed. 2-09.3(3)D Shoring and Cofferdams Definitions – Structural shoring is defined as a shoring system that is installed prior to excavation. Structural shoring shall provide lateral support of soils and limit lateral movement of soils supporting Structures, Roadways, utilities, railroads, etc., such that these items are not damaged as a result of the lateral movement of the supporting soils. Structural shoring systems includes driven cantilever sheet piles, sheet piles with tiebacks, sheet pile cofferdams with wale rings or struts, prestressed spud piles, cantilever soldier piles with lagging, soldier piles with lagging and tiebacks, and multiple tier tieback systems. Trench boxes, sliding trench shields, jacked shores, shoring systems that are installed after excavation, and soldier pile, sheet pile, or similar shoring walls installed in front of a pre-excavated slope, are not allowed as structural shoring. Page 2-44 2020 Standard Specifications M 41-10 2-09 Structure Excavation A cofferdam is any watertight enclosure, sealed at the bottom and designed for the dewatering operation, that surrounds the excavated area of a Structure. The Contractor shall use steel sheet pile or interlocking steel pile cofferdams in all excavation that is under water or affected by ground water. Submittals and Design Requirements – The Contractor shall submit Type 2E Working Drawings with supporting calculations showing the proposed methods and construction details of structural shoring or cofferdams in accordance with Sections 1-05.3 and 6-02.3(16). Structural shoring and cofferdams shall be designed in accordance with the WSDOT Geotechnical Design Manual M 46-03. Allowable stresses for materials shall not exceed stresses and conditions allowed by Section 6-02.3(17)B. For open temporary cuts associated with a shoring system, the requirements for open temporary cuts specified in Section 2-09.3(3)B shall be met. The structural shoring system shall be designed for site specific conditions which shall be shown and described in the Working Drawings. The structural shoring system design shall include the design of the slopes for stability above and below the shoring system. Except as otherwise noted, the design height of all structural shoring in design calculations and Working Drawings shall be for the depth of excavation as required by the Plans, plus an additional 2 feet to account for the possibility of overexcavation. If the Contractor provides written documentation to the satisfaction of the Engineer that the soil conditions at the site are not likely to require overexcavation, the Engineer may waive the requirement for 2 feet of overexcavation design height. Examples of such items that shall be shown on the structural shoring submittal and supported by calculations include, but are not limited to, the following: 1. Heights; soil slopes; soil benches; and controlling cross sections showing adjacent existing foundations, utilities, site constraints, and any surcharge loading conditions that could affect the stability of the shoring system, including any slopes above or below the shoring. 2. A summary clearly describing performance objectives, subsurface soil and groundwater conditions, sequencing considerations, and governing assumptions. 3. Any supplemental subsurface explorations made to meet the requirements for geotechnical design of excavation slopes, shoring walls, and other means of ground support, in accordance with the WSDOT Geotechnical Design Manual M 46-03. 4. Supporting geotechnical calculations used to design the shoring system, including the stability evaluation of the shoring system in its completed form as well as intermediate shoring system construction stages, the soil and material properties selected for design, and the justification for the selection for those properties, in accordance with the WSDOT Geotechnical Design Manual M 46-03. 2020 Standard Specifications M 41-10 Page 2-45 Structure Excavation 2-09 5. Safety factors, or load and resistance factors used, and justification for their selection. 6. Location and weight of construction equipment adjacent to the excavation; location of adjacent traffic; and structural shoring system material properties, spacing, size, connection details, weld sizes, and embedment depths. 7. Structural shoring installation and construction sequence, procedure, length of time for procedure and time between operations; proof load testing procedure if any; deadman anchor design and geometry; no load zones; grouting material and strengths; and a list of all assumptions. 8. Methods and materials to be used to fill voids behind lagging, when soldier piles with lagging are used as structural shoring. 9. A monitoring/testing plan to evaluate the performance of the excavation/shoring system throughout its design life, and 10. An estimate of expected displacements or vibrations, threshold limits that would trigger remedial actions, and a list of potential remedial actions should thresholds be exceeded. Thresholds shall be established to prevent damage to adjacent facilities, as well as degradation of the soil properties due to deformation. Construction Requirements – Structural shoring or cofferdams shall be provided for all excavations near completed Structures (foundations of bridges, walls, or buildings), near utilities, and near railroads. All other excavations 4 feet or more in depth shall either be shored with structural shoring or cofferdams, or shall meet the open-pit requirements of Section 2-09.3(3)B. Existing foundations shall be supported with structural shoring if the excavation is within the limits defined by a plane which extends out from the nearest edge of the existing footing a level distance of ½ the width of the existing footing and then down a slope of 1.5:1. When structural shoring or cofferdams are utilized, all excavation and structural shoring shall be constructed in accordance with the processed structural shoring submittal, including any required construction sequence noted in the Working Drawings. The Contractor shall remain responsible for satisfactory results. If soldier piles are placed in drilled holes, and lagging is installed concurrently with the excavation, all backfill above the bottom of the lagging shall consist of controlled-density fill or lean concrete. Backfill below the bottom of the lagging may consist of pea gravel. If full-height steel sheet lagging is installed prior to excavation, soldier pile holes may be backfilled with pea gravel. Page 2-46 2020 Standard Specifications M 41-10 2-09 Structure Excavation If lagging is used, void space behind the lagging shall be minimized. If the Engineer determines that the voids present could result in damage or serviceability problems for the structural shoring system or any Structures or facilities adjacent to the structural shoring system, the Contractor shall cease excavation and lagging installation, and shall fill the voids specified by the Engineer in accordance with the approved structural shoring submittal. Further excavation and lagging placement shall not continue until the specified voids are filled to the satisfaction of the Engineer. Excavation shall not proceed ahead of lagging installation by more than 4 feet or by the height that the soil will safely stand, whichever is least. For tieback shoring systems, excavation shall not proceed ahead by more than 4 feet of the tie installation and proof testing. In using cofferdams or structural shoring, the Contractor shall: 1. Extend cofferdams well below the bottom of the excavation, and embed structural shoring as shown in the structural shoring submittal as approved by the Engineer. 2. Provide enough clearance for constructing forms, inspecting concrete exteriors, and pumping water that collects outside the forms. If cofferdams tilt or move laterally during placement, the Contractor, at no expense to the Contracting Agency, shall straighten or enlarge them to provide the required clearance. 3. Secure the cofferdam in place to prevent tipping or movement. 4. Place structural shoring or cofferdams so that they will not interfere with any pile driving required. 5. Not place any shoring, braces, or kickers inside the cofferdams and structural shoring that will induce stress, shock, or vibration to the permanent Structure. 6. Vent cofferdams at the elevation commensurate with seal weight design, or as shown in the Plans. 7. Remove all bracing extending into the concrete being placed. When the Work is completed, the Contractor shall: 1. Remove all structural shoring to at least 2 feet below the finished ground line. 2. Remove all cofferdams to the natural bed of the waterway. 2-09.3(3)E Bearing Tests The Engineer may stop the excavation to make bearing tests at any time. The Contractor shall assist with these tests in any way the Engineer requires. During any test period, the Contractor shall, at no expense to the Contracting Agency, maintain ordinary working conditions at the bottom of the hole. The Contracting Agency will pay force account for all labor and materials the Contractor supplies for such tests. A single test shall not exceed 72 hours. 2020 Standard Specifications M 41-10 Page 2-47 Structure Excavation 2-09 2-09.3(4) Construction Requirements, Structure Excavation, Class B The above requirements for Structure excavation Class A, shall apply also to Structure excavation Class B, except as revised below. In addition, the Contractor shall follow Division 7 of these Specifications as it applies to the specific kinds of Work. The hole for any catch basin or manhole shall provide at least 1 foot of clearance between outside structural surfaces and the undisturbed earth bank. If workers enter any trench or other excavation 4 feet or more in depth that does not meet the open pit requirements of Section 2-09.3(3)B, it shall be shored or other safety method constructed in conformance with WISHA requirements. The Contractor alone shall be responsible for worker safety and the Contracting Agency assumes no responsibility. The Contractor shall submit Type 2E Working Drawings in accordance with Section 2-09.3(3)D. Trench boxes may be used for Structure excavation, Class B. Acceptance of trench boxes as a shoring method for Class B Structure excavation can be done by the Engineer provided it is not used to support adjacent traffic, existing footings, or other Structures. The Working Drawing submittal shall include the manufacturer’s certified trench box plans with depth restrictions, and the serial number for field verification of the trench box. Upon completing the Work, the Contractor shall remove all shoring unless the Plans or the Engineer direct otherwise. 2-09.4 Measurement Excavated materials will be measured in their original position by the cubic yard. The Contracting Agency will measure and pay for only the material excavated from inside the limits this section defines. If the Contractor excavates outside these limits or performs extra excavation as described in Section 2-09.3(3)B, it shall be considered for the Contractor’s benefit and shall be included in the cost of other Bid items. Horizontal Limits – The Contracting Agency will use the sides of the trench or pit as horizontal limits in measuring excavation. No payment for Structure excavation will be made for material removed (1) more than 1 foot outside the perimeter of any pile cap, footing, or seal; (2) more than 3 feet beyond the Roadway side of a wing wall; (3) more than 1 foot beyond the other sides and end of a wing wall; (4) more than 1 foot outside the perimeter of the soil reinforcement area for geosynthetic and structural earth walls; and (5) more than 4-feet beyond the inside opening of precast reinforced concrete box culverts and precast reinforced concrete split box culverts. For precast reinforced concrete three sided structures, no payment for Structure excavation will be made for material removed more than 1 foot outside the perimeter of the footing or more than 4 feet beyond the inside opening, whichever is greater. Page 2-48 2020 Standard Specifications M 41-10 2-09 Structure Excavation For all pipes, pipe arches, structural plate pipes, and underpasses, the Structure excavation quantity will be calculated based on the following trench widths: For drain and underdrain pipes, trench width = I.D. + 12 inches. For pipes 15 inches and under, trench width = I.D. + 30 inches. For pipes 18 inches and over, trench width = (1.5 × I.D.) + 18 inches. For a manhole, catch basin, grate inlet, or drop inlet, the limits will be 1 foot outside the perimeter of the Structure. For drywells, the limits shall be in accordance with the Standard Plans. Lower Limits – For a pile cap, footing, or seal, the bottom elevation shown in the Plans, or set by the Engineer, will serve as the lower limit in measuring Structure excavation. For a wing wall, the lower limit will follow a line parallel to the bottom and 1 foot below it. Any swell from pile driving will be excluded from excavation quantities. For pipelines the lower limit in measuring structure excavation will be the foundation level as shown in the Plans or as directed by the Engineer. Upper Limits – The top surface of the ground or streambed as the Work begins will be the upper limit for measuring excavation. If the Contract, or a separate contract, includes a pay item for grading to remove materials, the upper limit will be the neat lines of the grading section shown in the Plans. The Engineer may order the Contractor to partially build the embankment before placing pipe. In this case, the upper limit for measurement will be not more than 4 feet above the invert of the pipe. For a structural plate pipe, pipe arch, or underpass, the upper limit will be the top of the embankment at the time of installation as specified in Section 7-03.3(1)A. Gravel Backfill – Gravel backfill, except when used as bedding for culvert, storm sewer, sanitary sewer, manholes, and catch basins, will be measured by the cubic yard in place determined by the neat lines required by the Plans. Shoring or Extra Excavation – No specific unit of measurement shall apply to the lump sum item of shoring or extra excavation Class A. Shoring or extra excavation Class B will be measured by the square foot as follows: The area for payment will be one vertical plane measured along the centerline of the trench, including Structures. Measurement will be made from the existing ground line to the bottom of the excavation and for the length of the Work actually performed. If the Contract includes a pay item for grading to remove materials, the upper limit for measurement will be the neat lines of the grading section shown in the Plans. The bottom elevation for measurement will be the bottom of the excavation as shown in the Plans or as otherwise established by the Engineer. Controlled density fill will be measured by the cubic yard for the quantity of material placed in accordance with the producer’s invoice. 2020 Standard Specifications M 41-10 Page 2-49 Structure Excavation 2-09 2-09.5 Payment Payment will be made for the following Bid items when they are included in the Proposal: “Structure Excavation Class A”, per cubic yard. “Structure Excavation Class B”, per cubic yard. “Structure Excavation Class A Incl. Haul”, per cubic yard. “Structure Excavation Class B Incl. Haul”, per cubic yard. Payment for reconstruction of surfacing and paving within the limits of Structure excavation will be at the applicable unit prices for the items involved. If the Engineer orders the Contractor to excavate below the elevations shown in the Plans, the unit Contract price per cubic yard for “Structure Excavation Class A or B” will apply. But if the Contractor excavates deeper than the Plans or the Engineer requires, the Contracting Agency will not pay for material removed from below the required elevations. In this case, the Contractor, at no expense to the Contracting Agency, shall replace such material with concrete or other material the Engineer approves. “Shoring or Extra Excavation Cl. A _____”, lump sum. When extra excavation is used in lieu of constructing the shoring, cofferdam or caisson, the lump sum Contract price shall be full pay for all excavation, backfill, compaction, and other Work required. If select backfill material is required for backfilling within the limits of Structure excavation, it shall also be required as backfill material for the extra excavation at the Contractor’s expense. If it is necessary to place riprap outside of cofferdams to repair local scour, it shall be paid by agreed price or force account. If the Engineer requires shoring, cofferdams, or caissons when the Contract provides no Bid item for such Work, the Contracting Agency will pay as provided in Section 1-04.4. If the Engineer requires the Contractor to build shoring or extra excavation Class A that extends below the elevation shown in the Plans, the Contracting Agency shall pay the lump sum price and no more when the extra depth does not exceed 3 feet. For depths greater than 3 feet below the elevations shown, payment will be as provided in Section 1-04.4. “Shoring or Extra Excavation Class B”, per square foot. The unit Contract price per square foot shall be full pay for all excavation, backfill, compaction, and other Work required when extra excavation is used in lieu of constructing shoring. If select backfill material is required for backfilling within the limits of the Structure excavation, it shall also be required as backfill material for the extra excavation at the Contractor’s expense. Page 2-50 2020 Standard Specifications M 41-10 2-09 Structure Excavation If there is no Bid item for shoring or extra excavation Class B on a square foot basis and the nature of the excavation is such that shoring or extra excavation is required as determined by the Engineer, payment to the Contractor for the Work will be made in accordance with Section 1-04.4. “Gravel Backfill (_____________)”, per cubic yard. “Controlled Density Fill”, per cubic yard. 2020 Standard Specifications M 41-10 Page 2-51 2-10 Vacant 2-10 Vacant Page 2-52 2020 Standard Specifications M 41-10 2-11 Trimming and Cleanup 2-11 Trimming and Cleanup 2-11.1 Description This Work consists of dressing and trimming the entire Roadway(s) improved under the Contract, including Frontage Roads, connecting ramps, Auxiliary Lanes, and approach roads. This Work extends to Roadbeds, Shoulders, and ditches. 2-11.2 Vacant 2-11.3 Construction Requirements The Contractor shall: 1. Trim Shoulders and ditches to produce smooth surfaces and uniform cross-sections that conform to the grades set by the Engineer. 2. Open and clean all channels, ditches, and gutters to ensure proper drainage. 3. Dress the back slope of any ditch or borrow pit that will remain adjacent to the Roadway. Round off the top of the back slope and distribute the material evenly along its base. 4. Remove and dispose of all weeds, brush, refuse, and debris that lie on the Roadbed, Shoulders, ditches, and slopes. 5. Remove from paved Shoulders all loose rocks and gravel. 6. Distribute evenly along the embankment any material not needed to bring the Shoulders to the required cross-section. The Contractor shall not: 1. Use heavy equipment (tractors, graders, etc.) to trim the Shoulders of an existing or new bituminous surface. 2. Drag, push, or scrape Shoulder material across completed surfacing or pavement. When the Contract requires the Contractor to rebuild part of a Roadway only the rebuilt areas shall be trimmed and cleaned up. If the Contractor’s Work obstructs ditches or side roads, they shall be cleared and the debris disposed of as the Engineer directs. 2-11.4 Vacant 2-11.5 Payment Payment shall be made for the following Bid item when it is included in the Proposal: “Trimming and Cleanup”, lump sum. 2020 Standard Specifications M 41-10 Page 2-53 Construction Geosynthetic 2-12 2-12 Construction Geosynthetic 2-12.1 Description The Contractor shall furnish and place construction geosynthetic in accordance with the details shown in the Plans. 2-12.2 Materials Materials shall meet the requirements of the following section: Construction Geosynthetic 9-33 Geosynthetic roll identification, storage, and handling shall be in conformance to ASTM D4873. During periods of shipment and storage, the geosynthetic shall be stored off the ground. The geosynthetic shall be covered at all times during shipment and storage such that it is fully protected from ultraviolet radiation including sunlight, site construction damage, precipitation, chemicals that are strong acids or strong bases, flames including welding sparks, temperatures in excess of 160ºF, and any other environmental condition that may damage the physical property values of the geosynthetic. Unless specified otherwise in the Plans, the geotextile required for underground drainage shall be “Moderate Survivability” and “Drainage Class C” and permanent erosion control applications shall be “High Survivability” and “Drainage Class C”. 2-12.3 Construction Requirements The area to be covered by the geosynthetic shall be graded to a smooth, uniform condition free from ruts, potholes, and protruding objects such as rocks or sticks. The geosynthetic shall be spread immediately ahead of the covering operation. The geosynthetic shall not be left exposed to sunlight during installation for a total of more than 14 calendar days. The geosynthetic shall be laid smooth without excessive wrinkles. Under no circumstances shall the geosynthetic be dragged through mud or over sharp objects which could damage the geosynthetic. The cover material shall be placed on the geosynthetic such that the minimum initial lift thickness required will be between the equipment tires or tracks and the geosynthetic at all times. Construction vehicles shall be limited in size and weight, to reduce rutting in the initial lift above the geosynthetic, to not greater than 3 inches deep to prevent overstressing the geosynthetic. Turning of vehicles on the first lift above the geosynthetic will not be permitted. Soil piles or the manufacturer’s recommended method, shall be used as needed to hold the geosynthetic in place until the specified cover material is placed. Should the geosynthetic be torn, punctured, or the overlaps or sewn joints disturbed, as evidenced by visible geosynthetic damage, Subgrade pumping, intrusion, or Roadbed distortion, the backfill around the damaged or displaced area shall be removed and the damaged area repaired or replaced by the Contractor at no expense to the Contracting Agency. The repair shall consist of a patch of the same type of geosynthetic placed over the damaged area. The patch shall overlap the existing geosynthetic from the edge of any part of the damaged area by the minimum required overlap for the application. Page 2-54 2020 Standard Specifications M 41-10 2-12 Construction Geosynthetic If geotextile seams are to be sewn in the field or at the factory, the seams shall consist of one row of stitching unless the geotextile where the seam is to be sewn does not have a selvage edge. If a selvage edge is not present, the seams shall consist of two parallel rows of stitching, or shall consist of a J-seam, Type SSn-1, using a single row of stitching. The two rows of stitching shall be 1.0 inch apart with a tolerance of plus or minus 0.5 inch and shall not cross except for restitching. The stitching shall be a lock-type stitch. The minimum seam allowance, i.e., the minimum distance from the geotextile edge to the stitch line nearest to that edge, shall be 1½ inches if a flat or prayer seam, Type SSa-2, is used. The minimum seam allowance for all other seam types shall be 1.0 inch. The seam, stitch type, and the equipment used to perform the stitching shall be as recommended by the manufacturer of the geotextile and as approved by the Engineer. The seams shall be sewn in such a manner that the seam can be inspected readily by the Engineer or a representative. The seam strength will be tested and shall meet the requirements stated herein. 2-12.3(1) Underground Drainage Trench walls shall be smooth and stable. The geotextile shall be placed in a manner which will ensure intimate contact between the soil and the geotextile (i.e., no voids, folds, or wrinkles). The geotextile shall either be overlapped a minimum of 12 inches at all longitudinal and transverse joints, or the geotextile joints shall be sewn for medium survivability drainage applications. In those cases where the trench width is less than 12 inches, the minimum overlap shall be the trench width. In moderate survivability geotextile underdrain applications, the minimum overlap shall be 12 inches, or the geotextile joints shall be sewn, except where the geotextile is used in area drains. An area drain is defined as a geotextile layer placed over or under a horizontal to moderately sloping layer of drainage aggregate. For area drains, the geotextile shall be overlapped a minimum of 2 feet at all longitudinal and transverse joints, or the geotextile joints shall be sewn together. The minimum initial lift thickness over the geotextile in the area drain shall be 12 inches. In all cases, the upstream geotextile sheet shall overlap the next downstream sheet. 2-12.3(2) Separation The geotextile shall either be overlapped a minimum of 2 feet at all longitudinal and transverse joints, or the geotextile joints shall be sewn together. The initial lift thickness shall be 6 inches or more. 2020 Standard Specifications M 41-10 Page 2-55 Construction Geosynthetic 2-12 2-12.3(3) Soil Stabilization The geotextile shall either be overlapped a minimum, of 2 feet at all longitudinal and transverse joints, or the geotextile shall be sewn together. The initial lift thickness shall be 12 inches or more. Compaction of the first lift above the geotextile shall be by Method A according to Section 2-03.3(14)C. No vibratory compaction will be allowed on the first lift. 2-12.3(4) Permanent Erosion Control and Ditch Lining Unless otherwise shown in the Plans, the geotextile shall either be overlapped a minimum of 2 feet at all longitudinal and transverse joints, or the geotextile joints shall be sewn together. If overlapped, the geotextile shall be placed so that the upstream strip of geotextile will overlap the next downstream strip. When placed on slopes, each strip shall overlap the next downhill strip. Placement of aggregate and riprap or other cover material on the geotextile shall start at the toe of the slope and proceed upwards. The geotextile shall be keyed at the top and the toe of the slope as shown in the Plans. The geotextile shall be secured to the slope, but shall be secured loosely enough so that the geotextile will not tear when the riprap or other cover material is placed on the geotextile. The geotextile shall not be keyed at the top of the slope until the riprap or other cover material is in place to the top of the slope. All voids in the riprap or other cover material that allow the geotextile to be visible shall be backfilled with quarry spalls or other small stones, as designated by the Engineer, so that the geotextile is completely covered. When an aggregate cushion between the geotextile and the riprap or other cover material is required, it shall have a minimum thickness of 12 inches. An aggregate cushion will be required to facilitate drainage when hand placed riprap, as specified in Section 9-13.1(4), is used with the geotextile. Grading of slopes after placement of the riprap or other cover material will not be allowed if grading results in stone movement directly on the geotextile. Under no circumstances shall stones with a weight of more than 100 pounds be allowed to roll down slope. Stones shall not be dropped from a height greater than 3 feet above the geotextile surface if an aggregate cushion is present, or 1 foot if a cushion is not present. Lower drop heights may be required if geotextile damage from the stones is evident, as determined by the Engineer. If the geotextile is placed on slopes steeper than 2:1, the stones shall be placed on the slope without free-fall for moderate survivability, high survivability, and ditch lining geotextiles. Page 2-56 2020 Standard Specifications M 41-10 2-12 Construction Geosynthetic 2-12.4 Measurement Construction geotextile, with the exception of temporary silt fence geotextile and underground drainage geotextile used in trench drains, will be measured by the square yard for the ground surface area actually covered. Underground drainage geotextile used in trench drains will be measured by the square yard for the perimeter of drain actually covered. 2-12.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Construction Geotextile for Underground Drainage”, per square yard. “Construction Geotextile for Separation”, per square yard. “Construction Geotextile for Soil Stabilization”, per square yard. “Construction Geotextile for Permanent Erosion Control”, per square yard. “Construction Geotextile for Ditch Lining”, per square yard. Sediment removal behind silt fences will be paid by force account under temporary water pollution/erosion control. If a new silt fence is installed in lieu of sediment removal, the silt fence will be paid for at the unit Contract price per linear foot for “Construction Geotextile for Temporary Silt Fence”. 2020 Standard Specifications M 41-10 Page 3-1 Division 3 Aggregate Production and Acceptance 3-01 Production From Quarry and Pit Sites 3-01.1 Description This Work shall consist of manufacturing and producing crushed and screened aggregates including pit run aggregates of the kind, quality, and grading specified for use in the construction of concrete, hot mix asphalt, crushed surfacing, maintenance rock, ballast, gravel base, gravel backfill, gravel borrow, riprap, and bituminous surface treatments of all descriptions. The requirements specified shall apply whether the source is ledge rock, talus, gravel, sand, or any combination thereof. 3-01.2 Material Sources, General Requirements 3-01.2(1) Approval of Source Material sources must be approved in advance of use in the Work in accordance with the requirements of Section 1-06. This approval of source may require sampling and testing. If sampling is required, the samples must be taken at locations designated and witnessed by the Engineer or a designated representative. The Contractor is responsible for providing representative preliminary samples of aggregate sources to the Engineer. 3-01.2(2) Preparation of Site The portion of the quarry or pit site to be used shall be cleared and grubbed, and the area from which materials are to be taken shall be stripped of overburden as provided in Section 3-01.2(3). All combustible debris resulting from these operations shall be disposed of by the Contractor in a manner satisfactory to the Engineer. The Contractor shall provide sufficient space as required for the setup and operation of the Contracting Agency’s field testing facilities at the site of crushing or hot mix asphalt production. As directed by the Engineer, the Contractor shall provide one of the following to ensure 24-hour per day operation of the Contracting Agency’s laboratory trailer(s) that may be set up at the site during production: 1. A power source and a power cord of sufficient length to reach the Contracting Agency’s laboratory trailer(s) which may be set up at the site. The cord shall be capable of carrying at least 120/240 volts, 60 cycles at a sustained load of up to 200 amps. The cord and trailer(s) electrical hookup shall meet the NEC code. Power shall be provided and connected when requested by the Engineer. The laboratory trailer(s) hookup shall be protected by a 2 pole 50 amp 240 VAC circuit breaker. 2. A daily supply of fuel adequate for operation of the Contracting Agency’s generator(s). Page 3-2 2020 Standard Specifications M 41-10 3-01 Production From Quarry and Pit Sites Potable water shall be provided to the Contracting Agency’s laboratory trailer(s) for use during plant operations when requested by the Engineer. 3-01.2(3) Stripping Quarries and Pits Stripping of quarries and pits shall consist of the removal, after clearing and grubbing, of the surface material and overburden which is unsuitable for the kind of material to be borrowed or produced for use. Materials from stripping, to be used later as provided on the site reclamation plan specified in Section 3-03, shall be deposited within the quarry or pit site at such a location as not to interfere with future development within the site. 3-01.2(4) Production Requirements All oversize stones, rock fragments, or boulders occurring in the source, up to and including those measuring 18 inches in the greatest dimension, shall be utilized in the manufacture of crushed material. If the grading or quality of raw material in sources used for the manufacture of products covered by this section is such that the fracture, grading, or quality of the product specified cannot be obtained by utilizing the natural material, fine portions of the raw material shall be rejected to the extent necessary to produce products meeting all requirements of these Specifications. Failure of the Contracting Agency to include a scalping requirement in the Special Provisions shall not relieve the Contractor of the responsibility for rejecting fine portions of the material if such becomes necessary to produce products meeting all requirements of these Specifications. Scalping shall be performed after the pit-run or quarry-run material has passed through the primary crusher. When scalping over a screen of a specified size is required in the Special Provisions, the scalping screen shall be of such size and capacity that enough of the fine material will be removed to produce Work that conforms to the Specifications. Washing and reclaiming of the reject material and subsequent addition of this material to any finished products will not be allowed unless specifically authorized in writing by the Engineer. Surplus screenings accumulated during the crushing and screening of specified Roadway materials will be considered separate and distinct from reject material resulting from scalping operations. Both fine and coarse concrete aggregates shall be thoroughly washed in order to remove clay, loam, alkali, bark, sticks, organic castings, or other deleterious matter. Washing will be required in the production of other materials if necessary to produce products meeting all the quality requirements of these Specifications. 2020 Standard Specifications M 41-10 Page 3-3 Production From Quarry and Pit Sites 3-01 When producing screened gravel or sand materials, the Contractor shall remove all oversize material by screening at the pit site. The Contractor’s operations in the pit shall be conducted so that the grading of individual loads will be reasonably uniform. In general, the Contractor shall utilize the most suitable materials available and shall make as many moves of the loading equipment as may be necessary to fulfill these requirements. Where pit-run materials meet Specifications, screening or processing will not be required. 3-01.2(5) Final Cleanup Upon completion of the Contractor’s operation, the quarry or pit shall be cleared of all rubbish, temporary Structures, and equipment, and shall be left in a neat and presentable condition. The pit or quarry shall be reclaimed in accordance with the approved site reclamation plan specified in Section 3-03. 3-01.3 State Furnished Material Sources Unless specified in the Special Provisions, no Contracting Agency material sources are provided and the Contractor shall bear full responsibility for furnishing all materials. 3-01.3(1) Quality and Extent of Material Contracting Agency furnished material sources will be shown in the Plans and described in the Special Provisions. The quality of material in such sources will be acceptable in general, but the Contractor shall determine the amount of Work required to produce the material meeting these Specifications. It shall be understood that it is not feasible to ascertain from samples, the limits for an entire source, and that variations shall be considered as usual and are to be expected. The Engineer may order procurement of material from any portion of a source and may reject portions of the source as unacceptable. Since many material sources are acquired in fee by the Contracting Agency for use on future projects as well as for this Contract, it is in the public interest to preserve the future usefulness and adequacy of a source insofar as may be practical. To achieve this end, the Contractor shall not perform any Work within the source until receiving the Engineer’s approval of the Contractor’s work plan within the limits of the source. 3-01.3(2) When More Than One Site is Provided When more than one quarry or pit site is provided in the Special Provisions, the Contractor may obtain material from any of the sources. The Contracting Agency will specify the quantity of raw material available, as determined by tests, in each quarry or pit site. If the Contractor sets up in a site, and it is found that the quantity of raw material from that site, when the site is exhausted, is less than that specified by the Contracting Agency, then the provisions of Section 3-01.3(5) will apply. Page 3-4 2020 Standard Specifications M 41-10 3-01 Production From Quarry and Pit Sites 3-01.3(3) Reject Materials All scalpings that are unsatisfactory for use under these Specifications or Special Provisions shall be considered as reject material, subject to disposal as approved by the Engineer. Reject material shall be placed at such a location as not to interfere with future development within the site. 3-01.3(4) Surplus Screenings The surplus screenings accumulated during the production of the specified materials shall be stockpiled at a location within the site provided and become the property of the Contracting Agency. The stockpile site shall be prepared and constructed by the Contractor in accordance with the provisions of Section 3-02. All costs incurred in producing, hauling, and stockpiling the surplus screenings shall be incidental to the production of the specified materials and shall be included by the Contractor in the unit Bid prices in the Contract. 3-01.3(5) Moving Plant If, in the opinion of the Engineer, there should be insufficient suitable material in any quarry or pit site made available by the Contracting Agency, the Contracting Agency will acquire at its expense an additional source, in which event the Contractor will be required to move the crushing plant to the new quarry or site. Under such conditions, payment for the Contractor’s costs for the move will be made on a force account basis. Payment will be limited to the labor, equipment, and materials required for the move, and no allowance will be made for payment of standby costs for the crushing plant nor other equipment which may be temporarily idle as a result of the move. The clearing, grubbing, and preparing of the new quarries or pit sites as specified in Section 3-01.2(2) will be paid for in the manner provided in these Specifications for “Clearing”, “Grubbing”, and “Stripping Including Haul”. If there is no Bid item applicable, the payment for the preparation of the new site will be as provided in Section 1-04.4. If the moving of the plant due to shortage of the supply of material necessitates a longer haul on materials than required from the original source, the Contracting Agency will reimburse the Contractor for the additional haul at the rate of $0.25 per ton-mile haul. The unit ton-mile shall be the equivalent of 1 ton of material hauled a distance of 1 mile. The haul distance will be measured in ½-mile units, fractional half-miles being allowed as full half-miles. If the requirement for moving of the crushing plant results in a delay of performance of Work which is critical to completion of the project, as shown by the Contractor’s approved progress schedule, the Engineer will authorize a suspension of Work for the time required for the move. The above allowances, insofar as they may be applicable, shall be full pay for all claims of any kind or description by reason of the necessity of changing from one site to another due to shortage of the supply from sources made available by the Contracting Agency. Before moving a crushing plant as outlined above, the Contractor shall secure from the Engineer an order in writing to do so. Should the Contractor fail to secure such order, it 2020 Standard Specifications M 41-10 Page 3-5 Production From Quarry and Pit Sites 3-01 shall be considered sufficient proof that the move was immaterial insofar as to cost, and no allowance or pay will be made by reason of such move. 3-01.4 Contractor Furnished Material Sources 3-01.4(1) Acquisition and Development If, under the terms of the Contract, the Contractor is required to provide a source of materials, or if the Contractor elects to use materials from sources other than those provided by the Contracting Agency, the Contractor shall, at no expense to the Contracting Agency, make all necessary arrangements for obtaining the material and shall ensure the quantity of suitable material is available. Preliminary samples shall be taken by or in the presence of the Engineer or a designated representative unless the Engineer permits otherwise. Approval of the source does not relieve the Contractor from meeting these Specification requirements, nor does it guarantee that the material will meet these requirements without additional or proper processing. The Engineer may require additional preliminary samples at any time. Approval of a Contractor’s source offered in lieu of a Contracting Agency-provided source will be contingent upon the material therein being of equal quality, and no additional costs will accrue to the Contracting Agency as a result of such approval. Equivalency of quality will be based on those test values listed in the Special Provisions as being representative of material in the Contracting Agency-provided source. If no such values are listed, the minimum Specification requirements will apply. When measurement by weight is specified and when the specific gravity of material produced from the Contractor’s source is greater than that from the Contracting Agency-furnished source, any additional material required to construct the minimum specified surfacing depth shall be furnished by the Contractor at no expense to the Contracting Agency. The Contractor shall notify the State Departments of Ecology, Fish and Wildlife, and Natural Resources, in writing, of the intent to furnish the source, and shall, at no expense to the Contracting Agency, make all necessary arrangements with these agencies for the determinations of regulations which might be imposed upon the Contractor during removal of materials from the source. The source shall be selected so that, after the materials have been removed, the pit will drain to a natural drainage course and no ponding will result. Should the source selected by the Contractor be one which would not drain as outlined herein, permission shall be obtained by the Contractor from the governing body of the city or county for the removal of materials from the pit or quarry. The Contractor will not be permitted to operate a pit or a quarry site visible from a State Highway unless it can be demonstrated to the complete satisfaction of the Engineer that no unsightly condition will result from or remain as a result of the Contractor’s operations. If, in the opinion of the Engineer, unsightly conditions exist after removal of materials from the site, the Contractor shall correct such unsightly conditions as hereinafter provided. Page 3-6 2020 Standard Specifications M 41-10 3-01 Production From Quarry and Pit Sites Following removal of materials from the pit, the entire site shall be cleared of all rubbish, temporary Structures, and equipment which have resulted from the Contractor’s occupancy and operations. The Contractor shall obliterate or screen to the satisfaction of the Engineer any unsightly conditions that remain. The Contractor shall secure a written release from the permitter upon fulfillment of these requirements. All costs for cleaning up the pit site and for the installation or erection of screening or for other work required to correct unsightly conditions shall be at the Contractor’s expense. The requirements of this paragraph shall not apply to pits being operated commercially. All costs in connection with acquiring the rights to take materials from the source, for exploring and developing the site, for complying with the regulations of the aforesaid State agencies, for preparing the site as provided in Sections 3-01.2(2) and 3-03, for cleaning up the site, and for correcting unsightly conditions, shall be included in the unit Contract prices for the various pay items of Work involved. 3-01.4(2) Surplus Screenings Surplus screenings accumulated during the manufacture of specified material shall remain the property of the Contractor. 3-01.4(3) Substitution of Gravel Deposit in Lieu of Ledge Rock or Talus Source Provided by the Contracting Agency If the Contractor elects to substitute a gravel deposit of an approved source for the manufacture of ballast, crushed surfacing, or mineral aggregate in lieu of a ledge rock or talus source provided by the Contracting Agency in the Contract, all pit run materials passing a ½-inch-square sieve, or larger if ordered by the Engineer, shall be removed prior to crushing. 3-01.4(4) Gravel Base If the Contract requires the Contractor to provide the source of Gravel Base, or if the Contractor elects to furnish said material from sources other than those provided by the Contracting Agency, the material shall be produced from approved sources in accordance with the requirements of Section 3-01. The grading and quality shall be as specified in Section 9-03.10. Measurement and payment will be in accordance with Section 4-02. 2020 Standard Specifications M 41-10 Page 3-7 Production From Quarry and Pit Sites 3-01 3-01.5 Measurement For payment purposes, all crushed, screened, or naturally occurring materials that are to be paid for by the ton, dependent upon their grading, will be limited to the following water contents naturally occurring in the material source: Percent By Weight Passing No. 4 Maximum Water Content Percent By Weight Less than 20 4 20 or more 8 Water in excess of the maximum permissible amounts naturally occurring in the material source, as determined by the Engineer, will be deducted from the tonnage of material to be paid for on a daily basis. If the Contractor uses the Central Plant Mix Method of mixing water and surfacing materials in accordance with Section 4-04, the added water will be measured in accordance with Section 4-04.4. All other water added to the materials by the Contractor will be deducted from the weight of the aggregates including the added water, on a daily basis. Clearing and grubbing of quarries and pit sites will be measured in accordance with Section 2-01 when the Proposal includes such Bid items and such Work is required on a source provided by the Contracting Agency, except as modified in Section 3-01.3(5). Stripping of quarries and pit sites will be measured in cubic yards in its original position by cross-sectioning when the Proposal includes such Bid item and such stripping is required on a source provided by the Contracting Agency, except as modified in Section 3-01.3(5). Measurement of the particular materials or aggregates to be produced will be as specified in the appropriate section of these Specifications. 3-01.6 Payment All costs, except as specified, in connection with the production of materials meeting all quality requirements of these Specifications shall be included in the unit Contract prices of the various Bid items involved. Clearing and grubbing of quarries and pit sites will be paid in accordance with Section 2-01 when the Proposal includes such Bid items and such Work is required on a source provided by the Contracting Agency, except as modified in Section 3-01.3(5). “Stripping Incl. Haul”, shall be paid for at the unit Contract price per cubic yard when the Proposal includes such Bid item and such stripping is required on a source provided by the Contracting Agency, except as modified in Section 3-01.3(5). Page 3-8 2020 Standard Specifications M 41-10 3-02 Stockpiling Aggregates 3-02 Stockpiling Aggregates 3-02.1 Description This Work shall consist of preparing the stockpile sites and placing the specified aggregates in the stockpiles at the sites and in the amounts as shown in the Plans or as approved by the Engineer. This section also includes the requirements pertaining to the removal of aggregates from stockpiles and the requirements for dressing up the stockpiles and stockpile site at the completion of the Work. 3-02.2 General Requirements 3-02.2(1) Stockpile Sites Provided by the Contracting Agency The Contracting Agency may acquire and make available to the Contractor suitable areas as shown in the Plans for the construction of stockpiles. The stockpiled aggregates may be for use in the immediate Work or may be for future use as more fully described below. In either event, if the aggregates are required by these Specifications to be stockpiled, all costs in connection with the preparation of the stockpile sites as required in Section 3-02.2(5) shall be included in the various Bid items involved in the Contract; except that clearing and grubbing of the site will be measured and paid for in accordance with Section 2-01 only when such Bid items are included in the Proposal. In the event there is no Bid item included in the Proposal for construction and maintenance of haul roads to the stockpile site, the Contractor shall construct and maintain the haul roads as necessary and the cost thereof shall be included in the various Bid items in the Contract. 3-02.2(2) Stockpile Site Provided by the Contractor If the Plans do not provide a stockpile site for the use of the Contractor in stockpiling certain types and sizes of aggregates which are required by these Specifications to be stockpiled prior to use in the immediate Work, all costs in connection with the acquisition of a site, the preparation of the site, construction of the stockpiles, and the removal of the aggregates from the stockpiles shall be included in the Contract prices of the various Bid items of Work involved. 3-02.2(3) Stockpiling Aggregates for Future Use The Contracting Agency may require the production and stockpiling of aggregates on sites provided by the Contracting Agency for use on future construction or maintenance projects to be performed under a subsequent contract or by Contracting Agency forces. When the Contract includes the Bid item or items for specific aggregates in stockpile and these aggregates are not to be used in Work required under the Contract, the Contractor shall produce or furnish these aggregates complying with the quality and grading requirements of these Specifications and shall prepare the site and place the aggregates in stockpile in accordance with the requirements of this section or as ordered by the Engineer in accordance with Section 1-04.4. 2020 Standard Specifications M 41-10 Page 3-9 Stockpiling Aggregates 3-02 3-02.2(4) Stockpiling Aggregates for Immediate Use If the Contractor elects to stockpile aggregates from a source owned or controlled by the Contracting Agency prior to use in the immediate Work, the stockpiling shall be done within the area of the site provided by the Contracting Agency and in accordance with the requirements of these Specifications. If the Contractor elects to lease land to stockpile the aggregates, the stockpiling shall be done in accordance with these Specifications and upon proof that the lease will extend for a period of not less than one year beyond the completion date of the Contract. All excess aggregates remaining in stockpiles after satisfying the needs of the Contract—whether upon the site provided by the Contracting Agency or upon land leased by the Contractor—shall be disposed of in accordance with Section 1-09.10. All costs resulting from the production of the excess aggregates shall be included in the cost of production of the aggregates actually incorporated in the Work. If the Contractor elects to stockpile aggregates from a source not provided by the Contracting Agency prior to use in the immediate Work, it will be subject to the approval of the Engineer and provided that the aggregates comply with the quality and grading requirements of these Specifications. All costs in connection with the acquisition of the stockpile site, the preparation of the site, construction of the stockpiles, and the removal of the aggregates from the stockpiles shall be included in the Contract prices of the various Bid items of Work involved. 3-02.2(5) Preparation of Site Before placing aggregates upon the stockpile site, the site shall be cleared of vegetation, trees, stumps, brush, rocks, or other debris and the ground leveled to a smooth, firm, uniform surface. The debris resulting from clearing and preparing the site shall be disposed of in a manner satisfactory to the Engineer. 3-02.2(6) Construction of Stockpiles Stockpiles shall be constructed upon the prepared sites in accordance with stakes set by the Engineer. The piles when completed shall be neat and regular in shape. The stockpile height shall be limited to a maximum of 24 feet. Stockpiles in excess of 200 cubic yards shall be built up in layers not more than 4 feet in depth. Stockpile layers shall be constructed by trucks, clamshells, or other methods approved by the Engineer. Pushing aggregates into piles with a bulldozer will not be permitted. Each layer shall be completed over the entire area of the pile before depositing aggregates in the succeeding layer. The aggregate shall not be dumped so that any part of it runs down and over the lower layers in the stockpile. The method of dropping from a bucket or spout in one location to form a cone shaped pile will not be permitted. Any method of placing aggregates in stockpiles, which in the opinion of the Engineer, breaks, degrades, or otherwise damages the aggregate, will not be permitted. Plank runways will be required, when deemed necessary by the Engineer, for operating trucks on stockpiles to avoid tracking dirt or other foreign matter onto the stockpiled materials. Stockpiles of less than 200 cubic yards shall be piled in a manner to prevent segregation of the various sizes of material. Page 3-10 2020 Standard Specifications M 41-10 3-02 Stockpiling Aggregates No equipment other than pneumatic tired equipment shall be used in constructing the stockpiles of processed or manufactured aggregates. Stockpiles of different types or sizes of aggregate shall be spaced far enough apart, or separated by suitable walls or partitions, to prevent the mixing of the aggregates. Aggregate shall not be deposited where traffic, vehicles, or Contractor’s equipment will either run over or through the piles, or in any way cause foreign matter to become mixed with the aggregates. 3-02.2(7) Removing Aggregates From Stockpiles Aggregates shall be removed from stockpile in a manner to avoid separation of sizes or admixture of dirt or foreign material. The method and equipment used for loading will be approved by the Engineer. No equipment other than pneumatic tired equipment shall be used on stockpiles of processed or manufactured aggregates in removing the materials from the stockpiles. When removing materials from the face of the stockpile, the equipment shall be operated in a manner to face-load from the floor to the top of the stockpile to obtain maximum uniformity of material. The Contractor shall remove only the amount of materials from the stockpile required to satisfy the needs of the Contract. If a surplus remains in the stockpile, the Contractor shall leave the surplus material in neat, compact piles, free of foreign matter. The entire stockpile site shall be left in a neat and presentable condition. 3-02.3 Additional Requirements for Specific Aggregates 3-02.3(1) Washed Aggregates Drainpipes under the stockpile shall be provided at the Contractor’s expense when, in the opinion of the Engineer, such drains are necessary to properly drain the aggregates. The roads and ground adjacent to the stockpile shall be kept free of dust. Washed aggregate that has become coated with foreign material prior to use shall be washed until free of all foreign material or it may be rejected. Washed aggregate shall drain in hauling conveyances or stockpiles at least 12 hours before being weighed or measured for batching and for a longer time if so directed by the Engineer. 2020 Standard Specifications M 41-10 Page 3-11 Stockpiling Aggregates 3-02 3-02.4 Measurement Clearing and grubbing of the stockpile site will be measured in accordance with Section 2-01 when the Proposal includes such Bid items and such Work is required on a stockpile site provided by the Contracting Agency. Specific materials or aggregates designated in the Proposal to be in stockpile will be measured by the ton unless the Proposal shows by the cubic yard. The cubic yard volume for pay quantity will be determined by cross-sectioning the completed stockpile or by computation of the volume between the original ground surface and the stockpile surface using digital terrain modeling survey techniques. Specific materials or aggregates designated in the Proposal to be from stockpile will be measured by the ton or by the cubic yard, whichever is shown in the Proposal. If payment is to be made on the basis of cubic yards, measurement will be made of the volume in the hauling vehicle at the point of delivery on the Roadway. 3-02.5 Payment All costs involved in preparing stockpile sites shall be included in the unit Contract prices for the various Bid items being stockpiled, excepting that clearing and grubbing will be paid in accordance with Section 2-01 when the Proposal includes such Bid items and such Work is required on a stockpile site provided by the Contracting Agency. Page 3-12 2020 Standard Specifications M 41-10 3-03 Site Reclamation 3-03 Site Reclamation 3-03.1 Description This Work shall consist of reclaiming land used for borrowing material, mining for aggregates, sorting, or wasting materials as specified. 3-03.2 General Requirements 3-03.2(1) Contracting Agency-Provided Sites All borrow, quarry, or pit sites of over 3 acres in size of disturbed land or resulting in pit walls more than 30 feet high and steeper than a one to one slope which are owned or furnished by the Contracting Agency shall be reclaimed as shown in the Plans and as designated by the Engineer. Ultimate reclamation plans are not normally required for borrow, quarry, or pit sites not meeting the above criteria or for stockpile or waste sites. However, all such sites shall be reclaimed to the extent necessary to control erosion and provide a satisfactory appearance consistent with anticipated future use. 3-03.2(2) Contractor-Provided Sites All borrow, quarry, and pit sites of over 3 acres in size of disturbed land or resulting in pit walls more than 30 feet high and steeper than a 1:1 slope which are owned or furnished by the Contractor shall be reclaimed in accordance with the conditions and requirements of an approved reclamation permit acquired from the Department of Natural Resources. When the Contractor obtains a reclamation permit from the Department of Natural Resources, evidence of such approval shall be furnished to the Engineer prior to any Work within the site. Ultimate reclamation plans are not required for borrow, quarry, or pit sites not meeting the above criteria or for stockpile or waste sites. However, all such sites shall be reclaimed to the extent necessary to control erosion and provide a satisfactory appearance consistent with anticipated future use. Compliance with the State Environmental Policy Act (SEPA) is required for sites involving more than 100 cubic yards of excavation or landfill throughout the lifetime of the site unless the local agency in which the project is located establishes a greater amount. Sites involving more than 500 cubic yards of excavation or landfill throughout the lifetime of the site always require compliance with SEPA. Under no circumstance will the Contractor be allowed to waste material within a wetland as defined in Section 2-03.3(7). 2020 Standard Specifications M 41-10 Page 3-13 Site Reclamation 3-03 3-03.2(3) Out-of-State Sites All out-of-State borrow, quarry or pit, stockpile, and waste sites which are furnished by the Contractor exclusively for use on this Contract shall be reclaimed in accordance with an approved reclamation plan that is in compliance with local area restrictions. 3-03.3 Reclamation Plans 3-03.3(1) Contracting Agency-Provided Sites Reclamation plans for all borrow, quarry, or pit sites which are owned or furnished by the Contracting Agency will normally be furnished by the Contracting Agency and the requirements thereof included in the Contract documents. Should conditions require operations within a Contracting Agency-owned or Contracting Agency-furnished site not provided for in the Plans, the Contractor shall reclaim these sites in accordance with a reclamation plan furnished by the Engineer. 3-03.3(2) Contractor-Provided Sites A plan will not be required except on specific request for those sources of material for which the Contractor has obtained a valid surface mining permit issued by the Department of Natural Resources and has paid all required fees. 3-03.4 Construction Requirements 3-03.4(1) Erosion Control All sites owned or furnished by the Contracting Agency will specify the kind and amount of erosion control, if any, and include the requirements thereof in the Contract documents. All sites owned or furnished by the Contractor shall, if specified on a reclamation plan approved by the Engineer, require erosion control in accordance with Section 8-01 or plant materials in accordance with Section 8-02. 3-03.4(2) Deviations From Approved Reclamation Plans Reclamation of any site which deviates from the approved reclamation plan will not be permitted without first revising the approved reclamation plan and obtaining the approval of the Engineer. Page 3-14 2020 Standard Specifications M 41-10 3-03 Site Reclamation 3-03.5 Payment 3-03.5(1) Contracting Agency-Provided Sites All costs in connection with reclaiming sites to the full extent required by the Contract shall be included in the costs of other items of Work involved in the project. Payment will be made for any Work described in Sections 8-01 or 8-02 at applicable unit Contract prices. 3-03.5(2) Contractor-Provided Sites All costs involved in complying with the requirements of a reclamation permit acquired from the Department of Natural Resources, complying with the requirements of a reclamation plan approved by the Engineer, or with reclaiming sites to the full extent required by the Contract shall be included in the costs of other items of Work involved in the project. 2020 Standard Specifications M 41-10 Page 3-15 Acceptance of Aggregate 3-04 3-04 Acceptance of Aggregate 3-04.1 Description This work shall consist of acceptance of aggregate as provided for under statistical or nonstatistical evaluation. All aggregates shall meet the requirements in Section 9-03. Acceptance of aggregate by statistical evaluation is administered under Section 1-06.2. Statistical evaluation will be used for an aggregate material when the proposed plan quantity of the aggregate material exceeds two sublots as shown in Table 1. Nonstatistical evaluation will be used for the acceptance of aggregate materials when the proposed plan quantity is equal to or less than two sublots as shown in Table 1. 3-04.2 Materials Material shall meet the requirements of the following section: Aggregates 9-03 3-04.3 Construction Requirements 3-04.3(1) General For the purpose of statistical and nonstatistical acceptance sampling and testing, all test results obtained for a material type will be evaluated collectively. Sublot sampling and testing will be performed on a random basis at the frequency of one sample per sublot. Based on plan quantities, the sublot size will be determined to the nearest 100 tons (50 cy). The maximum sublot size will be as defined in Table 1. 3-04.3(2) Point of Acceptance The point of acceptance shall be as designated by the Engineer. Multiple sources shall not be placed within the same limits of each separate spreading operation or in such a way that the intermingling of different sources occurs. Individual compaction lifts may be of a different source. Page 3-16 2020 Standard Specifications M 41-10 3-04 Acceptance of Aggregate 3-04.3(3) Sampling The sampling of aggregate materials shall be performed on a random basis using WSDOT T 716, Method of Random Sampling. Samples for acceptance testing shall be obtained by the Engineer, or their designated representative. If ordered by the Engineer, the Contractor shall obtain the sample in the presence of the Engineer or their representative. The aggregate material shall be sampled in accordance with FOP for AASHTO R 90 and Section 1-05.6. The sample size shall be equal to the minimum requirements of FOP for AASHTO R 90. 3-04.3(4) Testing Results The results of all acceptance testing performed in the field and the Composite Pay Factor (CPF) of the lot after three sublots have been tested will be available to the Contractor through WSDOT’s website. 3-04.3(5) Nonstatistical Evaluation Each lot of aggregate materials produced under nonstatistical evaluation and having all constituents falling within the specification limits shall be accepted with no further evaluation. When one or more constituents fall outside the specification limits, the material will be statistically evaluated. A minimum of three sublots will be sampled and tested, when less than three sublots exist additional samples shall be tested to provide a minimum of three sets of results for evaluation. The test results of the sublots shall be evaluated in accordance with Section 1-06.2 using the price adjustment factors from Table 2 to determine the appropriate CPF. The maximum CPF shall be 1.00. If the CPF is below 1.00 but is equal to or above 0.75, a price adjustment will be calculated in accordance with Section 3-04.3(8). When the aggregate does not have established price adjustment factors, use the appropriate price adjustment factors from “Other Materials” as listed in Table 2. 3-04.3(6) Statistical Evaluation For statistical evaluation a lot is defined as 15 sublots, the final lot will be increased to a maximum of 25 sublots. All test results obtained for a material type will be evaluated in accordance with Section 1-06.2. Each lot of aggregate materials produced under statistical evaluation will be determined to be acceptable if the Composite Pay Factor (CPF) when calculated in accordance with Section 1-06.2(2) using the price adjustment factors from Table 2 is 1.00 or greater. The Contractor shall be paid the unit bid price for aggregate materials with a CPF of 1.00 or greater. If the CPF is below 1.00 but is equal to or above 0.75, calculate the price adjustment in accordance with Section 3-04.3(8). When the aggregate does not have established price adjustment factors, use the appropriate price adjustment factors from “Other Materials” as listed in Table 2. 2020 Standard Specifications M 41-10 Page 3-17 Acceptance of Aggregate 3-04 3-04.3(7) Rejected Work 3-04.3(7)A General Work that is defective or does not conform to Contract requirements shall be rejected. 3-04.3(7)B Rejection by Contractor The Contractor may, prior to sampling, elect to remove any defective material and replace it with new material. Any such new material will be sampled, tested, and evaluated for acceptance. 3-04.3(7)C Rejection Without Testing The Engineer may, without sampling, reject any load or stockpile that appears defective. Material rejected before placement shall not be incorporated into the work. Any rejected work shall be removed. No payment will be made for the rejected materials unless the Contractor requests that the rejected material be tested. If the Contractor elects to have the rejected material tested, a minimum of three representative samples shall be obtained and tested. Acceptance of rejected material will be based on conformance with the statistical acceptance Specification. If the CPF for the rejected material is less than 0.75, no payment will be made for the rejected material; in addition, the cost of sampling and testing shall be borne by the Contractor. If the CPF is greater than or equal to 0.75, the cost of sampling and testing will be borne by the Contracting Agency. If the material is rejected before placement and the CPF is greater than or equal to 0.75, compensation for the rejected material will be at a CPF of 0.75. If rejection occurs after placement and the CPF is greater than 0.75, compensation for the rejected mix will be at the calculated CPF with an addition of 25 percent of the unit Contract price added for the cost of removal and disposal. 3-04.3(7)D Lots and Sublots 3-04.3(7)D1 A Partial Sublot In addition to the preceding random acceptance sampling and testing, the Engineer may also isolate from a normal sublot any material that is suspected of being defective. Such isolated material will not include an original sample location. A minimum of three random samples of the suspect material will be obtained and tested. The material will then be evaluated as an independent lot in accordance with Section 1-06.2(2). 3-04.3(7)D2 An Entire Sublot An entire sublot that is suspect of being defective may be rejected. When a sublot is rejected a minimum of two additional samples from this sublot will be obtained. These additional samples and the original sublot will be evaluated as an independent lot in accordance with Section 1-06.2(2). Page 3-18 2020 Standard Specifications M 41-10 3-04 Acceptance of Aggregate 3-04.3(7)D3 A Lot in Progress The Contractor shall shut down operations and shall not resume placement of the aggregate until such time as the Engineer is satisfied that material conforming to the specification can be produced: a. When the Composite Pay Factor (CPF), for a lot in progress, is less than 1.00 and the contractor is taking no corrective action; or b. When the Pay Factor (PF) for any component of the lot in progress, is less than 0.95 and the contractor is taking no corrective action; or c. When either the PFi for any constituent or the CPF for a lot in progress is less than 0.75. 3-04.3(7)D4 An Entire Lot An entire lot with a CPF of less than 0.75 will be rejected. 3-04.3(8) Price Adjustments for Quality of Aggregate All aggregate material will be subject to price adjustments. The maximum attainable Composite Pay Factor (CPF) shall be 1.00. The aggregate Compliance Price Adjustment for acceptance of the aggregate will be calculated as follows: Aggregate Compliance Price Adjustment = (Composite Pay Factor – 1.00) (quantity of material) (unit bid price or Contingent Unit Price as shown in Table 1, whichever is higher) For aggregate materials lacking a separate unit bid price, the unit bid prices shall be taken as the value listed in Table 1 for “Contingent Unit Price”. If a component is not measured in accordance with these specifications, its individual pay factor will be considered 1.00 in calculating the composite pay factor. 3-04.4 Vacant 2020 Standard Specifications M 41-10 Page 3-19 Acceptance of Aggregate 3-04 3-04.5 Payment “Aggregate Compliance Price Adjustment”, by calculation. “Aggregate Compliance Price Adjustment” shall be calculated and paid for as described under Section 3-04.3(8) Price Adjustments for Quality of Aggregate. Table 1 Aggregate Acceptance Parameters Standard Specifications Item Maximum Sublot Size (Tons) Maximum Sublot Size (CY) Contingent Unit Price Per Ton Contingent Unit Price Per CY 9-03.1 Concrete Aggregate (except pavement) 2000 10001 $15.002 $30.002 9-03.1 Concrete Aggregate (pavement)4000 20001 $15.002 $30.002 9-03.4(2)Crushed Screening3 1000 500 $20.00 $40.00 9-03.8(2)HMA Aggregate 2000 $15.00 9-03.9(1)Ballast 2000 1000 $20.00 $40.00 9-03.9(2)Permeable Ballast 2000 1000 $25.00 $50.00 9-03.9(3)Crushed Surfacing 2000 1000 $20.00 $40.00 9-03.9(4)Maintenance Rock 2000 1000 $20.00 $40.00 9-03.10 Gravel Base 4000 2000 $15.00 $30.00 9-03.11(1)Streambed Sediment 500 250 $30.00 $60.00 9-03.12(1)A Gravel Backfill for Foundations Class A 1000 500 $30.00 $60.00 9-03.12(1)B Gravel Backfill for Foundations Class B 1000 500 $30.00 $60.00 9-03.12(2)Gravel Backfill for Walls 1000 500 $30.00 $60.00 9-03.12(3)Gravel Backfill for Pipe Zone Bedding 1000 500 $30.00 $60.00 9-03.12(4)Gravel Backfill for Drains 500 250 $30.00 $60.00 9-03.12(5)Gravel Backfill for Drywells 500 250 $30.00 $60.00 9-03.13 Backfill for Sand Drains 2000 1000 $30.00 $60.00 9-03.13(1)Sand Drainage Blanket 4000 2000 $30.00 $60.00 9-03.14(1)Gravel Borrow 4000 2000 $15.00 $30.00 9-03.14(2)Select Borrow 4000 2000 $15.00 $30.00 9-03.14(4)Gravel Borrow for Structural Earth Walls 4000 2000 $30.00 $60.00 9-03.17 Foundation Material, Class A and B 1000 500 $25.00 $50.00 9-03.18 Foundation Material Class C 1000 500 $25.00 $50.00 9-03.19 Bank Run Gravel for Trench Backfill 4000 2000 $30.00 $60.00 1Based on 1000 CY of Concrete. 2 Price adjustment only applies to the actual quantity of aggregate used in the concrete. 3Contingent unit price per S.Y. is $0.30. Page 3-20 2020 Standard Specifications M 41-10 3-04 Acceptance of Aggregate Table 2 Price Adjustment FactorsStandard SpecificationsItemMaximum Size Sieve: 100% Pass Nominal Maximum Size Sieve: 100% Pass1Other Specifications Sieves #4 and LargerSpecification Sieves: #8 to #100#200 SieveSand EquivalentFracture2Other9-03.1Concrete Aggregate (all concrete aggregate -including pavement)22210209-03.4(2)Crushed Screening225520159-03.8(2)HMA Aggregate1515Uncompacted Void Content 159-03.9(1)Ballast22551015Dust Ratio 159-03.9(2)Permeable Ballast2255159-03.9(3)Crushed Surfacing22551015159-03.9(4)Maintenance Rock22551015159-03.10Gravel Base25610Dust Ratio 109-03.11(1)Streambed Sediment2255109-03.12(1)AGravel Backfill for Foundations Class A39-03.12(1)BGravel Backfill for Foundations Class B25610Dust Ratio 109-03.12(2)Gravel Backfill for Walls225610Dust Ratio 109-03.12(3)Gravel Backfill for Pipe Zone Bedding22556109-03.12(4)Gravel Backfill for Drains22569-03.12(5)Gravel Backfill for Drywells22569-03.13Backfill for Sand Drains253109-03.13(1)Sand Drainage Blanket253109-03.14(1)Gravel Borrow22555109-03.14(2)Select Borrow22556109-03.14(4)Gravel Borrow for Structural Earth Walls2255510Other49-03.17Foundation Material, Class A & B239-03.18Foundation Material Class C239-03.19Bank Run Gravel for Trench Backfill225610Dust Ratio 10Other Materials2255101515Dust Ratio 101For Aggregate, the nominal maximum size sieve is the largest standard sieve opening listed in the applicable specification upon which more than 1-percent of the material by weight is permitted to be retained. For concrete aggregate, the nominal maximum size sieve is the smallest standard sieve opening through which the entire amount of aggregate is permitted to pass.2Price adjustment factor applies where criteria is contained in the material specification.3Use the price adjustment factors for the material that is actually used.4Resistivity 10, pH 10, Chlorides 5, and Sulfates 5. 2020 Standard Specifications M 41-10 Page 4-1 Division 4 Bases 4-01 Vacant Page 4-2 2020 Standard Specifications M 41-10 4-02 Gravel Base 4-02.1 Description This Work shall consist of constructing one or more layers of gravel base upon a prepared Subgrade in accordance with these Specifications and in conformity with the lines, grades, depth, and typical cross-section shown in the Plans or as established by the Engineer. 4-02.2 Materials Materials shall meet the requirements of the following section: Gravel Base 9-03.10 4-02.3 Construction Requirements Gravel base shall be uniformly spread upon the prepared Subgrade to the depth, width, and cross-section shown in the Plans. Construction methods used shall meet the applicable requirements of Sections 4-04.3. 4-02.4 Measurement Gravel base will be measured in the same manner prescribed for the measurement of crushed surfacing materials as set forth in Section 4-04.4. 4-02.5 Payment Payment will be made for the following Bid item when shown in the Proposal: “Gravel Base”, per ton, or per cubic yard. 4-02 Gravel Base 2020 Standard Specifications M 41-10 Page 4-3 4-03 Vacant Vacant 4-03 Page 4-4 2020 Standard Specifications M 41-10 4-04 Ballast and Crushed Surfacing 4-04 Ballast and Crushed Surfacing 4-04.1 Description This Work consists of constructing one or more courses of crushed stone upon a prepared Subgrade in accordance with these Specifications in conformity with the lines, grades, depth, and typical cross-sections shown in the Plans or as established by the Engineer. Surfacing materials and ballast may also be specified to be placed in stockpiles for future use. 4-04.2 Materials Materials shall meet the requirements of the following sections: Ballast 9-03.9(1) Permeable Ballast 9-03.9(2) Crushed Surfacing 9-03.9(3) Maintenance Rock 9-03.9(4) 4-04.3 Construction Requirements 4-04.3(1) Equipment All equipment necessary for the satisfactory performance of this construction shall be on the project and approved by the Engineer prior to beginning work. If central mix plant methods are used, the central mixing plant shall comply with the following requirements: The cold aggregate feeder shall be mechanically operated and adjustable to the extent necessary to provide a uniform and continuous flow of materials. These materials shall be deposited in an approved mixer with a sufficient amount of water being added to obtain the required density when spread and compacted. The water shall be weighed or metered, and dispensed through a device providing uniform dispersion across the mixer. The mixing plant shall be provided with weighing or calibrating devices, feeders, provisions for sampling, and other devices and equipment so designed, coordinated, and operated to produce a uniform mixture, and to permit the sampling of the materials before and after mixing. The mixer shall be kept in good condition, and mixing blades or paddles shall be of proper size, adjustment, and clearance to provide positive and uniform mixing of the mixture at all times. The capacity of the plant and equipment furnished for the Work shall be adequate at all times to provide for efficient and continuous operations insofar as practical. 2020 Standard Specifications M 41-10 Page 4-5 Ballast and Crushed Surfacing 4-04 4-04.3(2) Subgrade The Subgrade shall be prepared as specified in Section 2-06 and shall be approved by the Engineer before placing ballast or surfacing materials. 4-04.3(3) Mixing Unless otherwise specified, the Contractor may use either, or both, of the following described methods: 1. Central Plant Mix Method – The surfacing material and water shall be mixed in an approved mixing plant as described in Section 4-04.3(1). The completed mixture shall be a thoroughly mixed combination of proportioned materials and water, uniform in distribution of particle sizes and moisture content. A mixture containing water in excess of the proportion established by the Engineer will not be accepted. 2. Road Mix Method – After material for each layer of surfacing has been placed, the material shall be mixed until uniform throughout by motor graders or other equipment approved by the Engineer. Water to facilitate mixing and compacting shall be added in amounts approved by the Engineer. 4-04.3(4) Placing and Spreading 1. Central Plant Mix Method – After mixing, material for each layer of surfacing shall be transported to the Roadway in approved vehicles. Vehicles for hauling the mixture shall be capable of depositing the mixture within the receiving hopper of the spreading equipment, or in windrows of uniform size in front of the spreading equipment, with a minimum of segregation of the mix. A motor grader may be used as the spreading machine or the spreading machine shall be capable of receiving the material by direct deposit in its hopper from the hauling vehicle or from a uniform windrow, and be capable of spreading and screeding the material to a depth and surface that when compacted will be true to line, grade, depth of course, and cross-section without further shaping. 2. Road Mix Method – Each layer of surfacing material shall be spread by equipment that is approved by the Engineer. Equipment that causes segregation of the surfacing material during the spreading operation will not be allowed. Similar types of spreading equipment shall be used throughout the limits of each separate spreading operation. Spreading on small areas of less than 2,000 square yards or on areas irregular in shape, may be accomplished by other means as approved by the Engineer. The following nominal depth of compacted material shall not be exceeded in any one course without the approval of the Engineer: Ballast 0.50 foot Gravel Base 0.75 foot Crushed Surfacing 0.35 foot Page 4-6 2020 Standard Specifications M 41-10 4-04 Ballast and Crushed Surfacing 4-04.3(5) Shaping and Compaction Immediately following spreading and final shaping, each layer of surfacing shall be compacted to at least 95 percent of maximum density determined by the requirements of Section 2-03.3(14)D before the next succeeding layer of surfacing or pavement is placed. The determination of field in-place density shall be made by the Nuclear gauge. When the thickness of surfacing is less than 0.15 foot, density testing will not be required and the Engineer will determine the number of coverages required for the particular compaction equipment available. Vibratory compactors and rollers shall obtain the specified density for each layer. A mist spray of water shall be applied as needed to replace moisture lost by evaporation. The completed layer shall have a smooth, tight, uniform surface true to the line, grade, and cross-section shown in the Plans, or as staked. When using 100% Recycled Concrete Aggregate, the Contractor may submit a written request to use a test point evaluation for compaction acceptance testing in lieu of compacting to 95% of the standard density as determined by the requirements of Section 2-03.3(14)D. The test point evaluation shall be performed in accordance with SOP 738. 4-04.3(6) Keystone When necessary, as determined by the Engineer, crushed surfacing top course shall be used for keystone to key the top surface of ballast, gravel base, crushed surfacing base course, or any other surfacing course that requires keying. The keystone shall be spread evenly on top of the surfacing course by means of approved spreading equipment. The surface shall be watered and, if necessary, bladed lightly until the keystone is worked into the interstices of the surfacing course without excessive displacement and shall be compacted. The operations of adding keystone, wetting, blading, and compacting shall be continued until the course has become thoroughly keyed and compacted. When keystone is required, that is subject to public traffic, it shall be placed before terminating each day’s operation. Keystone placed for the convenience of the Contractor, with approval of the Engineer, for the purpose of creating a more dense surface on which to pave will be allowed within the top 0.20 foot of crushed surfacing base course, gravel base, or ballast. Keystone placed for this purpose will be paid for at the lower unit Contract price for either the base material being keyed or crushed surfacing top course. 4-04.3(7) Miscellaneous Requirements The surface of each layer of surfacing material shall be maintained true to line, grade, and cross-section by grading, watering, and rolling until placing the next succeeding course. The first course of surfacing material shall be placed on all available Subgrade before placing the succeeding course unless otherwise authorized by the Engineer. Unless otherwise approved, there shall be a distance of not less than one station between the construction of any two courses of surfacing or ballast. 2020 Standard Specifications M 41-10 Page 4-7 Ballast and Crushed Surfacing 4-04 Should irregularities develop in any surface during or after compaction, they shall be remedied by loosening the surface and correcting the defects after which the entire area including the surrounding surface shall be thoroughly recompacted. Any additional materials necessary to make the repairs shall be furnished by the Contractor at the unit Contract price. 4-04.3(8) Weather Limitations When, in the opinion of the Engineer, the weather is such that satisfactory results cannot be obtained, the Contractor shall suspend operations until the weather is favorable. No surfacing materials shall be placed in snow or on a soft, muddy, or frozen Subgrade. 4-04.3(9) Hauling Hauling equipment shall be routed over the Roadway in a manner to be most effective in the compacting of the surfacing. Hauling over any of the surfacing in the process of construction will not be permitted when, in the opinion of the Engineer, the effect will be detrimental. All loads shall be of uniform capacity unless deviation is expressly authorized by the Engineer. 4-04.3(10) Hours of Work The Contractor shall arrange surfacing operations so that the placing of materials will be accomplished during daylight hours. However, when necessary to complete the project within the time specified, or to avoid peak periods of public traffic, Work may be undertaken during the hours of darkness, provided the Contractor furnishes and operates adequate lighting. Inability to demonstrate reliable and satisfactory results will be reason to order termination of night operations, and the Contractor shall procure additional equipment and personnel necessary to satisfactorily complete the Work as specified while operating during daylight hours only. 4-04.3(11) Permeable Ballast Permeable ballast shall not be placed until the abutting pavement has been completed unless designated by the Engineer. Permeable ballast shall be placed through a spreader box in one lift. Processing of the permeable ballast course on the Roadway will not be permitted. Compaction shall be accomplished by making a minimum of three passes over the aggregate with a vibratory compactor of a type acceptable to the Engineer. The density requirements of Section 4-04.3(5) shall not apply. Page 4-8 2020 Standard Specifications M 41-10 4-04 Ballast and Crushed Surfacing 4-04.4 Measurement Crushed surfacing top course, base course, ballast, and gravel base, when mixed at a central plant, will be measured by the ton. The weight of water added at the plant will be deducted on a daily basis from the total tonnage of aggregates, including water, placed that day which were processed through the central plant and placed on the Roadway. The resultant tonnage of surfacing materials will be paid for at the unit Contract price. The weight of deducted water will be converted to gallons and will be paid for at the unit Contract price for water. Crushed surfacing top course, base course, ballast, and gravel base, when mixed by the road mix method, will be measured by the ton or by the cubic yard. If measured by the cubic yard, measurement will be made in the hauling conveyance at the point of delivery on the Roadway. Permeable ballast will be measured by the ton or by the cubic yard. Crushed surfacing materials for placement in stockpile will be measured by the ton or cubic yard. If measured by the cubic yard, the volume will be determined by cross- sectioning the stockpile. Maintenance rock will be measured in the same manner prescribed for crushed surfacing materials. Water used in placing and compacting surfacing materials on the Roadway will be measured in accordance with Section 2-07. 4-04.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Crushed Surfacing Top Course (or Base Course)”, per ton, or per cubic yard. “Crushed Surfacing Top Course (or Base Course) in Stockpile”, per ton, or per cubic yard. “Crushed Surfacing Top Course (or Base Course) from Stockpile”, per ton, or per cubic yard. “Ballast”, per ton, or per cubic yard. “Ballast in Stockpile”, per ton, or per cubic yard. “Ballast from Stockpile”, per ton, or per cubic yard. “Permeable Ballast”, per ton, or per cubic yard. “Permeable Ballast in Stockpile”, per ton or per cubic yard. “Permeable Ballast from Stockpile”, per ton or per cubic yard. “Maintenance Rock ½ In. Minus in Stockpile”, per ton, or per cubic yard. 2020 Standard Specifications M 41-10 Page 5-1 Division 5 Surface Treatments and Pavements 5-01 Cement Concrete Pavement Rehabilitation 5-01.1 Description This Work consists of rehabilitating or replacing section(s) of cement concrete pavement in accordance with these Specifications and in conformity with the lines, grades, thicknesses, and typical cross-sections shown in the Plans or established by the Engineer. 5-01.2 Materials Materials shall meet the following requirements of the following sections: Cement 9-01 Fine Aggregate 9-03 Coarse Aggregate 9-03 Combined Aggregate 9-03 Joint Filler 9-04.1 Joint Sealants 9-04.2 Closed Cell Foam Backer Rod 9-04.2(3)A Dowel Bars 9-07.5 Tie Bars 9-07.6 Concrete Patching Material, Grout, and Mortar 9-20.1 Curing Materials and Admixtures 9-23 Water 9-25 Epoxy Resins (bonding agents) 9-26 Parting Compound shall be a curing compound, grease or other substance approved by the Engineer. Dowel Bar Retrofit Dowel bar expansion caps shall be tight fitting and made of non-metallic material, which will allow for ¼ inch of movement at each end of the bar. Chairs for supporting the dowel bar shall be epoxy coated according to Section 9-07.3 or made from non-metallic material. The foam insert shall be closed cell foam faced with poster board material or plastic faced material on each side commonly referred to as foam core board by office suppliers. The foam insert shall be capable of remaining in a vertical position and tight to all edges during the placement of the concrete patching material. Caulking filler used for sealing the transverse joint at the bottom and sides of the slot shall be a silicone caulk. Page 5-2 2020 Standard Specifications M 41-10 5-01 Cement Concrete Pavement Rehabilitation 5-01.3 Construction Requirements 5-01.3(1) Vacant 5-01.3(1)A Mix Designs The Contractor shall use either concrete patching materials or cement concrete for the rehabilitation of cement concrete pavement. Concrete patching materials shall be used for spall repair and dowel bar retrofitting and cement concrete shall be used for concrete panel replacement. 5-01.3(1)A1 Concrete Patching Materials 1. Materials – The prepackaged concrete patching material and the aggregate extender shall conform to Section 9-20.1. 2. Submittals and Mix Approval – The Contractor shall use the Manufacturer’s recommended proportions for the mix design to be submitted to the Engineer for the concrete patching material. The Contractor’s submittal shall include the mix proportions of the prepackaged concrete patching material, water, aggregate extender, and the proposed sources for all aggregates. If not approved for use on the QPL, submit test data indicating compliance with Section 9-20.1. 5-01.3(1)A2 Cement Concrete for Panel Replacement Cement concrete for panel replacement shall meet the requirements of Sections 5-05.3(1) and 5-05.3(2) and be air entrained with a design air content of 5.5 percent. Cement concrete for panel replacement may use rapid hardening hydraulic cement meeting the requirements of Section 9-01.2(2). Rapid hardening hydraulic cement will be considered a cementitious material for the purpose of calculating the water/cementitious materials ratio and the minimum cementitious materials requirement. 5-01.3(1)B Equipment for Panel Replacement In addition to Sections 5-05.3(3)A, 5-05.3(3)B, 5-05.3(3)D, and 5-05.3(3)E the following shall apply: 1. Mobile volumetric mixers shall be calibrated in accordance with Section 6-09.3(1)H. The references to the latex admixture shall not apply. 2. The equipment for grinding cement concrete pavement shall use diamond embedded saw blades gang mounted on a self propelled machine that is specifically designed to smooth and texture concrete pavement. The equipment shall not damage the underlying surface, cause fracture, or spalling of any joints. 2020 Standard Specifications M 41-10 Page 5-3 Cement Concrete Pavement Rehabilitation 5-01 5-01.3(2) Material Acceptance 5-01.3(2)A Concrete Patching Material Acceptance shall be based on field verification of the prepackaged patching material, and whether the amount of added water and aggregate extender complies with the mix design. 5-01.3(2)B Cement Concrete for Panel Replacement The point of acceptance will be at the discharge of the placement system. The concrete producer shall provide a certificate of compliance for each truckload of concrete in accordance with Section 6-02.3(5)B. Acceptance testing for compliance of air content and 28-day compressive strength shall be conducted from samples obtained according to FOP for WAQTC TM 2. Air content shall be determined by conducting FOP for AASHTO T 152. Compressive Strength shall be determined by FOP for AASHTO T 22 and FOP for AASHTO T 23. The lower Specification limit for air content shall be 3 percent, and the upper Specification limit for air content shall be 7 percent. The lower Specification limit for compressive strength shall be 4,000 psi. The Contractor shall provide cure boxes in accordance with Section 6-02.3(5)H, and protect concrete cylinders in cure boxes from excessive vibration and shock waves during the curing period in accordance with Section 6-02.3(6)D. Payment for cure boxes shall be in accordance with Section 6-02.5. 5-01.3(2)B1 Conformance to Mix Design Acceptance of cement concrete pavement for panel replacement shall be in accordance with Section 5-01.3(2)B. The cement, coarse, and fine aggregate weights shall be within the tolerances of the mix design in accordance with Section 5-05.3(1). 5-01.3(2)B2 Rejection of Concrete Rejection by the Contractor: The Contractor may, prior to sampling, elect to remove any defective material and replace it with new material at no expense to the Contracting Agency. The replacement material will be sampled, tested and evaluated for acceptance. Rejection without Testing: The Engineer may reject any load that appears defective prior to placement. Material rejected before placement shall not be incorporated into the pavement. No payment will be made for the rejected materials unless the Contractor requests that the rejected material be tested. If the Contractor elects to have the rejected materials tested, a sample will be taken and both the air content and strength shall be tested by WSDOT. Page 5-4 2020 Standard Specifications M 41-10 5-01 Cement Concrete Pavement Rehabilitation Payment for rejected material will be based on the results of the one sample, which was taken and tested. If the rejected material fails either test, no payment will be made for the rejected material and in addition, the cost of sampling and testing, at the rate of $250.00 per sample shall be borne by the Contractor. If the rejected material passes both tests the mix will be compensated for at actual invoice cost and the cost of the sampling and testing will borne by the Contracting Agency. 5-01.3(3) Vacant 5-01.3(4) Replace Cement Concrete Panel 5-01.3(4)A General Curing, cold weather Work, concrete pavement construction in adjacent lanes, and protection of pavement shall meet the requirements of Section 5-05.3(13) through Section 5-05.3(15). The Contractor, at no cost to the Contracting Agency, shall repair any damage to existing pavement caused by the Contractor’s operations. 5-01.3(4)B Sawing and Dimensional Requirements Concrete slabs to be replaced as shown in the Plans or staked by the Engineer shall be at least 6.0 feet long and full width of an existing pavement panel. The portion of the panel to remain in place shall have a minimum dimension of 6 feet in length and full panel width; otherwise the entire panel shall be removed and replaced. There shall be no new joints closer than 3.0 feet to an existing transverse joint or crack. A vertical full depth saw cut is required along all longitudinal joints and at transverse locations and, unless the Engineer allows otherwise, an additional vertical full depth relief saw cut located 12 to 18 inches from and parallel to the initial longitudinal and transverse saw cut locations is also required. Removal of existing cement concrete pavement shall not cause damage to adjacent slabs that are to remain in place. In areas that will be ground, slab replacements shall be performed prior to pavement grinding. Side forms shall meet the requirements of Section 5-05.3(7)B whenever a sawed full depth vertical face cannot be maintained. 5-01.3(4)C Dowel Bars and Tie Bars For the half of a dowel bar or tie bar placed in fresh concrete, comply with the requirements of Section 5-05. For the half of a dowel bar or tie bar placed in hardened concrete, comply with the Standard Plans and the following. After drilling, secure dowel bars and tie bars into the existing pavement with either an epoxy bonding agent Type I or IV as specified in Section 9-26.1, or a grout Type 2 for non- shrink applications as specified in Section 9-20.3. 2020 Standard Specifications M 41-10 Page 5-5 Cement Concrete Pavement Rehabilitation 5-01 Dowel bars shall be placed at the mid depth of the concrete slab, centered over the transverse joint, and parallel to the centerline and to the Roadway surface, within the tolerances within the table below. Dowel bars may be adjusted to avoid contact with existing dowel bars in the transverse joint at approach slabs or existing panels provided the adjusted dowel bars meet the tolerances below. Tie bars shall be placed at the mid depth of the concrete slab, centered over the joint, perpendicular to centerline, and parallel to the Roadway surface, within the tolerances in the table below. The horizontal position of tie bars may be adjusted to avoid contact with existing tie bars in the longitudinal joint where panel replacement takes place, provided the adjusted tie bars meet the tolerances below. Placement Tolerances Dowel Bars Tie Bars Vertical: Center of Bar to Center of Slab Depth ± 1.00 inch max ± 1.00 inch max Dowel Bar Centered Over the Transverse Joint ± 1.00 inch max N/A Tie Bar Centered Over the Longitudinal Joint N/A ± 1.00 inch max Parallel to Centerline Over the Length of the Dowel Bar ± 0.50 inch max N/A Perpendicular to Longitudinal Joint Over the Length of the Tie Bar N/A ± 1.00 inch max Parallel to Roadway Surface Over the Length of the Bar ± 0.50 inch max ± 1.00 inch max Dowel bars and tie bars shall be placed according to the Standard Plan when multiple panels are placed. Panels shall be cast separately from the bridge approach slab. Dowel bars to be drilled into existing concrete or at a new transverse contraction joint shall have a parting compound, such as curing compound, grease, or other Engineer accepted equal, applied to them prior to placement. Clean the drilled holes in accordance with the epoxy or grout manufacturer’s instructions. Holes shall be clean and dry at the time of placing the epoxy, or grout and tie bars. Completely fill the void between the tie bar and the outer limits of the drilled hole with epoxy or grout. Use retention rings to prevent leakage of the epoxy or grout and support the tie bar to prevent movement until the epoxy or grout has cured the minimum time recommended by the manufacturer. 5-01.3(4)D Foundation Preparation The Contractor shall smooth the surfacing below the removed panel and compact it to the satisfaction of the Engineer. Crushed surfacing base course, or hot mix asphalt may be needed to bring the surfacing to grade prior to placing the new concrete. If the material under the removed panel is uncompactable and the Engineer requires it, the Contractor shall excavate the Subgrade 2 feet, place a soil stabilization construction geotextile meeting the requirements of Section 9-33, and backfill with crushed surfacing base course. This Work may include: 1. Furnishing and hauling crushed surfacing base course to the project site. 2. Excavating uncompactable material. Page 5-6 2020 Standard Specifications M 41-10 5-01 Cement Concrete Pavement Rehabilitation 3. Furnishing and placing a soil stabilization construction geotextile. 4. Backfilling and compacting crushed surfacing base course. 5. Removing, hauling and restocking any unused crushed surfacing base course. 5-01.3(4)E Concrete Finishing Grade control shall be the responsibility of the Contractor. All panels shall be struck off level with the adjacent panels and floated to a smooth surface. Final finish texturing shall meet the requirements of Section 5-05.3(11). In areas where the Plans do not require grinding, the surface smoothness will be measured with a 10-foot straightedge by the Engineer in accordance with Section 5-05.3(12). If the replacement panel is located in an area that will be ground as part of concrete pavement grinding in accordance with Section 5-01.3(9), the surface smoothness shall be measured, by the Contractor, in conjunction with the smoothness measurement done in accordance with Section 5-01.3(10). 5-01.3(4)F Joints All transverse and longitudinal joints shall be sawed and sealed in accordance with Section 5-05.3(8). The Contractor may use a hand pushed single blade saw for sawing joints. 5-01.3(4)G Cracked Panels Replacement panels that crack shall be repaired as specified in Section 5-05.3(22) at no cost to the Contracting Agency. When repairing replacement panels that have cracked, epoxy-coated dowel bars meeting the requirements of Section 9-07.5(1) may be substituted for the corrosion resistant dowel bars specified. 5-01.3(4)H Opening to Traffic Opening to traffic shall meet the requirements of Section 5-05.3(17). 5-01.3(5) Partial Depth Spall Repair Removal of the existing pavement shall not damage any pavement to be left in place. Any existing pavement that is to remain that has been damaged shall be repaired at the Contractor’s expense. If jackhammers are used for removing pavement, they shall not weigh more than 30 pounds, and chipping hammers shall not weigh more than 15 pounds. All power driven hand tools used for the removal of pavement shall be operated at angles less than 45 degrees as measured from the surface of the pavement to the tool. The patch limits shall extend beyond the spalled area a minimum of 3 inches. Repair areas shall be kept square or rectangular. Repair areas that are within 12 inches of another repair area shall be combined. 2020 Standard Specifications M 41-10 Page 5-7 Cement Concrete Pavement Rehabilitation 5-01 A vertical saw cut shall be made to a minimum depth of 2 inches around the area to be patched as marked by the Engineer. The Contractor shall remove material within the perimeter of the saw cut to a depth of 2 inches, or to sound concrete as determined by the Engineer. The surface patch area shall be sand blasted and all loose material removed. All sandblasting residue shall be removed. Spall repair shall not be done in areas where dowel bars are encountered. When a partial depth repair is placed directly against an adjacent longitudinal joint, a bond-breaking material such as polyethylene film, roofing paper, or other material as approved by the Engineer shall be placed between the existing concrete and the area to be patched. Patches that abut working transverse joints or cracks require placement of a compressible insert. The new joint or crack shall be formed to the same width as the existing joint or crack. The compressible joint material shall be placed into the existing joint 1 inch below the depth of repair. The compressible insert shall extend at least 3 inches beyond each end of the patch boundaries. Patches that abut the lane/Shoulder joint require placement of a formed edge, along the slab edge, even with the surface. The patching material shall be mixed, placed, consolidated, finished, and cured according to manufacturer’s recommendations. Slab/patch interfaces that will not receive pavement grinding shall be sealed (painted) with a 1:1 cement-water grout along the patch perimeter. The Contractor shall reseal all joints in accordance with Section 5-05.3(8)B. Opening to traffic shall meet the requirements of Section 5-05.3(17). 5-01.3(6) Dowel Bar Retrofit Dowel bars shall be installed in the existing concrete pavement joints and transverse cracks where shown in the Plans or as marked by the Engineer. Saw cut slots will be required in the pavement to place the center of the dowel at mid- depth in the concrete slab. The completed slot shall provide a level, secure surface for the feet of the dowel bar chairs. Slots that intersect longitudinal or random cracks shall not be retrofitted. When gang saws are used, slots that are not used shall be cleaned and sealed with either Type I or IV epoxy resin as specified in Section 9-26. The transverse joint between cement concrete pavement and a Bridge approach slab shall not be retrofitted. Saw cut slots shall be prepared such that dowel bars can be placed at the mid depth of the concrete slab, centered over the transverse joint, and parallel to the centerline and to the Roadway surface. Page 5-8 2020 Standard Specifications M 41-10 5-01 Cement Concrete Pavement Rehabilitation Placement Tolerances for Dowel Bars 1. ± 1 inch of the middle of the concrete slab depth. 2. ± 1 inch of being centered over the transverse joint. 3. ± ½ inch from parallel to the centerline. 4. ± ½ inch from parallel to the Roadway surface. If jackhammers are used to break loose the concrete they shall weigh less than 30 pounds. All slot surfaces shall be cleaned to bare concrete by sand blasting. The cleaning shall remove all slurry, parting compound, and other foreign materials prior to installation of the dowel. Any damage to the concrete shall be repaired by the Contractor at no cost to the Contracting Agency. Traffic shall not be allowed on slots where concrete has been removed. Prior to placement, the dowel bars shall be lightly coated with a parting compound and placed on a chair that will provide a minimum of ½-inch clearance between the bottom of the dowel and the bottom of the slot. The chair design shall hold the dowel bar tightly in place during placement of the concrete patching material. If the transverse joint or crack is open ¼ inch or more, the Contractor shall caulk the transverse joint or crack at the bottom and sides of the slot as shown in the Plans immediately prior to placement of the dowel bar and concrete patching material. The caulking filler shall not be placed any farther than ½ inch outside either side of the joint or crack. The transverse joint or crack shall be caulked sufficiently to satisfy the above requirements and to prevent any of the patching material from entering the joint/crack at the bottom or sides of the slot. A ⅜-inch-thick foam insert shall be placed at the middle of the dowel to maintain the transverse joint. The foam insert shall fit tightly around the dowel and to the bottom and edges of the slot and extend to the top of the existing pavement surface. The foam insert shall be capable of remaining in a vertical position and held tightly to all edges during placement of the patch. If for any reason the foam insert shifts during placement of the patch the Work shall be rejected and redone at the Contractor’s expense. Patching material shall be consolidated by using a 1-inch or less diameter vibrator as approved by the Engineer. The Contractor shall not overwork the patching material during the patch consolidation process. The patching material on the surface of the dowel bar slots shall not be overworked, causing segregation and leaving the fine material on the surface. The patching material shall be left ⅛ to ¼ inch high and not finished flush with the existing concrete surface. The joint shall be maintained by saw cutting the surface with a hand pushed single blade saw. The cut width shall be 3/16 to 5/16 inch and the depth 1½ inches. The cut length shall be 2¼ feet long centered over the three retrofit dowel bars and shall be sawed within 24 hours after placement of the concrete patching material. 2020 Standard Specifications M 41-10 Page 5-9 Cement Concrete Pavement Rehabilitation 5-01 5-01.3(7) Sealing Existing Concrete Random Cracks The Contractor shall route, clean and seal existing concrete random cracks where indicated by the Engineer. Cracks smaller than 5/16 inch in width shall be routed to 5/16 inch wide by 1 inch deep prior to placing the sealant. Cracks over 5/16 inch in width shall be cleaned and sealed. All incompressible material shall be completely removed from the existing random crack to a depth of ¾ inch. Immediately prior to sealing, the cracks shall be clean. The top surface of the sealant shall be at least ¼ inch below the surface of the pavement. 5-01.3(8) Sealing Existing Longitudinal and Transverse Joint The Contractor shall clean and seal existing longitudinal and transverse joints where shown in the Plans or as marked by the Engineer. Old sealant and incompressible material shall be completely removed from the joint to the depth of the new reservoir with a diamond blade saw in accordance with the detail shown in the Standard Plans. The removed sealant shall become the property of the Contractor and be removed from the jobsite. Removal of the old sealant for the entire depth of the joint is not required if the depth of the new reservoir is less than the depth of the existing joint. Joints constructed with joint tape do not require cleaning and sealing. Immediately prior to sealing, the cracks shall be clean. If shown in the Plans, a backer rod shall be placed at the base of the sawn reservoir. The joints shall be completely dry before the sealing installation may begin. Immediately following the air blowing and backer rod replacement, if required, the sealant material shall be installed in conformance to manufacturer’s recommendations and in accordance with Section 5-05.3(8)B. The top surface of the sealant shall be at least ¼ inch below the surface of the pavement. 5-01.3(9) Cement Concrete Pavement Grinding Pavement grinding shall begin within 10 working days of placing dowel bar retrofit patching materials. Once the grinding operation has started it shall be continuous until completed. If new cement concrete pavement, in accordance with Section 5-05, is to be placed next to rehabilitated cement concrete pavement, grind one pass along the edge of the rehabilitated cement concrete pavement adjacent to where the new cement concrete pavement is to be placed before the new cement concrete pavement is placed. The pavement shall be ground in a longitudinal direction beginning and ending at lines normal to the pavement centerline. Ninety-five percent of the surface area of the pavement to be ground shall have a minimum of ⅛ inch removed by grinding. Bridge decks, bridge approach slabs, and bridge overlay insets shall not be ground. The ground pavement shall be feathered to match the elevation of the above features. Page 5-10 2020 Standard Specifications M 41-10 5-01 Cement Concrete Pavement Rehabilitation 5-01.3(9)A Surface Finish The final surface texture shall be uniform in appearance with longitudinal corduroy type texture. The grooves shall be between 3/32 and 5/32 inches wide, and no deeper than 1/16 inch. The land area between the grooves shall be between 1/16 and ⅛ inches wide. 5-01.3(10) Pavement Smoothness Pavement surface smoothness for cement concrete pavement grinding on this project will include International Roughness Index (IRI) testing. Ride quality will be evaluated using the Mean Roughness Index (MRI) calculated by averaging the IRI data for the left and right wheel path within the section. Smoothness Testing Equipment and Operator Certification Use an inertial profiler and operator that meet the requirements of Section 5-05.3(3)E. Surface Smoothness Operate the inertial profiler in accordance with AASHTO R 57. Collect two longitudinal traces, one in each wheel path. Collect the control profile at locations designated in Table 2 prior to any pavement rehabilitation Work on the areas to be tested. Collect an acceptance profile at locations designated in Table 2 after completion of all cement concrete pavement grinding on the project. Profiles shall be collected in a continuous pass including areas excluded from pay adjustments. Provide notice to the Engineer a minimum of seven calendar days prior to testing. Table 2 Locations Requiring MRI Testing Travel lanes where cement concrete grinding is shown in the plans Control profile Additional locations designated by the Engineer Control profile Travel lanes with completed cement concrete pavement grinding Acceptance profile Bridges, approach panels and 0.02 miles before and after bridges and approach panels and other excluded areas within lanes requiring testing Control and acceptance profile Ramps, Shoulders and Tapers Do not test Within 30 calendar days after the Contractor’s testing, the Engineer may perform verification testing. If the verification testing shows a difference in MRI greater than the 10 percent, the following resolution process will be followed: 1. The profiles, equipment and procedures will be evaluated to determine the cause of the difference. 2. If the cause of the discrepancy cannot be resolved the pavement shall be retested with both profilers at a mutually agreed time. The two profilers will test the section within 30 minutes of each other. If the retest shows a difference in MRI equal or greater than the percentages shown in Table 2 of AASHTO R 54 the Engineer’s test results will be used for pavement smoothness acceptance. 2020 Standard Specifications M 41-10 Page 5-11 Cement Concrete Pavement Rehabilitation 5-01 The Contractor shall evaluate profiles for acceptance or corrective action using the current version of ProVAL and provide the results including the profile data in unfiltered electronic Engineering Research Division (ERD) file format to the Engineer within 3 calendar days of completing each days profile testing. If the profile data files are created using an export option in the manufacturer’s software where filter settings can be specified, use the filter settings that were used to create data files for certification. Analyze the entire profile. Exclude areas listed in Table 3. Table 3 Areas Excluded from MRI Acceptance Requirements Location Exclude Beginning and end of grinding Pavement within 0.02 mile Bridges and approach slabs The bridge and approach slab and 0.02 mile from the ends of the bridge or approach slab Defects in the existing roadway identified by the Contractor that adversely affect the MRI such as dips, depressions and wheel path longitudinal joints.1 0.01-mile section containing the defect and the 0.01-mile section following the section with the defect. 1 The presence of defects is subject to verification by the Engineer Report the MRI results in inches per mile for each 0.01-mile section and each 0.10-mile section. Do not truncate 0.10-mile sections for areas excluded from MRI acceptance requirements. MRI requirements will not apply to 0.10-mile sections with more than three 0.01 mile-sections excluded. MRI requirements for the individual 0.01-mile sections shall still apply. The Engineer will verify the analysis. The MRI for each 0.10 mile of ground lane will comply with the following: Control Profile per 0.10 Mile Maximum MRI of Acceptance Profile per 0.10 Mile ≤130 inches/mile 78 inches/mile >130 inches/mile 0.6 x Control Profile MRI The MRI for each 0.01 mile of the completed cement concrete grinding shall not exceed 160 inches/mile. All Work is subject to parallel and transverse 10-foot straightedge requirements, corrective work and disincentive adjustments. Surface smoothness of travel lanes including areas subject to MRI testing shall not vary more than ⅛ inch from the lower edge of a 10-foot straightedge placed on the surface parallel to the centerline. The smoothness perpendicular to the centerline will be measured with a 10-foot straightedge within the lanes. There shall be not vertical elevation difference of more than a ¼ inch between lanes. Page 5-12 2020 Standard Specifications M 41-10 5-01 Cement Concrete Pavement Rehabilitation Pavement that does not meet these requirements will be subject to corrective Work. All corrective Work shall be completed at no additional expense, including traffic control, to the Contracting Agency. Pavement shall be repaired by one or more of the following methods: 1. Diamond grinding. 2. By other method accepted by the Engineer. Repair areas shall be re-profiled to ensure they no longer require corrective Work. With concurrence of the Engineer, a 10-foot straight edge may be used in place of the inertial profiler. If correction of the roadway as listed above either will not or does not produce satisfactory results as to smoothness or serviceability the Engineer may accept the completed pavement and a credit will be calculated in accordance with Section 5-01.5. Under these circumstances, the decision whether to accept the completed pavement or to require corrective work as described above shall be vested entirely in the Engineer. 5-01.3(11) Concrete Slurry and Grinding Residue All concrete slurry and grinding residue shall be removed from the pavement surface on a continual basis immediately behind the grinding or cutting operations. Slurry shall not be allowed to drain into an area open to traffic, off of the paved surface, into any drainage structure, water of the state, or wetlands. The Contractor shall collect the concrete slurry and grinding residue from the pavement surface and dispose of it in accordance with Section 2-03.3(7)C. The Contractor shall submit copies of all disposal tickets to the Engineer within 5 calendar days. Opening to traffic shall meet the requirements of Section 5-05.3(17). 5-01.4 Measurement Replacement cement concrete panels will be measured by the square yard, based on the actual width and length of the surface area placed. Retrofit dowel bars will be measured per each for the actual number of bars used in the completed Work. Sealing existing concrete random cracks will be measured by the linear foot, measured along the crack sealed. Sealing existing longitudinal and transverse joint will be measured by the linear foot, measured along the line of the completed joint. Cement concrete pavement grinding will be measured by the square yard, based on the actual width and length of area ground. Extra passes to meet the Specifications or overlaps will not be measured. 2020 Standard Specifications M 41-10 Page 5-13 Cement Concrete Pavement Rehabilitation 5-01 5-01.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Replace Cement Concrete Panel”, per square yard. The unit Contract price per square yard shall be full payment for all costs to complete the Work as specified, including saw cutting full depth, removal and disposal of the existing panels off of the Contracting Agency’s Right of Way, preparing the surfacing below the new panel, provide, place and compact the crushed surfacing or hot mix asphalt, furnishing and placing polyethylene film or building paper, furnishing and placing the cement concrete, drilling the holes, providing and anchoring the dowel bars and tie bars, and for all incidentals required to complete the Work as specified. “Retrofit Dowel Bars”, per each. The unit Contract price per each shall be full payment for all costs to complete the Work as specified, including furnishing and installing parting compound, dowel bar expansion caps, caulking filler, foam core insert material, cement patch where pavement is removed for dowel bar retrofit and for all incidentals required to complete the Work as specified. “Partial Depth Spall Repair”, by force account as provided in Section 1-09.6. To provide a common Proposal for all Bidders, the Contracting Agency has entered an amount in the Proposal to become a part of the total Bid by the Contractor. “Sealing Existing Concrete Random Crack”, per linear foot. The unit Contract price per linear foot for “Sealing Existing Concrete Random Crack” shall be full payment for all costs to complete the Work as specified, including removing incompressible material, preparing and sealing existing random cracks where existing random cracks are cleaned and for all incidentals required to complete the Work as specified. “Grinding Smoothness Compliance Adjustment”, by calculation. Grinding Smoothness Compliance Adjustments will be based on the requirements in Section 5-01.3(10) and the following calculations: A smoothness compliance adjustment will be calculated in the sum of minus $100 for each and every section of single traffic lane 0.01 mile in length and $1,000 for each and every section of single traffic lane 0.10 mile in length that does not meet the requirements in Section 5-01.3(10) after corrective Work. “Sealing Existing Longitudinal and Transverse Joint”, per linear foot. The unit Contract price per linear foot for “Sealing Existing Longitudinal and Transverse Joint”, shall be full payment for all costs to complete the Work as specified, including removing incompressible material, preparing and sealing existing transverse and longitudinal joints where existing transverse and longitudinal joints are cleaned and for all incidentals required to complete the Work as specified. “Cement Concrete Pavement Grinding”, per square yard. Page 5-14 2020 Standard Specifications M 41-10 5-01 Cement Concrete Pavement Rehabilitation The unit Contract price per square yard for “Cement Concrete Pavement Grinding”, when multiplied by the number of units measured, shall be full payment for all costs to complete the Work as specified. The costs of any additional pavement grinding and profiling required to complete the Work as specified is also included in this payment. “Replace Uncompactable Material”, by force account as provided in Section 1-09.6. Payment for “Replace Uncompactable Material” will be by force account as provided in Section 1-09.6 and will be full payment for all work required to replace uncompactable material and provide base for the Concrete panel. This will include, but not be limited to, excavating the subgrade, placement of a soil stabilization construction geotextile, and backfilling with crushed surfacing base course, as well as the work detailed in items 1 through 5 noted in Section 5-01.3(4). For the purpose of providing a common Proposal for Bidders, the Contracting Agency has entered an amount in the Proposal to become a part of the total Bid by the Contractor. All costs associated with the containment, collection and disposal of concrete slurry and grinding residue shall be included in the applicable concrete grinding or cutting items of Work. 2020 Standard Specifications M 41-10 Page 5-15 Bituminous Surface Treatment 5-02 5-02 Bituminous Surface Treatment 5-02.1 Description This Work shall consist of constructing a single or multiple course bituminous surface treatment (BST) in accordance with these Specifications and in conformity with the lines and cross-sections shown in the Plans or as designated by the Engineer. 5-02.1(1) New Construction This method of treatment requires two applications of emulsified asphalt and three applications of aggregate. The first application of emulsified asphalt is applied to an untreated Roadway that is followed with an application of aggregate. The second application of emulsified asphalt is followed with two additional applications of aggregate. 5-02.1(2) Seal Coats This method requires the placing of one application of emulsified asphalt and one or more sizes of aggregate as specified to an existing pavement to seal and rejuvenate the surface and to produce a uniform Roadway surface with acceptable nonskid characteristics. 5-02.1(3) Pavement Sealers – Fog Seal This method of treatment requires an application of emulsified asphalt over an existing or newly constructed pavement as specified. 5-02.2 Materials Materials shall meet the requirements of the following sections: Cationic Emulsified Asphalt 9-02.1(6) Aggregates for Bituminous Surface Treatment 9-03.4 Each source of aggregate for bituminous surface treatment shall be evaluated separately for acceptance in accordance with Section 3-04. 5-02.3 Construction Requirements 5-02.3(1) Equipment The equipment used by the Contractor shall be subject to approval by the Engineer before its use. The distributor shall be capable of uniformly applying emulsified asphalt at the required application temperature and rate. A temperature measuring device shall be capable of reporting the temperature of emulsified asphalt in the tank. A tachometer shall be required to accurately control the application of emulsified asphalt. Distributors shall be equipped with an adjustable spray bar with pressure pump and gauge. The power for operating the pressure pump shall be supplied by a power unit which will provide a uniform spray from each of the nozzles across the spray bar and extensions. The Page 5-16 2020 Standard Specifications M 41-10 5-02 Bituminous Surface Treatment distributor truck shall have a volume control gauge. All reading devices and gauges shall be easily accessible by Inspectors from the ground. Rollers for seal coats shall be self-propelled pneumatic tired rollers. Rollers for new construction shall be a combination of self-propelled pneumatic tired rollers and smooth- wheeled rollers. Each roller shall not weigh less than 12 tons and shall be capable of providing constant contact pressure. Operation of the roller shall be in accordance with the manufacturer’s recommendations. Aggregate spreading equipment shall be self-propelled, supported on at least four pneumatic tires, with an approved device for accurately metering and distributing the aggregate uniformly over the Roadway surface. Spreading equipment shall be so equipped that the operator has positive width control. This control shall allow the operator to adjust the spreading width of aggregates in 6-inch increments without stopping the machine. Brooms shall be motorized and capable of controlling vertical pressure. Other equipment necessary to satisfactorily perform the Work as specified herein or as designated by the Engineer shall be subject to approval by the Engineer before its use in the Work. Additional units shall be used in the Work when, in the opinion of the Engineer, it is considered necessary in order to fulfill the requirements of these Specifications, or to complete the Work within the time specified. 5-02.3(2) Preparation of Roadway Surface 5-02.3(2)A New Construction The existing Roadway surface shall be shaped to a uniform grade and cross-section as shown in the Plans, or as designated by the Engineer. The Roadway shall be dampened, bladed and rolled until the entire Roadway surface shows a uniform grading and conforms to the line, grade, and cross-section shown in the Plans, or as staked. During the operation of blading and rolling, water shall be applied, if necessary, in the amount and at the locations designated by the Engineer. The entire surface shall be rolled with a smooth-wheeled or pneumatic-tired roller, or both, as designated by the Engineer, except that the final rolling shall be accomplished with a smooth-wheeled roller as specified in Section 5-02.3(1). Rolling shall continue until the entire Roadway presents a firm, damp and unyielding surface. Immediately before the first application of emulsified asphalt, the Roadway surface shall be in the following condition: firm and unyielding, damp, free from irregularities and material segregation, and true to line, grade, and cross-section. No traffic will be allowed on the prepared surface until the first application of emulsified asphalt and aggregate has been completed. 2020 Standard Specifications M 41-10 Page 5-17 Bituminous Surface Treatment 5-02 5-02.3(2)B Seal Coats The existing bituminous surface shall be swept with a power broom until it is free from dirt or other foreign matter. Hand push brooms shall be used to clean omissions of the power broom. In addition to power and hand brooms, the use of other equipment may be necessary to thoroughly clean the Roadway prior to the application of emulsified asphalt. Berms created by the removal of dirt or other foreign matter shall be evenly distributed over the fore slope. Repair of existing pavement shall be done in accordance with Section 5-04. The HMA in repaired areas shall be fog sealed. HMA repaired areas may require a second fog seal depending on surface texture as required by the Engineer. The pavement surface shall be dry prior to fog sealing. 5-02.3(2)C Pavement Sealing – Fog Seal Where shown in the Plans or directed by the Engineer, the Contractor shall apply a fog seal. Before application of the fog seal, all surfaces shall be thoroughly cleaned of dust, soil, pavement grindings, and other foreign matter. The existing pavement surface shall be dry. 5-02.3(2)D Soil Residual Herbicide Where shown in the Plans, soil residual herbicide shall be applied in accordance with Section 5-04. Application of the BST shall begin within 24 hours after application of the herbicide. 5-02.3(2)E Crack Sealing Where shown in the Plans, seal cracks and joints in the pavement in accordance with Section 5-04.3(4)A1 and the following: 1. Cracks ¼ inch to 1 inch in width – fill with hot poured sealant. 2. Cracks greater than 1 inch in width – fill with sand slurry. Page 5-18 2020 Standard Specifications M 41-10 5-03 Vacant 5-02.3(3) Application of Emulsified Asphalt and Aggregate Upon the properly prepared Roadway surface, emulsified asphalt of the grade specified in the Special Provisions shall be uniformly applied with distributors and specified aggregates spread at the following rates: Application Rate Undiluted Emulsified Asphalt (gal. per sq. yd.) Applied Aggregate Size Aggregate Application Rate (lbs. per sq. yd.) New Construction First Application 0.35-0.65 ½ inch - No. 4 or ¾ inch - ½ inch 25-45 Second Application 0.35-0.60 ½ inch - No. 4 25-40 Choke Stone N/A No. 4 - 0 4-6 Seal Coats ⅝ inch – No. 4 Choke Stone 0.40-0.65 ⅝ inch - No. 4 No. 4 - 0 25-45 4-6 ½ inch – No. 4 Choke Stone 0.35-0.55 ½ inch - No. 4 No. 4 - 0 20-35 4-6 ⅜ inch – No. 4 0.35-0.55 ⅜ inch - No. 4 20-30 Choke Stone N/A No. 4 - 0 4-6 The Engineer will determine the application rates. The second application of emulsified asphalt shall be applied the next day, or as approved by the Engineer. Longitudinal joints will be allowed at only the centerline of the Roadway, the center of the driving lanes, or the edge of the driving lanes. To ensure uniform distribution of emulsified asphalt and that the distributor is correctly calibrated, the Contractor shall provide a minimum 1,000-foot test strip when beginning a BST section. To avoid gaps and ridges at transverse junctions of separate applications of emulsified asphalt and aggregate, the Contractor shall spread sufficient building paper over the treated surface to ensure that the distributor will be functioning normally when the untreated surface is reached. If ordered by the Engineer, the joints shall be cut back to a neat edge prior to placing the building paper. Should ridges, overlaps, or gaps occur at transverse joints, the Contractor shall repair the defects to the satisfaction of the Engineer. In lieu of repair the Engineer may elect to accept the completed joints and will deduct from monies due or that may become due the Contractor, the sum of $200 for each joint where the deviations described above are found. Should longitudinal joints occur outside the centerline of the Roadway, the center of the driving lanes, or the edge of the driving lanes, the Contractor shall repair the defects to the satisfaction of the Engineer. 2020 Standard Specifications M 41-10 Page 5-19 Bituminous Surface Treatment 5-02 All costs involved in making the corrections to defects described above shall be borne by the Contractor and no payment will be made for this Work. Omissions (skips) by the distributor or tire marks on the uncovered emulsified asphalt shall be immediately covered by hand patching with the same grade of emulsified asphalt and aggregate used on the project. The area covered by any one spread of emulsified asphalt shall be no more than can be covered with aggregate within 1 minute from the time of application upon any part of the spread. If field conditions warrant, this time may be increased as designated by the Project Engineer. Unless otherwise designated by the Engineer, emulsified asphalt shall be spread toward the source of aggregate to avoid injury to the freshly treated surface. Before application to the Roadway, emulsified asphalt shall be heated to the following temperatures or that recommended by the manufacturer: Type and Grade of Emulsified Asphalt Distributor Temperature Min. °F Max. °F New Construction and Seal Coats CRS-1, CRS-2, CRS-2P 125 195 CMS-2, CMS-2S, CMS-2h 125 185 Fog Seal CSS-1, CSS-1h 70 140 Before application of the fog seal, all surfaces shall be thoroughly cleaned of dust, soil, pavement grindings, and other foreign matter. The fog seal emulsified asphalt shall be CSS-1 or CSS-1h diluted with water at a rate of one part water to one part emulsified asphalt unless otherwise approved by the Engineer. The fog seal shall be uniformly applied to the pavement at a diluted rate of 0.10 – 0.18 gal/sy. The finished application shall be free of streaks and bare spots. Fog sealing shall be applied no sooner than 3 days, but no later than 14 days after new construction or seal coat. If required, newly placed aggregates shall be swept prior to the fog seal application. Rebrooming for fog seal applications shall be paid under “Additional Brooming”, per hour as specified in Section 5-02.5. 5-02.3(4) Vacant Page 5-20 2020 Standard Specifications M 41-10 5-02 Bituminous Surface Treatment 5-02.3(5) Application of Aggregates All aggregate stockpiles shall be watered down to provide aggregates that are uniformly damp at the time of placement on the Roadway. After the emulsified asphalt has been spread evenly over the Roadway surface, aggregates of the type specified shall be evenly applied to the Roadway surface by spreader equipment. The aggregate shall be spread in one operation in such a manner that an 8-inch strip of emulsified asphalt is left exposed along the longitudinal joint to form a lap for the succeeding applications of emulsified asphalt. If necessary, thin or bare spots in the spread of aggregate shall be corrected immediately by re-spreading with the chip spreader or by hand spreading the aggregate. A minimum of three pneumatic tired rollers providing a minimum of two complete coverages to the Roadway immediately behind the spreading equipment for the coarse aggregate shall be required. The maximum rate of roller travel shall be limited to 8 mph. The Contractor shall apply choke stone to the Roadway with additional spreading equipment immediately following the initial rolling of the coarse aggregate unless otherwise specified in the Contract documents or specified by the Engineer. Excess aggregate shall be removed from the Roadway. A minimum of one pass with a pneumatic roller shall be made across the entire width of the applied choke stone. The operation of trucks hauling aggregate from the stockpile shall be so regulated that no damage, as determined by the Engineer, will result to the Highway or the freshly applied asphalt surface. The completed surface shall be allowed to cure and then broomed as soon as practical. If brooming causes rock to be turned or if the Engineer determines that additional cure is needed, the Contractor shall broom the Roadway when directed by the Engineer. If, after completion of the initial brooming, the Engineer determines the need to remobilize for additional brooming, the Contractor shall rebroom the areas designated by the Engineer. The Contractor shall apply water for dust control during brooming operations when safety or environmental concerns arise, or as otherwise determined by the Project Engineer. The Contractor shall be held responsible for protecting all surface waters, riparian habitats, or other sensitive areas that may be encroached upon by brooming operations. Materials such as dirt, foreign material, or aggregates removed from these areas shall become the property of the Contractor and shall be disposed of in accordance with Section 2-03.3(7). 2020 Standard Specifications M 41-10 Page 5-21 Bituminous Surface Treatment 5-02 The Contractor shall use a pickup broom in all curbed areas, on all bridges, within city limits, within sensitive areas, and where shown in the Plans both before the application of emulsified asphalt and during the final brooming operation. When the pickup broom does not satisfactorily pickup the aggregate, manual methods shall be used. Materials collected by the pick up broom shall become the property of the Contractor and shall be disposed of in accordance with Section 2-03.3(7). Aggregates accumulated in intersections and driveways due to brooming operations shall become the property of the Contractor and shall be disposed of in accordance with Section 2-03.3(7). The Contractor shall notify the Engineer when the brooming for each section is considered complete. The Engineer will indicate acceptance or inform the Contractor of deficiencies within 24 hours of notification. 5-02.3(6) Additional Emulsified Asphalt and Aggregate If the application of emulsified asphalt or aggregate, or both, is insufficient or excessive for the required results, the Engineer may require the Contractor to make an additional application of one or both materials in accordance with these Specifications, or at the direction of the Engineer. Additional emulsified asphalt or aggregate used will be paid for at the unit Contract prices for the materials used. 5-02.3(7) Patching and Correction of Defects Omissions by the distributor or damage to the treated surface of any coat shall be immediately covered by hand patching with emulsified asphalt in adequate quantities. Holes which develop in the surface shall be patched in the same manner as specified in Section 5-02.3(2)A. All costs incurred by the Contractor, in coating omissions and patching, shall be included in the unit Contract prices for the materials used. Defects such as raveling, lack of uniformity, or other imperfections caused by faulty workmanship shall be corrected and new Work shall not be started until such defects have been remedied. All improper workmanship and defective materials resulting from overheating, improper handling or application, shall be removed from the Roadway by the Contractor and be replaced with approved materials and workmanship at no expense to the Contracting Agency. If the Engineer determines a fog seal is necessary at any time during the life of the Contract, the Contractor shall apply a fog seal. The CSS-1 or CSS-1h emulsified asphalt may be diluted with water at a rate of one part water to one part emulsified asphalt unless otherwise specified by the Engineer. Page 5-22 2020 Standard Specifications M 41-10 5-02 Bituminous Surface Treatment 5-02.3(8) Progress of Work The Contractor shall organize the Work so that no longitudinal joints shall remain open overnight. 5-02.3(9) Protection of Structures The Contractor shall be responsible for protecting monument covers, sewer lids, manhole covers, water valve covers, drainage grates, inlets, railroad tracks, bridge handrails and expansion joints, guardrails, curbs, road signs, guide posts, or other facilities from the application of emulsified asphalt and aggregates. This protective effort is to include uncovering these items the same working day that the completed BST or seal coat construction has passed the protected locations. If needed, drainage inlets shall be cleaned out immediately after final brooming is completed. All costs incurred by the Contractor in necessary protective measures shall be included in the unit Contract prices for the various Bid items of Work involved. 5-02.3(10) Unfavorable Weather Emulsified asphalt shall not be applied to a wet Roadway. Subject to the determination of the Engineer, emulsified asphalt shall not be applied during rainfall, sand or dust storms, or before any imminent storms that might damage the construction. The Engineer will have the discretion as to whether the surface and materials are dry enough to proceed with construction. The application of any emulsified asphalt to the Roadway shall be restricted to the following conditions: 1. The Roadway surface temperature shall be at least 55ºF. The air temperature shall be at least 60ºF and rising. The air temperature shall be not less than 70ºF when falling and the wind shall be less than 10 mph as estimated by the Engineer. 2. The surface temperature shall be not more than 130º F or as otherwise determined by the Engineer. 3. No emulsified asphalt shall be applied which cannot be covered 1 hour before darkness. The Engineer may require the Contractor to delay application of emulsified asphalt until the atmospheric and Roadway conditions are satisfactory. 4. Construction of bituminous surface treatments shall not be carried out before May 1 or after August 31 of any year except upon written order of the Project Engineer. 5-02.3(11) Temporary Pavement Markings During bituminous surface treatment paving operations, temporary pavement markings shall be maintained throughout the project. Temporary pavement markings shall be installed on the Roadway that was paved that day. Temporary pavement markings shall be in accordance with Section 8-23. 2020 Standard Specifications M 41-10 Page 5-23 Bituminous Surface Treatment 5-02 5-02.4 Measurement Processing and finishing will be measured by the mile to the nearest 0.01 mile along the main line Roadway. All related supplemental Roadways and irregular shaped areas will be incidental. Emulsified asphalt of the grade or grades specified will be measured by the ton in accordance with Section 1-09. Asphalt for fog seal will be measured by the ton, before dilution, in accordance with Section 1-09. Aggregate from stockpile for BST will be measured by the cubic yard in trucks at the point of delivery on the Roadway. Furnishing and placing crushed aggregate will be measured by the cubic yard in trucks at the point of delivery on the Roadway, or by the ton in accordance with Section 1-09.1. Additional brooming will be measured by the hour. Water will be measured in accordance with Section 2-07. 5-02.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Processing and Finishing”, per mile. The unit Contract price per mile for “Processing and Finishing” shall be full pay for all costs to perform the specified Work including blading, scarifying, processing, leveling, finishing, and the manipulation of aggregates as required. In the event the Proposal does not include a Bid item for “Processing and Finishing” then all costs for processing and finishing shall be included in other related items of Work. “Emulsified Asphalt (_______)”, per ton. The unit Contract price per ton for “Emulsified Asphalt (_______) shall be full pay for all costs to perform the specified Work including furnishing, heating, hauling, and spreading the emulsified asphalt on the Roadway. “Asphalt for Fog Seal”, per ton. The unit Contract price per ton for “Asphalt for Fog Seal” shall be full pay for all costs to perform the specified Work for fog seal. “Agg. from Stockpile for BST”, per cubic yard. The unit Contract price per cubic yard for “Aggregate from Stockpile for BST” shall be full pay for all costs to perform the specified Work including loading, transporting, and placing the material in the finished Work. “Furnishing and Placing Crushed (_______)”, per cubic yard. “Furnishing and Placing Crushed (_______)”, per ton. Page 5-24 2020 Standard Specifications M 41-10 5-02 Bituminous Surface Treatment The unit Contract price per cubic yard or per ton for “Furnishing and Placing Crushed (_______) shall be full pay for all costs to perform the specified Work including furnishing, transporting, and placing the material in the finished Work. “Additional Brooming”, per hour. The unit Contract price per hour for “Additional Brooming” shall be full pay for all costs to perform the specified Work including rebrooming the Roadway. “Water”, per M gal. Payment for “Water” shall be in accordance with Section 2-07.5. If the Proposal does not include a Bid item for water, the Contractor shall dampen stockpiled or furnished aggregate as required, and the cost thereof shall be included in other related items of the Work. Any incidental Work required to complete the bituminous surface treatment that is not specifically mentioned as included with the Bid items above shall be performed by the Contractor and shall be included in the unit Contract prices of the various related Bid items. 2020 Standard Specifications M 41-10 Page 5-25 Vacant 5-03 5-03 Vacant Page 5-26 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04 Hot Mix Asphalt This Section 5-04 is written in a style which, unless otherwise indicated, shall be interpreted as direction to the Contractor. 5-04.1 Description This Work consists of providing and placing one or more layers of plant-mixed hot mix asphalt (HMA) on a prepared foundation or base, in accordance with these Specifications and the lines, grades, thicknesses, and typical cross-sections shown in the Plans. The manufacture of HMA may include additives or processes that reduce the optimum mixing temperature (Warm Mix Asphalt) or serve as a compaction aid in accordance with these Specifications. HMA shall be composed of asphalt binder and mineral materials as required, and may include reclaimed asphalt pavement (RAP) or reclaimed asphalt shingles (RAS), mixed in the proportions specified to provide a homogeneous, stable, and workable mix. 5-04.2 Materials Provide materials as specified in these sections: Asphalt Binder 9-02.1(4) Cationic Emulsified Asphalt 9-02.1(6) Anti-Stripping Additive 9-02.4 HMA Additive 9-02.5 Aggregates 9-03.8 Reclaimed Asphalt Pavement (RAP) 9-03.8(3)B Reclaimed Asphalt Shingles (RAS) 9-03.8(3)B Mineral Filler 9-03.8(5) Recycled Material 9-03.21 Joint Sealants 9-04.2 Closed Cell Foam Backer Rod 9-04.2(3)A 5-04.2(1) How to Get an HMA Mix Design on the QPL Comply with each of the following: • Develop the mix design in accordance with WSDOT SOP 732. • Develop a mix design that complies with Sections 9-03.8(2) and 9-03.8(6). • Develop a mix design no more than 6 months prior to submitting it for QPL evaluation. • Submit mix designs to the WSDOT State Materials Laboratory in Tumwater, including WSDOT Form 350-042. • Include representative samples of the materials that are to be used in the HMA production as part of the mix design submittal. 2020 Standard Specifications M 41-10 Page 5-27 Hot Mix Asphalt 5-04 • Identify the brand, type, and percentage of anti-stripping additive in the mix design submittal. • Include with the mix design submittal a certification from the asphalt binder supplier that the anti-stripping additive is compatible with the crude source and the formulation of asphalt binder proposed for use in the mix design. • Do not include HMA additives that reduce the optimum mixing temperature or serve as a compaction aid when developing a mix design or submitting a mix design for QPL evaluation. The use of HMA additives is not part of the process for obtaining approval for listing a mix design on the QPL. Refer to Section 5-04.2(2)B. The Contracting Agency’s basis for approving, testing, and evaluating HMA mix designs for approval on the QPL is dependent on the contractual basis for acceptance of the HMA mixture, as shown in Table 1. Table 1 Basis for Contracting Agency Evaluation of HMA Mix Designs for Approval on the QPL Contractual Basis for Acceptance of HMA Mixture [see Section 5-04.3(9)] Basis for Contracting Agency Approval of Mix Design for Placement on QPL Contracting Agency Materials Testing for Evaluation of the Mix Design Statistical Evaluation WSDOT Standard Practice QC-8 located in the WSDOT Materials Manual M 46-01 The Contracting Agency will test the mix design materials for compliance with Sections 9-03.8(2) and 9-03.8(6). Visual Evaluation Review of Form 350-042 for compliance with Sections 9-03.8(2) and 9-03.8(6)) The Contracting Agency may elect to test the mix design materials, or evaluate in accordance with WSDOT Standard Practice QC-8, at its sole discretion. If the Contracting Agency approves the mix design, it will be listed on the QPL for 12 consecutive months. The Contracting Agency may extend the 12 month listing provided the Contractor submits a certification letter to the Qualified Products Engineer verifying that the aggregate source and job mix formula (JMF) gradation, and asphalt binder crude source and formulation have not changed. The Contractor may submit the certification no sooner than three months prior to expiration of the initial 12 month mix design approval. Within 7 calendar days of receipt of the Contractor’s certification, the Contracting Agency will update the QPL. The maximum duration for approval of a mix design and listing on the QPL will be 24 months from the date of initial approval or as approved by the Engineer. Page 5-28 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.2(1)A Mix Designs Containing RAP and/or RAS Mix designs are classified by the RAP and/or RAS content as shown in Table 2. Table 2 Mix Design Classification Based on RAP/RAS Content RAP/RAS Classification RAP/RAS Content1 Low RAP/No RAS 0% ≤ RAP% ≤ 20% and RAS% = 0% High RAP/Any RAS 20% < RAP% ≤ Maximum Allowable RAP2 and/or 0% < RAS% ≤ Maximum Allowable RAS2 1Percentages in this table are by total weight of HMA. 2See Table 4 in Section 5-04.2(1)A2 to determine the limits on the maximum amount RAP and/or RAS. 5-04.2(1)A1 Low RAP/No RAS – Mix Design Submittals for Placement on QPL For Low RAP/No RAS mix designs, comply with the following additional requirements: 1. Develop the mix design with or without the inclusion of RAP. 2. The asphalt binder grade shall be the grade indicated in the Bid item name or as otherwise required by the Contract. 3. Submit samples of RAP if used in development of the mix design. 4. Testing RAP or RAS stockpiles is not required for obtaining approval for placing these mix designs on the QPL. 5-04.2(1)A2 High RAP/Any RAS – Mix Design Submittals for Placement on QPL For High RAP/Any RAS mix designs, comply with the following additional requirements: 1. For mix designs with any RAS, test the RAS stockpile (and RAP stockpile if any RAP is in the mix design) in accordance with Table 3. 2. For High RAP mix designs with no RAS, test the RAP stockpile in accordance with Table 3. 3. For mix designs with High RAP/Any RAS, construct a single stockpile for RAP and a single stockpile for RAS and isolate (sequester) these stockpiles from further stockpiling before beginning development of the mix design. Test the RAP and RAS during stockpile construction as required by item 1 and 2 above. Use the test data in developing the mix design, and report the test data to The Contracting Agency on WSDOT Form 350-042 as part of the mix design submittal for approval on the QPL. Account for the reduction in asphalt binder contributed from RAS in accordance with AASHTO PP 78. Do not add to these stockpiles after starting the mix design process. 2020 Standard Specifications M 41-10 Page 5-29 Hot Mix Asphalt 5-04 Table 3 Test Frequency of RAP/RAS During RAP/RAS Stockpile Construction For Approving a High RAP/Any RAS Mix Design for Placement on the QPL Test Frequency1 Test for Test Method • 1/1000 tons of RAP (minimum of 10 per mix design) and • 1/100 tons of RAS (minimum of 10 per mix design) Asphalt Binder Content and Sieve Analysis of Fine and Coarse Aggregate FOP for AASHTO T 308 and FOP for AASHTO T 30/T 11 1“tons”, in this table, refers to tons of the reclaimed material before being incorporated into HMA. 4. Limit the amount of RAP and/or RAS used in a High RAP/Any RAS mix design by the amount of binder contributed by the RAP and/or RAS, in accordance with Table 4. Table 4 Maximum Amount of RAP and/or RAS in HMA Mixture Maximum Amount of Binder Contributed from: RAP RAS 40%1 minus contribution of binder from RAS 20%2 1 Calculated as the weight of asphalt binder contributed from the RAP as a percentage of the total weight of asphalt binder in the mixture. 2 Calculated as the weight of asphalt binder contributed from the RAS as a percentage of the total weight of asphalt binder in the mixture. 5. Develop the mix design including RAP, RAS, recycling agent, and new binder. 6. Extract, recover, and test the asphalt residue from the RAP and RAS stockpiles to determine the percent of recycling agent and/or grade of new asphalt binder needed to meet but not exceed the performance grade (PG) of asphalt binder required by the Contract. a. Perform the asphalt extraction in accordance with AASHTO T 164 or ASTM D 2172 using reagent grade solvent. b. Perform the asphalt recovery in accordance with AASHTO R 59 or ASTM D 1856. c. Test the recovered asphalt residue in accordance with AASHTO R 29 to determine the asphalt binder grade in accordance with Section 9-02.1(4). d. After determining the recovered asphalt binder grade, determine the percent of recycling agent and/or grade of new asphalt binder in accordance with ASTM D 4887. Page 5-30 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt e. Test the final blend of recycling agent, binder recovered from the RAP and RAS, and new asphalt binder in accordance with AASHTO R 29. The final blended binder shall meet but not exceed the performance grade of asphalt binder required by the Contract and comply with the requirements of Section 9-02.1(4). 7. Include the following test data with the mix design submittal: a. All test data from RAP and RAS stockpile construction. b. All data from testing the recovered and blended asphalt binder. 8. Include representative samples of the following with the mix design submittal: a. RAP and RAS. b. 150 grams of recovered asphalt residue from the RAP and RAS that are to be used in the HMA production. 5-04.2(1)B Commercial HMA – Mix Design Submittal for Placement on QPL For HMA used in the Bid item Commercial HMA, in addition to the requirements of Section 5-04.2(1) identify the following in the submittal: 1. Commercial HMA 2. Class of HMA 3. Performance grade of binder 4. Equivalent Single Axle Load (ESAL) The Contracting Agency may elect to approve Commercial HMA mix designs without evaluation. 5-04.2(1)C Mix Design Resubmittal for QPL Approval Develop a new mix design and resubmit for approval on the QPL when any of the following changes occur. When these occur, discontinue using the mix design until after it is reapproved on the QPL. 1. Change in the source of crude petroleum used in the asphalt binder. 2. Changes in the asphalt binder refining process. 3. Changes in modifiers used in the asphalt binder. 4. Changes in the anti-strip additive, brand, type or quantity. 5. Changes to the source of material for aggregate. 6. Changes to the job mix formula that exceed the amounts as described in item 2 of Section 9-03.8(7), unless otherwise approved by the Engineer. 2020 Standard Specifications M 41-10 Page 5-31 Hot Mix Asphalt 5-04 7. Changes in the percentage of material from a stockpile, when such changes exceed 5 percent of the total aggregate weight. a. For Low RAP/No RAS mix designs developed without RAP, changes to the percentage of material from a stockpile will be calculated based on the total aggregate weight not including the weight of RAP. b. For Low RAP/No RAS mix designs developed with RAP, changes to the percentage of material from a stockpile will be calculated based on the total aggregate weight including the weight of RAP. c. For High RAP/Any RAS mix designs, changes in the percentage of material from a stockpile will be based on total aggregate weight including the weight of RAP (and/or RAS when included in the mixture). Prior to making any change in the amount of RAS in an approved mix design, notify the Engineer for determination of whether a new mix design is required, and obtain the Engineer’s approval prior to implementing such changes. 5-04.2(2) Mix Design – Obtaining Project Approval Use only mix designs listed on the Qualified Products List (QPL). Submit WSDOT Form 350-041 to the Engineer to request approval to use a mix design from the QPL. Changes to the job mix formula (JMF) that have been approved on other contracts may be included. The Engineer may reject a request to use a mix design if production of HMA using that mix design on any contract is not in compliance with Section 5-04.3(11)D, E, F, and G for mixture or compaction. 5-04.2(2)A Changes to the Job Mix Formula The approved mix design obtained from the QPL will be considered the starting job mix formula (JMF) and shall be used as the initial basis for acceptance of HMA mixture, as detailed in Section 5-04.3(9). During production the Contractor may request to adjust the JMF. Any adjustments to the JMF will require approval of the Engineer and shall be made in accordance with item 2 of Section 9-03.8(7). After approval by the Engineer, such adjusted JMFs shall constitute the basis for acceptance of the HMA mixture. 5-04.2(2)B Using HMA Additives The Contractor may, at the Contractor’s discretion, elect to use additives that reduce the optimum mixing temperature or serve as a compaction aid for producing HMA. Additives include organic additives, chemical additives, and foaming processes. The use of Additives is subject to the following: • Do not use additives that reduce the mixing temperature in accordance with Section 5-04.3(6) in the production of High RAP/Any RAS mixtures. • Before using additives, obtain the Engineer’s approval using WSDOT Form 350-076 to describe the proposed additive and process. Page 5-32 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.3 Construction Requirements 5-04.3(1) Weather Limitations Do not place HMA for wearing course on any Traveled Way beginning October 1st through March 31st of the following year, without written concurrence from the Engineer. Do not place HMA on any wet surface, or when the average surface temperatures are less than those specified in Table 5, or when weather conditions otherwise prevent the proper handling or finishing of the HMA. Table 5 Minimum Surface Temperature for Paving Compacted Thickness (Feet)Wearing Course Other Courses Less than 0.10 55°F 45°F 0.10 to 0.20 45°F 35°F More than 0.20 35°F 35°F 5-04.3(2) Paving Under Traffic These requirements apply when the Roadway being paved is open to traffic. In hot weather, the Engineer may require the application of water to the pavement to accelerate the finish rolling of the pavement and to shorten the time required before reopening to traffic. During paving operations, maintain temporary pavement markings throughout the project. Install temporary pavement markings on the Roadway prior to opening to traffic. Temporary pavement markings shall comply with Section 8-23. 5-04.3(3) Equipment 5-04.3(3)A Mixing Plant Equip mixing plants as follows: 1. Use tanks for storage and preparation of asphalt binder which: • Heat the contents by means that do not allow flame to contact the contents or the tank, such as by steam or electricity. • Heat and hold contents at the required temperatures. • Continuously circulate contents to provide uniform temperature and consistency during the operating period. • Provide an asphalt binder sampling valve, in either the storage tank or the supply line to the mixer. 2020 Standard Specifications M 41-10 Page 5-33 Hot Mix Asphalt 5-04 2. Provide thermometric equipment: • In the asphalt binder feed line near the charging valve at the mixer unit, capable of detecting temperature ranges expected in the HMA and in a location convenient and safe for access by Inspectors. • At the discharge chute of the drier to automatically register or indicate the temperature of the heated aggregates, and situated in full view of the plant operator. 3. When heating asphalt binder: • Do not exceed the maximum temperature of the asphalt binder recommended by the asphalt binder supplier. • Avoid local variations in heating. • Provide a continuous supply of asphalt binder to the mixer at a uniform average temperature with no individual variations exceeding 25°F. 4. Provide a mechanical sampler for sampling mineral materials that: • Meets the crushing or screening requirements of Section 1-05.6. 5. Provide HMA sampling equipment that complies with FOP for AASHTO T 168: • Use a mechanical sampling device accepted by the Engineer, or • Platforms or devices to enable sampling from the truck transport without entering the truck transport for sampling HMA. 6. Provide for setup and operation of the Contracting Agency’s field testing: • As required in Section 3-01.2(2). 7. Provide screens or a lump breaker: • When using any RAP or any RAS, to eliminate oversize RAP or RAS particles from entering the pug mill or drum mixer. 5-04.3(3)B Hauling Equipment Provide HMA hauling equipment with tight, clean, smooth metal beds and a cover of canvas or other suitable material of sufficient size to protect the HMA from adverse weather. Securely attach the cover to protect the HMA whenever the weather conditions during the work shift include, or are forecast to include, precipitation or an air temperature less than 45°F. Prevent HMA from adhering to the hauling equipment. Spray metal beds with an environmentally benign release agent. Drain excess release agent prior to filling hauling equipment with HMA. Do not use petroleum derivatives or other coating material that contaminate or alter the characteristics of the HMA. For hopper trucks, operate the conveyer during the process of applying the release agent. Page 5-34 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.3(3)C Pavers Use self-contained, power-propelled pavers provided with an internally heated vibratory screed that is capable of spreading and finishing courses of HMA in lane widths required by the paving section shown in the Plans. When requested by the Engineer, provide written certification that the paver is equipped with the most current equipment available from the manufacturer for the prevention of segregation of the coarse aggregate particles. The certification shall list the make, model, and year of the paver and any equipment that has been retrofitted to the paver. Operate the screed in accordance with the manufacturer’s recommendations and in a manner to produce a finished surface of the required evenness and texture without tearing, shoving, segregating, or gouging the mixture. Provide a copy of the manufacturer’s recommendations upon request by the Contracting Agency. Extensions to the screed will be allowed provided they produce the same results, including ride, density, and surface texture as obtained by the primary screed. In the Traveled Way do not use extensions without both augers and an internally heated vibratory screed. Equip the paver with automatic screed controls and sensors for either or both sides of the paver. The controls shall be capable of sensing grade from an outside reference line, sensing the transverse slope of the screed, and providing automatic signals that operate the screed to maintain the desired grade and transverse slope. Construct the sensor so it will operate from a reference line or a mat referencing device. The transverse slope controller shall be capable of maintaining the screed at the desired slope within plus or minus 0.1 percent. Equip the paver with automatic feeder controls, properly adjusted to maintain a uniform depth of material ahead of the screed. Manual operation of the screed is permitted in the construction of irregularly shaped and minor areas. These areas include, but are not limited to, gore areas, road approaches, tapers and left-turn channelizations. When specified in the Contract, provide reference lines for vertical control. Place reference lines on both outer edges of the Traveled Way of each Roadway. Horizontal control utilizing the reference line is permitted. Automatically control the grade and slope of intermediate lanes by means of reference lines or a mat referencing device and a slope control device. When the finish of the grade prepared for paving is superior to the established tolerances and when, in the opinion of the Engineer, further improvement to the line, grade, cross-section, and smoothness can best be achieved without the use of the reference line, a mat referencing device may be substituted for the reference line. Substitution of the device will be subject to the continued approval of the Engineer. A joint matcher may be used subject to the approval of the Engineer. The reference line may be removed after completion of the first course of HMA when approved by the Engineer. Whenever the Engineer determines that any of these methods are failing to provide the necessary vertical control, the reference lines will be reinstalled by the Contractor. 2020 Standard Specifications M 41-10 Page 5-35 Hot Mix Asphalt 5-04 Furnish and install all pins, brackets, tensioning devices, wire, and accessories necessary for satisfactory operation of the automatic control equipment. If the paving machine in use is not providing the required finish, the Engineer may suspend Work as allowed by Section 1-08.6. 5-04.3(3)D Material Transfer Device or Material Transfer Vehicle Use a material transfer device (MTD) or material transfer vehicle (MTV) to deliver the HMA from the hauling equipment to the paving machine for any lift in (or partially in) the top 0.30 feet of the pavement section used in traffic lanes. However, an MTD/V is not required for HMA placed in irregularly shaped and minor areas such as tapers and turn lanes, or for HMA mixture that is accepted by Visual Evaluation. At the Contractor’s request the Engineer may approve paving without an MTD/V; the Engineer will determine if an equitable adjustment in cost or time is due. If a windrow elevator is used, the Engineer may limit the length of the windrow in urban areas or through intersections. To be approved for use, an MTV: 1. Shall be self-propelled vehicle, separate from the hauling vehicle or paver. 2. Shall not be connected to the hauling vehicle or paver. 3. May accept HMA directly from the haul vehicle or pick up HMA from a windrow. 4. Shall mix the HMA after delivery by the hauling equipment and prior to placement into the paving machine. 5. Shall mix the HMA sufficiently to obtain a uniform temperature throughout the mixture. To be approved for use, an MTD: 1. Shall be positively connected to the paver. 2. May accept HMA directly from the haul vehicle or pick up HMA from a windrow. 3. Shall mix the HMA after delivery by the hauling equipment and prior to placement into the paving machine. 4. Shall mix the HMA sufficiently to obtain a uniform temperature throughout the mixture. 5-04.3(3)E Rollers Operate rollers in accordance with the manufacturer’s recommendations. When requested by the Engineer, provide a Type 1 Working Drawing of the manufacturer’s recommendation for the use of any roller planned for use on the project. Do not use rollers that crush aggregate, produce pickup or washboard, unevenly compact the surface, displace the mix, or produce other undesirable results. Page 5-36 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.3(4) Preparation of Existing Paved Surfaces Before constructing HMA on an existing paved surface, the entire surface of the pavement shall be clean. Entirely remove all fatty asphalt patches, grease drippings, and other deleterious substances from the existing pavement to the satisfaction of the Engineer. Thoroughly clean all pavements or bituminous surfaces of dust, soil, pavement grindings, and other foreign matter. Thoroughly remove any cleaning or solvent type liquids used to clean equipment spilled on the pavement before paving proceeds. Fill all holes and small depressions with an appropriate class of HMA. Level and thoroughly compact the surface of the patched area. Apply a uniform coat of asphalt (tack coat) to all paved surfaces on which any course of HMA is to be placed or abutted. Apply tack coat to cover the cleaned existing pavement with a thin film of residual asphalt free of streaks and bare spots. Apply a heavy application of tack coat to all joints. For Roadways open to traffic, limit the application of tack coat to surfaces that will be paved during the same working shift. Equip the spreading equipment with a thermometer to indicate the temperature of the tack coat material. Do not operate equipment on tacked surfaces until the tack has broken and cured. Repair tack coat damaged by the Contractor’s operation, prior to placement of the HMA. Unless otherwise allowed by the Engineer, use cationic emulsified asphalt CSS-1, CSS-1h, or Performance Graded (PG) asphalt for tack coat. The CSS-1 and CSS-1h may be diluted with water at a rate not to exceed one part water to one part emulsified asphalt. Do not allow the tack coat material to exceed the maximum temperature recommended by the asphalt supplier. When shown in the Plans, prelevel uneven or broken surfaces over which HMA is to be placed by using an asphalt paver, a motor patrol grader, or by hand raking, as approved by the Engineer. 5-04.3(4)A Crack Sealing 5-04.3(4)A1 General When the Proposal includes a pay item for crack sealing, seal all cracks ¼ inch in width and greater. Cleaning: Ensure that cracks are thoroughly clean, dry and free of all loose and foreign material when filling with crack sealant material. Use a hot compressed air lance to dry and warm the pavement surfaces within the crack immediately prior to filling a crack with the sealant material. Do not overheat pavement. Do not use direct flame dryers. Routing cracks is not required. Sand Slurry: For cracks that are to be filled with sand slurry, thoroughly mix the components and pour the mixture into the cracks until full. Add additional CSS-1 cationic emulsified asphalt to the sand slurry as needed for workability to ensure the mixture will completely fill the cracks. Strike off the sand slurry flush with the existing pavement 2020 Standard Specifications M 41-10 Page 5-37 Hot Mix Asphalt 5-04 surface and allow the mixture to cure. Top off cracks that were not completely filled with additional sand slurry. Do not place the HMA overlay until the slurry has fully cured. Hot Poured Sealant: For cracks that are to be filled with hot poured sealant, apply the material in accordance with these requirements and the manufacturer’s recommendations. Furnish a Type 1 Working Drawing of the manufacturer’s product information and recommendations to the Engineer prior to the start of work, including the manufacturer’s recommended heating time and temperatures, allowable storage time and temperatures after initial heating, allowable reheating criteria, and application temperature range. Confine hot poured sealant material within the crack. Clean any overflow of sealant from the pavement surface. If, in the opinion of the Engineer, the Contractor’s method of sealing the cracks with hot poured sealant results in an excessive amount of material on the pavement surface, stop and correct the operation to eliminate the excess material. 5-04.3(4)A2 Crack Sealing Areas Prior to Paving In areas where HMA will be placed, use sand slurry to fill the cracks. 5-04.3(4)A3 Crack Sealing Areas Not to be Paved In areas where HMA will not be placed, fill the cracks as follows: 1. Cracks ¼ inch to 1 inch in width - fill with hot poured sealant. 2. Cracks greater than 1 inch in width – fill with sand slurry. 5-04.3(4)B Soil Residual Herbicide Where shown in the Plans, apply one application of an approved soil residual herbicide. Comply with Section 8-02.3(3)B. Complete paving within 48 hours of applying the herbicide. Use herbicide registered with the Washington State Department of Agriculture for use under pavement. Before use, obtain the Engineer’s approval of the herbicide and the proposed rate of application. Include the following information in the request for approval of the material: 1. Brand Name of the Material, 2. Manufacturer, 3. Environmental Protection Agency (EPA) Registration Number, 4. Material Safety Data Sheet, and 5. Proposed Rate of Application. Page 5-38 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.3(4)C Pavement Repair Excavate pavement repair areas and backfill these with HMA in accordance with the details shown in the Plans and as staked. Conduct the excavation operations in a manner that will protect the pavement that is to remain. Repair pavement not designated to be removed that is damaged as a result of the Contractor’s operations to the satisfaction of the Engineer at no cost to the Contracting Agency. Excavate only within one lane at a time unless approved otherwise by the Engineer. Do not excavate more area than can be completely backfilled and compacted during the same shift. Unless otherwise shown in the Plans or determined by the Engineer, excavate to a depth of 1.0 feet. The Engineer will make the final determination of the excavation depth required. The minimum width of any pavement repair area shall be 40 inches unless shown otherwise in the Plans. Before any excavation, sawcut the perimeter of the pavement area to be removed unless the pavement in the pavement repair area is to be removed by a pavement grinder. Excavated materials shall be the property of the Contractor and shall be disposed of in a Contractor-provided site off the Right of Way or used in accordance with Sections 2-02.3(3) or 9-03.21. Apply a heavy application of tack coat to all surfaces of existing pavement in the pavement repair area, in accordance with Section 5-04.3(4). Place the HMA backfill in lifts not to exceed 0.35-foot compacted depth. Thoroughly compact each lift by a mechanical tamper or a roller. 5-04.3(5) Producing/Stockpiling Aggregates, RAP, & RAS Produce aggregate in compliance with Section 3-01. Comply with Section 3-02 for preparing stockpile sites, stockpiling, and removing from stockpile each of the following: aggregates, RAP, and RAS. Provide sufficient storage space for each size of aggregate, RAP and RAS. Fine aggregate or RAP may be uniformly blended with the RAS as a method of preventing the agglomeration of RAS particles. Remove the aggregates, RAP and RAS from stockpile(s) in a manner that ensures minimal segregation when being moved to the HMA plant for processing into the final mixture. Keep different aggregate sizes separated until they have been delivered to the HMA plant. 5-04.3(5)A Stockpiling RAP or RAS for High RAP/Any RAS Mixes Do not place any RAP or RAS into a stockpile which has been sequestered for a High RAP/Any RAS mix design. Do not incorporate any RAP or RAS into a High RAP/Any RAS mixture from any source other than the stockpile which was sequestered for approval of that particular High RAP/Any RAS mix design. RAP that is used in a Low RAP/No RAS mix is not required to come from a sequestered stockpile. 2020 Standard Specifications M 41-10 Page 5-39 Hot Mix Asphalt 5-04 5-04.3(6) Mixing The asphalt supplier shall introduce recycling agent and anti-stripping additive, in the amount designated on the QPL for the mix design, into the asphalt binder prior to shipment to the asphalt mixing plant. Anti-strip is not required for temporary work that will be removed prior to Physical Completion. Use asphalt binder of the grade, and from the supplier, in the approved mix design. Prior to introducing reclaimed materials into the asphalt plant, remove wire, nails, and other foreign material. Discontinue use of the reclaimed material if the Engineer, in their sole discretion, determines the wire, nails, or other foreign material to be excessive. Size RAP and RAS prior to entering the mixer to provide uniform and thoroughly mixed HMA. If there is evidence of the RAP or RAS not breaking down during the heating and mixing of the HMA, immediately suspend the use of the RAP or RAS until changes have been approved by the Engineer. After the required amount of mineral materials, RAP, RAS, new asphalt binder and recycling agent have been introduced into the mixer, mix the HMA until complete and uniform coating of the particles and thorough distribution of the asphalt binder throughout the mineral materials, RAP and RAS is ensured. Upon discharge from the mixer, ensure that the temperature of the HMA does not exceed the optimum mixing temperature shown on the accepted Mix Design Report by more than 25°F, or as allowed by the Engineer. When an additive is included in the manufacture of HMA, do not heat the additive (at any stage of production including in binder storage tanks) to a temperature higher than the maximum recommended by the manufacturer of the additive. A maximum water content of 2 percent in the mix, at discharge, will be allowed providing the water causes no problems with handling, stripping, or flushing. If the water in the HMA causes any of these problems, reduce the moisture content. During the daily operation, HMA may be temporarily held in approved storage facilities. Do not incorporate HMA into the Work that has been held for more than 24 hours after mixing. Provide an easily readable, low bin-level indicator on the storage facility that indicates the amount of material in storage. Waste the HMA in storage when the top level of HMA drops below the top of the cone of the storage facility, except as the storage facility is being emptied at the end of the working shift. Dispose of rejected or waste HMA at no expense to the Contracting Agency. Page 5-40 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.3(7) Spreading and Finishing Do not exceed the maximum nominal compacted depth of any layer in any course, as shown in Table 6, unless approved by the Engineer: Table 6 Maximum Nominal Compacted Depth of Any Layer HMA Class Wearing Course Other than Wearing Course 1 inch 0.35 feet 0.35 feet ¾ and ½ inch 0.30 feet 0.35 feet ⅜ inch 0.25 feet 0.30 feet Use HMA pavers complying with Section 5-04.3(3) to distribute the mix. On areas where irregularities or unavoidable obstacles make the use of mechanical spreading and finishing equipment impractical, the paving may be done with other equipment or by hand. When more than one JMF is being utilized to produce HMA, place the material produced for each JMF with separate spreading and compacting equipment. Do not intermingle HMA produced from more than one JMF. Each strip of HMA placed during a work shift shall conform to a single JMF established for the class of HMA specified unless there is a need to make an adjustment in the JMF. 5-04.3(8) Aggregate Acceptance Prior to Incorporation in HMA Sample aggregate for meeting the requirements of Section 3-04 prior to being incorporated into HMA. (The acceptance data generated for the Section 3-04 acceptance analysis will not be commingled with the acceptance data generated for the Section 5-04.3(9) acceptance analysis.) Aggregate acceptance samples shall be taken as described in Section 3-04. Aggregate acceptance testing will be performed by the Contracting Agency. Aggregate contributed from RAP and/or RAS will not be evaluated under Section 3-04. The Contracting Agency’s combined aggregate bulk specific gravity (Gsb) blend as shown on the HMA Mix Design will be used for VMA calculations until the contactor submits a written request for a Gsb test. The new Gsb will be used in the VMA calculations for HMA from the date the Project Engineer receives the written request for a Gsb retest. The Contractor may request aggregate specific gravity (Gsb) testing be performed by the Contracting Agency twice per project. The Gsb blend of the combined stockpiles will be used to calculate voids in mineral aggregate (VMA) of any HMA produced after the new Gsb is determined. For aggregate that will be used in HMA mixture which will be accepted by Statistical Evaluation, the Contracting Agency’s acceptance of the aggregate will be based on: 1. Samples taken prior to mixing with asphalt binder, RAP, or RAS; 2. Testing for the materials properties of fracture, uncompacted void content, and sand equivalent; 2020 Standard Specifications M 41-10 Page 5-41 Hot Mix Asphalt 5-04 3. Evaluation by the Contracting Agency in accordance with Section 3-04, including price adjustments as described therein. For aggregate that will be used in HMA which will be accepted by Visual Evaluation, evaluation in accordance with items 1, 2, and 3 above is at the discretion of the Engineer. 5-04.3(9) HMA Mixture Acceptance The Contracting Agency will evaluate HMA mixture for acceptance by one of two methods as determined from the criteria in Table 7. Table 7 Basis of Acceptance for HMA Mixture Visual Evaluation Statistical Evaluation Criteria for Selecting the Evaluation Method • Commercial HMA placed at any location • Any HMA placed in: – sidewalks – road approaches – ditches – slopes – paths – trails – gores – prelevel – temporary pavement1 – pavement repair • Other nonstructural applications of HMA as approved by the Engineer • All HMA mixture other than that accepted by Visual Evaluation 1 Temporary pavement is HMA that will be removed before Physical Completion of the Contract. 5-04.3(9)A Test Sections This section applies to HMA mixture accepted by Statistical Evaluation. A test section is not allowed for HMA accepted by Visual Evaluation. The purpose of a test section is to determine whether or not the Contractor’s mix design and production processes will produce HMA meeting the Contract requirements related to mixture. Construct HMA mixture test sections at the beginning of paving, using at least 600 tons and a maximum of 1,000 tons or as specified by the Engineer. Each test section shall be constructed in one continuous operation. 5-04.3(9)A1 Test Section – When Required, When to Stop Use Tables 8 and 9 to determine when a test section is required, optional, or not allowed, and to determine when performing test sections may end. Each mix design will be evaluated independently for the test section requirements. If more than one test section is required, each test section shall be evaluated separately by the criteria in Tables 8 and 9. Page 5-42 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt Table 8 Criteria for Conducting and Evaluating HMA Mixture Test Sections (For HMA Mixture Accepted by Statistical Evaluation) High RAP/Any RAS Low RAP/No RAS Is Mixture Test Section Optional or Mandatory?Mandatory1 At Contractor’s Option Waiting period after paving the test section.4 calendar days2 4 calendar days2 What Must Happen to Stop Performing Test Sections? Meet “Results Required to Stop Performing Test Sections” in Table 9 for High RAP/Any RAS. Provide samples and respond to WSDOT test results required by Table 9 for Low RAP/No RAS. 1 If a mix design has produced an acceptable test section on a previous contract (paved in the same calendar year, from the same plant, using the same JMF) the test section may be waived if approved by the Engineer. 2 This is to provide time needed by the Contracting Agency to complete testing and the Contractor to adjust the mixture in response to those test results. Paving may resume when this is done. Table 9 Results Required to Stop Performing HMA Mixture Test Sections1 (For HMA Mixture Accepted by Statistical Evaluation) Test Property Type of HMA High RAP/Any RAS Low RAP/No RAS Gradation Minimum PFi of 0.95 based on the criteria in Section 5-04.3(9)B42 None4 Asphalt Binder Minimum PFi of 0.95 based on the criteria in Section 5-04.3(9)B42 None4 VMA Minimum PFi of 0.95 based on the criteria in Section 5-04.3(9)B42 None4 Va Minimum PFi of 0.95 based on the criteria in Section 5-04.3(9)B42 None4 Hamburg Wheel Track Indirect Tensile Strength Meet requirements of Section 9-03.8(2)3 These tests will not be done as part of Test Section. Aggregates Sand Equivalent Uncompacted Void Content Fracture Nonstatistical Evaluation in accordance with the requirements of Section 3-043 None3 1 In addition to the requirements of this table, acceptance of the HMA mixture used in each test section is subject to the acceptance criteria and price adjustments for Statistical Evaluation (see Table 9a in Section 5-04.3(9)A2). 2 Divide the test section lot into three sublots, approximately equal in size. Take one sample from each sublot, and test each sample for the properties in the first column. 3 Take one sample for each test section lot. Test the sample for the property in the first column. 4 Divide the test section lot into three sublots, approximately equal in size. Take one sample from each sublot, and test each sample for the property in the first column. There are no criteria for discontinuing test sections for these mixes; however, the contractor must comply with Section 5-04.3(11)F before resuming paving. 2020 Standard Specifications M 41-10 Page 5-43 Hot Mix Asphalt 5-04 5-04.3(9)A2 Test Section – Evaluating the HMA Mixture in a Test Section The Engineer will evaluate the HMA mixture in each test section for rejection, acceptance, and price adjustments based on the criteria in Table 9a using the data generated from the testing required by Table 9 in Section 5-04.3(9)A1. Each test section shall be considered a separate lot. Table 9a Acceptance Criteria for HMA Mixture Placed in a Test Section (For HMA Mixture Accepted by Statistical Evaluation) Test Property Type of HMA High RAP/Any RAS Low RAP/No RAS Gradation, Asphalt Binder, VMA and Va Statistical Evaluation Statistical Evaluation Hamburg Wheel Track Indirect Tensile Strength Pass/Fail for the requirements of Section 9-03.8(2)1 N/A Aggregates Sand Equivalent Uncompacted Void Content Fracture Nonstatistical Evaluation in accordance with the requirements of Section 3-04 Nonstatistical Evaluation in accordance with the requirements of Section 3-04 1Failure to meet the specifications for Hamburg and/or IDT will cause the mixture in the test section to be rejected. Refer to Section 5-04.3(11). 5-04.3(9)B Mixture Acceptance – Statistical Evaluation 5-04.3(9)B1 Mixture Statistical Evaluation – Lots and Sublots HMA mixture which is accepted by Statistical Evaluation will be evaluated by the Contracting Agency dividing that HMA tonnage into mixture lots, and each mixture lot will be evaluated using stratified random sampling by the Contracting Agency sub-dividing each mixture lot into mixture sublots. All mixture in a mixture lot shall be of the same mix design. The mixture sublots will be numbered in the order in which the mixture (of a particular mix design) is paved. Each mixture lot comprises a maximum of 15 mixture sublots, except: • The final mixture lot of each mix design on the Contract will comprise a maximum of 25 sublots. • A mixture lot for a test section will consist of three sublots. Each mixture sublot shall be approximately uniform in size with the maximum mixture sublot size as specified in Table 10. The quantity of material represented by the final mixture sublot of the project, for each mix design on the project, may be increased to a maximum of two times the mixture sublot quantity calculated. Page 5-44 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt Table 10 Maximum HMA Mixture Sublot Size For HMA Accepted by Statistical Evaluation HMA Original Plan Quantity (tons)1 Maximum Sublot Size (tons)2 < 20,000 1,000 20,000 to 30,000 1,500 >30,000 2,000 1“Plan quantity” means the plan quantity of all HMA of the same class and binder grade which is accepted by Statistical Evaluation. 2The maximum sublot size for each combination of HMA class and binder grade shall be calculated separately. • For a mixture lot in progress with a mixture CPF less than 0.75, a new mixture lot will begin at the Contractor’s request after the Engineer is satisfied that material conforming to the Specifications can be produced. See also Section 5-04.3(11)F. • If, before completing a mixture lot, the Contractor requests a change to the JMF which is approved by the Engineer, the mixture produced in that lot after the approved change will be evaluated on the basis of the changed JMF, and the mixture produced in that lot before the approved change will be evaluated on the basis of the unchanged JMF; however, the mixture before and after the change will be evaluated in the same lot. Acceptance of subsequent mixture lots will be evaluated on the basis of the changed JMF. 5-04.3(9)B2 Mixture Statistical Evaluation – Sampling Comply with Section 1-06.2(1). Samples of HMA mixture which is accepted by Statistical Evaluation will be randomly selected from within each sublot, with one sample per sublot. The Engineer will determine the random sample location using WSDOT Test Method T 716. The Contractor shall obtain the sample when ordered by the Engineer. The Contractor shall sample the HMA mixture in the presence of the Engineer and in accordance with FOP for AASHTO 168. 5-04.3(9)B3 Mixture Statistical Evaluation – Acceptance Testing Comply with Section 1-06.2(1). The Contracting Agency will test the mixture sample from each sublot (including sublots in a test section) for the properties shown in Table 11. Table 11 Testing Required for each HMA Mixture Sublot Test Procedure Performed by VMA and Va WSDOT SOP 731 Engineer Asphalt Binder Content FOP for AASHTO T 308 Engineer Gradation: percent Passing 1½″, 1″, ¾″, ½″, ⅜″, No. 4, No. 8, No. 200 FOP for AASHTO T 30/T 11 Engineer 2020 Standard Specifications M 41-10 Page 5-45 Hot Mix Asphalt 5-04 The mixture samples and tests taken for the purpose of determining acceptance of the test section (as described in Section 5-04.3(9)A) shall also be used as the test results for acceptance of the mixture described in Sections 5-04.3(9)B3, 5-04.3(9)B4, 5-04.3(9)B5, and 5-04.3(9)B6. 5-04.3(9)B4 Mixture Statistical Evaluation – Pay Factors Comply with Section 1-06.2(2). The Contracting Agency will determine a pay factor (PFi) for each of the properties in Table 11 of Section 5-04.3(9)B3, for each mixture lot, using the quality level analysis in Section 1-06.2(2)D. For Gradation, a pay factor will be calculated for each of the sieve sizes listed in Table 11 of Section 5-04.3(9)B3, which is equal to or smaller than the maximum allowable aggregate size (100 percent passing sieve) of the HMA mixture. The USL and LSL shall be calculated using the Job Mix Formula Tolerances (for Statistical Evaluation) in Section 9-03.8(7). If a constituent is not measured in accordance with these Specifications, its individual pay factor will be considered 1.00 in calculating the Composite Pay Factor (CPF). 5-04.3(9)B5 Mixture Statistical Evaluation – Composite Pay Factors (CPF) Comply with Section 1-06.2(2). In accordance with Section 1-06.2(2)D4, the Contracting Agency will determine a Composite Pay Factor (CPF) for each mixture lot from the pay factors calculated in Section 5-04.3(9)B4, using the price adjustment factors in Table 12. Unless otherwise specified, the maximum CPF for HMA mixture shall be 1.05. Table 12 HMA Mixture Price Adjustment Factors Constituent Factor “f” All aggregate passing: 1½″, 1″, ¾″, ½″, ⅜″ and No.4 sieves 2 All aggregate passing No. 8 sieve 15 All aggregate passing No. 200 sieve 20 Asphalt binder 40 Voids in Mineral Aggregate (VMA)2 Air Voids (Va)20 Page 5-46 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.3(9)B6 Mixture Statistical Evaluation – Price Adjustments For each HMA mixture lot, a Job Mix Compliance Price Adjustment will be determined and applied, as follows: JMCPA = [0.60 × (CPF – 1.00)] × Q × UP Where JMCPA = Job Mix Compliance Price Adjustment for a given lot of mixture ($) CPF = Composite Pay Factor for a given lot of mixture (maximum is 1.05) Q = Quantity in a given lot of mixture (tons) UP = Unit price of the HMA in a given lot of mixture ($/ton) 5-04.3(9)B7 Mixture Statistical Evaluation – Retests The Contractor may request that a mixture sublot be retested. To request a retest, submit a written request to the Contracting Agency within 7 calendar days after the specific test results have been posted to the website or emailed to the Contractor, whichever occurs first. The Contracting Agency will send a split of the original acceptance sample for testing by the Contracting Agency to either the Region Materials Laboratory or the State Materials Laboratory as determined by the Engineer. The Contracting Agency will not test the split of the sample with the same equipment or by the same tester that ran the original acceptance test. The sample will be tested for a complete gradation analysis, asphalt binder content, VMA and Va, and the results of the retest will be used for the acceptance of the HMA mixture in place of the original mixture sublot sample test results. The cost of testing will be deducted from any monies due or that may come due the Contractor under the Contract at the rate of $250 per sample. 5-04.3(9)C Vacant 5-04.3(9)D Mixture Acceptance – Visual Evaluation Visual Evaluation of HMA mixture will be by visual inspection by the Engineer or, in the sole discretion of the Engineer, the Engineer may sample and test the mixture. 5-04.3(9)D1 Mixture Visual Evaluation – Lots, Sampling, Testing, Price Adjustments HMA mixture accepted by Visual Evaluation will not be broken into lots unless the Engineer determines that testing is required. When that occurs, the Engineer will identify the limits of the questionable HMA mixture, and that questionable HMA mixture shall constitute a lot. Then, the Contractor will take samples from the truck, or the Engineer will take core samples from the roadway at a minimum of three random locations from within the lot, selected in accordance with WSDOT Test Method T 716, taken from the roadway in accordance with WSDOT SOP 734, and tested in accordance with WSDOT SOP 737. The Engineer will test one of the samples for all constituents in Section 5-04.3(9)B3. If all constituents from that test fall within the Job Mix Formula Tolerances (for Visual Evaluation) in Section 9-03.8(7), the lot will be accepted at the unit Contract price with no further evaluation. 2020 Standard Specifications M 41-10 Page 5-47 Hot Mix Asphalt 5-04 When one or more constituents fall outside those tolerance limits, the other samples will be tested for all constituents in Section 5-04.3(9)B3, and a Job Mix Compliance Price Adjustment will be calculated in accordance with Table 13. Table 13 Visual Evaluation – Out of Tolerance Procedures Comply with the Following1 Pay Factors1 Section 5-04.3(9)B4 Composite Pay Factors2 Section 5-04.3(9)B5 Price Adjustments Section 5-04.3(9)B6 1The Visual Evaluation tolerance limits in Section 9-03.8(7) will be used in the calculation of the PFi. 2The maximum CPF shall be 1.00. 5-04.3(9)E Mixture Acceptance – Notification of Acceptance Test Results The results of all mixture acceptance testing and the Composite Pay Factor (CPF) of the lot after three sublots have been tested will be available to the Contractor through the Contracting Agency’s website. The Contracting Agency will endeavor to provide written notification (via email to the Contractor’s designee) of acceptance test results through its web-based materials testing system Statistical Analysis of Materials (SAM) within 24 hours of the sample being made available to the Contracting Agency. However, the Contractor agrees: 1. Quality control, defined as the system used by the Contractor to monitor, assess, and adjust its production processes to ensure that the final HMA mixture will meet the specified level of quality, is the sole responsibility of the Contractor. 2. The Contractor has no right to rely on any testing performed by the Contracting Agency, nor does the Contractor have any right to rely on timely notification by the Contracting Agency of the Contracting Agency’s test results (or statistical analysis thereof), for any part of quality control and/or for making changes or correction to any aspect of the HMA mixture. 3. The Contractor shall make no claim for untimely notification by the Contracting Agency of the Contracting Agency’s test results or statistical analysis. 5-04.3(10) HMA Compaction Acceptance For all HMA, the Contractor shall comply with the General Compaction Requirements in Section 5-04.3(10)A. The Contracting Agency will evaluate all HMA for compaction compliance with one of the following - Statistical Evaluation, Visual Evaluation, or Test Point Evaluation - determined by the criteria in Table 14: Page 5-48 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt Table 14 Criteria for Determining Method of Evaluation for HMA Compaction1 Statistical Evaluation of HMA Compaction is Required For: Visual Evaluation of HMA Compaction is Required For: Test Point Evaluation of HMA Compaction is Required For: • Any HMA for which the specified course thickness is greater than 0.10 feet, and the HMA is in: – traffic lanes, including but not limited to: • ramp lanes • truck climbing lanes • weaving lanes • speed change lanes • “HMA for Preleveling…” • “HMA for Pavement Repair…” • Any HMA not meeting the criteria for Statistical Evaluation or Visual Evaluation 1 This table applies to all HMA, and shall be the sole basis for determining the acceptance method for compaction. The Contracting Agency may, at its sole discretion, evaluate any HMA for compliance with the Cyclic Density requirements of Section 5-04.3(10)B. 5-04.3(10)A HMA Compaction – General Compaction Requirements Immediately after the HMA has been spread and struck off, and after surface irregularities have been adjusted, thoroughly and uniformly compact the mix. The completed course shall be free from ridges, ruts, humps, depressions, objectionable marks, and irregularities and shall conform to the line, grade, and cross-section shown in the Plans. If necessary, alter the JMF in accordance with Section 9-03.8(7) to achieve desired results. Compact the mix when it is in the proper condition so that no undue displacement, cracking, or shoving occurs. Compact areas inaccessible to large compaction equipment by mechanical or hand tampers. Remove HMA that becomes loose, broken, contaminated, shows an excess or deficiency of asphalt, or is in any way defective. Replace the removed material with new HMA, and compact it immediately to conform to the surrounding area. The type of rollers to be used and their relative position in the compaction sequence shall generally be the Contractor’s option, provided the specified densities are attained. An exception shall be that pneumatic tired rollers shall be used for compaction of the wearing course beginning October 1st of any year through March 31st of the following year. Coverage with a steel wheel roller may precede pneumatic tired rolling. Unless otherwise approved by the Engineer, operate rollers in the static mode when the internal temperature of the mix is less than 175°F. Regardless of mix temperature, do not operate a roller in a mode that results in checking or cracking of the mat. On bridge decks and on roadway approaches within five feet of a bridge/back of pavement seat, rollers shall not be operated in a vibratory mode, defined as a mode in which the drum vibrates vertically. However, unless otherwise noted on the plans, rollers may be operated in an oscillatory mode, defined as a mode in which the drum vibrates in the horizontal direction only. 2020 Standard Specifications M 41-10 Page 5-49 Hot Mix Asphalt 5-04 5-04.3(10)B HMA Compaction – Cyclic Density Low cyclic density areas are defined as spots or streaks in the pavement that are less than 90 percent of the theoretical maximum density. At the Engineer’s discretion, the Engineer may evaluate the HMA pavement for low cyclic density, and when doing so will follow WSDOT SOP 733. A $500 Cyclic Density Price Adjustment will be assessed for any 500-foot section with two or more density readings below 90 percent of the theoretical maximum density. 5-04.3(10)C HMA Compaction Acceptance – Statistical Evaluation HMA compaction which is accepted by Statistical Evaluation will be based on acceptance testing performed by the Contracting Agency, and statistical analysis of those acceptance tests results. This will result in a Compaction Price Adjustment. 5-04.3(10)C1 HMA Compaction Statistical Evaluation – Lots and Sublots HMA compaction which is accepted by Statistical Evaluation will be evaluated by the Contracting Agency dividing the project into compaction lots, and each compaction lot will be evaluated using stratified random sampling by the Contracting Agency sub-dividing each compaction lot into compaction sublots. All mixture in any individual compaction lot shall be of the same mix design. The compaction sublots will be numbered in the order in which the mixture (of a particular mix design) is paved. Each compaction lot comprises a maximum of 15 compaction sublots, except for the final compaction lot of each mix design on the Contract, which comprises a maximum of 25 sublots. Each compaction sublot shall be uniform in size as shown in Table 15, except that the last compaction sublot of each day may be increased to a maximum of two times the compaction sublot quantity calculated. Minor variations in the size of any sublot shall not be cause to invalidate the associated test result. Table 15 HMA Compaction Sublot Size HMA Original Plan Quantity (tons)1 Compaction Sublot Size (tons) <20,000 100 20,000 to 30,000 150 >30,000 200 1In determining the plan quantity tonnage, do not include any tons accepted by test point evaluation. Page 5-50 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt The following will cause one compaction lot to end prematurely and a new compaction lot to begin: • For a compaction lot in progress with a compaction CPF less than 0.75 using an LSL = 91.5, a new compaction lot will begin at the Contractor’s request after the Engineer is satisfied that material conforming to the Specifications can be produced. See also Section 5-04.3(11)F. All HMA which is paved on a bridge and accepted for compaction by Statistical Evaluation will compose a bridge compaction lot. If the contract includes such HMA on more than one bridge, compaction will be evaluated on each bridge individually, as separate bridge compaction lots. Bridge compaction sublots will be determined by the Engineer subject to the following: • All sublots on a given bridge will be approximately the same size. • Sublots will be stratified from the lot. • In no case will there be less than 3 sublots in each bridge compaction lot. • No sublot will exceed 50 tons. • Compaction test locations will be determined by the Engineer in accordance with WSDOT Test Method T 716. 5-04.3(10)C2 HMA Compaction Statistical Evaluation – Acceptance Testing Comply with Section 1-06.2(1). The location of HMA compaction acceptance tests will be randomly selected by the Contracting Agency from within each sublot, with one test per sublot. The Contracting Agency will determine the random sample location using WSDOT Test Method T 716. Use Table 16 to determine compaction acceptance test procedures and to allocate compaction acceptance sampling and testing responsibilities between the Contractor and the Contracting Agency. HMA cores shall be taken or nuclear density testing shall occur after completion of the finish rolling, prior to opening to traffic, and on the same day that the mix is placed. 2020 Standard Specifications M 41-10 Page 5-51 Hot Mix Asphalt 5-04 Table 16 HMA Compaction Acceptance Testing Procedures and Responsibilities When Contract Includes Bid Item “HMA Core – Roadway” or “HMA Core – Bridge”4 When Contract Does Not Include Bid Item “HMA Core – Roadway” or “HMA Core – Bridge”4 Basis for Test:Cores Cores3 Nuclear Density Gauge3 In-Place Density Determined by: Contractor shall take cores1 using WSDOT SOP 7342 Contracting Agency will determine core density using FOP for AASHTO T 166 Contracting Agency will take cores1 using WSDOT SOP 734 Contracting Agency will determine core density using FOP for AASHTO T 166 Contracting Agency, using FOP for AASHTO T 355 Theoretical Maximum Density Determined by: Contracting Agency, using FOP for AASHTO T 209 Rolling Average of Theoretical Maximum Densities Determined by: Contracting Agency, using WSDOT SOP 729 Percent Compaction in Each Sublot Determined by: Contracting Agency, using WSDOT SOP 736 Contracting Agency, using WSDOT SOP 736 Contracting Agency, using FOP for AASHTO T 355 1 The core diameter shall be 4-inches unless otherwise approved by the Engineer. 2 The Contractor shall take the core samples in the presence of the Engineer, at locations designated by the Engineer, and deliver the core samples to the Contracting Agency. 3 The Contracting Agency will determine, in its sole discretion, whether it will take cores or use the nuclear density gauge to determine in-place density. Exclusive reliance on cores for density acceptance is generally intended for small paving projects and is not intended as a replacement for nuclear gauge density testing on typical projects. 4 The basis for test of all compaction sublots in a bridge compaction lot shall be cores. These cores shall be taken by the Contractor when the Proposal includes the bid item “HMA Cores – Bridge”. When there is no bid item for “HMA Cores – Bridge”, the Engineer will be responsible for taking HMA cores for all compaction sublots in a bridge compaction lot. In either case, the Engineer will determine core location, in-place density of the core, theoretical maximum density, rolling average of theoretical maximum density, and percent compaction using the procedure called for in this section. When using the nuclear density gauge for acceptance testing of pavement density, the Engineer will follow WSDOT SOP 730 for correlating the nuclear gauge with HMA cores. When cores are required for the correlation, coring and testing will be by the Contracting Agency. When a core is taken for gauge correlation at the location of a sublot, the relative density of the core will be used for the sublot test result and is exempt from retesting. Page 5-52 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.3(10)C3 HMA Statistical Compaction – Price Adjustments For each HMA compaction lot (that is accepted by Statistical Evaluation) which has less than three compaction sublots, for which all compaction sublots attain a minimum of 91 percent compaction determined in accordance with FOP for AASHTO T 355 (or WSDOT SOP 736 when provided by the Contract), the HMA will be accepted at the unit Contract price with no further evaluation. For each HMA compaction lot (that is accepted by Statistical Evaluation) which does not meet the criteria in the preceding paragraph, the compaction lot shall be evaluated in accordance with Section 1-06.2(2)D5 to determine the appropriate Composite Pay Factor (CPF). All of the test results obtained from the acceptance samples from a given compaction lot shall be evaluated collectively. Additional testing by either a nuclear density gauge or cores will be completed as required to provide a minimum of three tests for evaluation. Determine the Compaction Price Adjustment (CPA) from the table below, selecting the equation for CPA that corresponds to the value of CPF determined above. Calculating HMA Compaction Price Adjustment (CPA) Value of CPF Equation for Calculating CPA When CPF > 1.00 CPA = [1.00 × (CPF – 1.00)] × Q × UP When CPF = 1.00 CPA = $0 When CPF < 1.0 CPA = [0.60 × (CPF – 1.00)] × Q × UP Where CPA = Compaction Price Adjustment for the compaction lot ($) CPF = Composite Pay Factor for the compaction lot (maximum is 1.05) Q = Quantity in the compaction lot (tons) UP = Unit price of the HMA in the compaction lot ($/ton) 5-04.3(10)C4 HMA Statistical Compaction – Requests for Retesting For a compaction sublot that has been tested with a nuclear density gauge that did not meet the minimum of 91.5 percent of the theoretical maximum density in a compaction lot with a CPF below 1.00 and thus subject to a price reduction or rejection, the Contractor may request that a core, taken at the same location as the nuclear density test, be used for determination of the relative density of the compaction sublot. The relative density of the core will replace the relative density determined by the nuclear density gauge for the compaction sublot and will be used for calculation of the CPF and acceptance of HMA compaction lot. When cores are taken by the Contracting Agency at the request of the Contractor, they shall be requested by noon of the next workday after the test results for the compaction sublot have been provided or made available to the Contractor. Traffic control shall be provided by the Contractor as requested by the Engineer. Failure by the Contractor to provide the requested traffic control will result in forfeiture of the request for retesting. When the CPF for the compaction lot based on the results of the cores is less than 1.00, the Contracting Agency will deduct the cost for the coring from any monies due or that may become due the Contractor under the Contract at the rate of $200 per core and the Contractor shall pay for the cost of the traffic control. 2020 Standard Specifications M 41-10 Page 5-53 Hot Mix Asphalt 5-04 5-04.3(10)D HMA Compaction – Visual Evaluation Visual Evaluation will be the basis of acceptance for compaction of the Bid items “HMA for Pavement Repair Cl. ___ PG ___” and “HMA for Prelevelling Class___ PG___”. This HMA shall be thoroughly compacted to the satisfaction of the Engineer. HMA that is used to prelevel wheel ruts shall be compacted with a pneumatic tire roller. 5-04.3(10)E HMA Compaction – Test Point Evaluation When compaction acceptance is by Test Point Evaluation, compact HMA based on a test point evaluation of the compaction train. Perform the test point evaluation in accordance with instructions from the Engineer. The number of passes with an approved compaction train, required to attain the maximum test point density, shall be used on all subsequent paving. 5-04.3(10)F HMA Compaction Acceptance – Notification of Acceptance Test Results The obligations and responsibilities for notifying the Contractor of compaction acceptance test results are the same as for mixture acceptance test results. See Section 5-04.3(9)E. 5-04.3(11) Reject Work This section applies to HMA and all requirements related to HMA (except aggregates prior to being incorporated into HMA). For rejection of aggregate prior to its incorporation into HMA refer to Section 3-04. 5-04.3(11)A Reject Work – General Work that is defective or does not conform to Contract requirements shall be rejected. The Contractor may propose, in writing, alternatives to removal and replacement of rejected material. Acceptability of such alternative proposals will be determined at the sole discretion of the Engineer. 5-04.3(11)B Rejection by Contractor The Contractor may, prior to acceptance sampling and testing, elect to remove any defective material and replace it with new material. Any such new material will be sampled, tested, and evaluated for acceptance. 5-04.3(11)C Rejection Without Testing (Mixture or Compaction) The Engineer may, without sampling, reject any batch, load, or section of Roadway that appears defective. Material rejected before placement shall not be incorporated into the pavement. No payment will be made for the rejected materials or the removal of the materials unless the Contractor requests the rejected material to be tested. If the Contractor requests testing, acceptance will be by Statistical Evaluation, and a minimum of three samples will be obtained and tested. When uncompacted material is required for testing but Page 5-54 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt not available, the Engineer will determine random sample locations on the roadway in accordance with WSDOT Test Method T 716, take cores in accordance with WSDOT SOP 734, and test the cores in accordance with WSDOT SOP 737. If the CPF for the rejected material is less than 0.75, no payment will be made for the rejected material; in addition, the cost of sampling and testing shall be borne by the Contractor. If the CPF is greater than or equal to 0.75, the cost of sampling and testing will be borne by the Contracting Agency. If the material is rejected before placement and the CPF is greater than or equal to 0.75, compensation for the rejected material will be at a CPF of 0.75. If rejection occurs after placement and the CPF is greater than or equal to 0.75, compensation for the rejected material will be at the calculated CPF with an addition of 25 percent of the unit Contract price added for the cost of removal and disposal. 5-04.3(11)D Rejection – A Partial Sublot (Mixture or Compaction) In addition to the random acceptance sampling and testing, the Engineer may also isolate from a mixture or compaction sublot any material that is suspected of being defective in relative density, gradation or asphalt binder content. Such isolated material will not include an original sample location. The Contracting Agency will obtain a minimum of three random samples of the suspect material and perform the testing. When uncompacted material is required for testing but is not available, the Engineer will select random sample locations on the roadway in accordance with WSDOT Test Method T 716, take cores samples in accordance with WSDOT SOP 734, and test the material in accordance with WSDOT SOP 737. The material will then be statistically evaluated as an independent lot in accordance with Section 1-06.2(2). 5-04.3(11)E Rejection – An Entire Sublot (Mixture or Compaction) An entire mixture or compaction sublot that is suspected of being defective may be rejected. When this occurs, a minimum of two additional random samples from this sublot will be obtained. When uncompacted material is required for the additional samples but the material has been compacted, the Contracting Agency will take and test cores from the roadway as described in Section 5-04.3(11)D. The additional samples and the original sublot will be evaluated as an independent lot in accordance with Section 1-06.2(2). 5-04.3(11)F Rejection - A Lot in Progress (Mixture or Compaction) The Contractor shall shut down operations and shall not resume HMA placement until such time as the Engineer is satisfied that material conforming to the Specifications can be produced when: 1. the Composite Pay Factor (CPF) of a mixture or compaction lot in progress drops below 1.00 and the Contractor is taking no corrective action, or 2. the Pay Factor (PFi) for any constituent of a mixture or compaction lot in progress drops below 0.95 and the Contractor is taking no corrective action, or 3. either the PFi for any constituent (or the CPF) of a mixture or compaction lot in progress is less than 0.75. 2020 Standard Specifications M 41-10 Page 5-55 Hot Mix Asphalt 5-04 5-04.3(11)G Rejection – An Entire Lot (Mixture or Compaction) An entire lot with a CPF of less than 0.75 will be rejected. 5-04.3(12) Joints 5-04.3(12)A HMA Joints 5-04.3(12)A1 Transverse Joints Conduct operations such that the placement of the top or wearing course is a continuous operation or as close to continuous as possible. Unscheduled transverse joints will be allowed, but the roller may pass over the unprotected end of the freshly laid HMA only when the placement of the course is discontinued for such a length of time that the HMA will cool below compaction temperature. When the Work is resumed, cut back the previously compacted HMA to produce a slightly beveled edge for the full thickness of the course. Construct a temporary wedge of HMA on a 50H:1V where a transverse joint as a result of paving or planing is open to traffic. Separate the HMA in the temporary wedge from the permanent HMA upon which it is placed by strips of heavy wrapping paper or other methods approved by the Engineer. Remove the wrapping paper and trim the joint to a slightly beveled edge for the full thickness of the course prior to resumption of paving. Waste the material that is cut away and place new HMA against the cut. Use rollers or tamping irons to seal the joint. 5-04.3(12)A2 Longitudinal Joints Offset the longitudinal joint in any one course from the course immediately below by not more than 6 inches nor less than 2 inches. Locate all longitudinal joints constructed in the wearing course at a lane line or an edge line of the Traveled Way. Construct a notched wedge joint along all longitudinal joints in the wearing surface of new HMA unless otherwise approved by the Engineer. The notched wedge joint shall have a vertical edge of not less than the maximum aggregate size nor more than ½ of the compacted lift thickness, and then taper down on a slope not steeper than 4H:1V. Uniformly compact the sloped portion of the HMA notched wedge joint. On one-lane ramps a longitudinal joint may be constructed at the center of the traffic lane, subject to approval by the Engineer, if: 1. The ramp must remain open to traffic, or 2. The ramp is closed to traffic and a hot-lap joint is constructed. a. Two paving machines shall be used to construct the hot-lap joint. b. The pavement within 6 inches of the hot-lap joint will not be excluded from random location selection for compaction testing. c. Construction equipment other than rollers shall not operate on any uncompacted HMA. Page 5-56 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt When HMA is placed adjacent to cement concrete pavement, construct longitudinal joints between the HMA and the cement concrete pavement. Saw the joint to the dimensions shown on Standard Plan A-40.10 and fill with joint sealant meeting the requirements of Section 9-04.2. 5-04.3(12)B Bridge Paving Joint Seals 5-04.3(12)B1 HMA Sawcut and Seal Prior to placing HMA on the bridge deck, establish sawcut alignment points at both ends of the bridge paving joint seals to be placed at the bridge ends, and at interior joints within the bridge deck when and where shown in the Plans. Establish the sawcut alignment points in a manner that they remain functional for use in aligning the sawcut after placing the HMA overlay. Submit a Type 1 Working Drawing consisting of the sealant manufacturer’s application procedure. Construct the bridge paving joint seal as specified in the Plans and in accordance with the detail shown in the Standard Plans. Construct the sawcut in accordance with Section 5-05.3(8). Apply the sealant in accordance with Section 5-05.3(8)B and the manufacturer’s application procedure. 5-04.3(12)B2 Paved Panel Joint Seal Construct the paved panel joint seal in accordance with the requirements specified in Section 5-04.3(12)B1 and the following requirement: 1. Clean and seal the existing joint between concrete panels in accordance with Section 5-01.3(8) and the details shown in the Standard Plans. 5-04.3(13) Surface Smoothness The completed surface of all courses shall be of uniform texture, smooth, uniform as to crown and grade, and free from defects of all kinds. The completed surface of the wearing course shall not vary more than ⅛ inch from the lower edge of a 10-foot straightedge placed on the surface parallel to the centerline. The transverse slope of the completed surface of the wearing course shall vary not more than ¼ inch in 10 feet from the rate of transverse slope shown in the Plans. When deviations in excess of the above tolerances are found that result from a high place in the HMA, correct the pavement surface by one of the following methods: 1. Remove material from high places by grinding with an approved grinding machine, or 2. Remove and replace the wearing course of HMA, or 3. By other method approved by the Engineer. Correct defects until there are no deviations anywhere greater than the allowable tolerances. 2020 Standard Specifications M 41-10 Page 5-57 Hot Mix Asphalt 5-04 Deviations in excess of the above tolerances that result from a low place in the HMA and deviations resulting from a high place where corrective action, in the opinion of the Engineer, will not produce satisfactory results will be accepted with a price adjustment. The Engineer shall deduct from monies due or that may become due to the Contractor the sum of $500.00 for each and every section of single traffic lane 100 feet in length in which any excessive deviations described above are found. When concrete pavement is to be placed on HMA, the surface tolerance of the HMA shall be such that no surface elevation lies above the Plan grade minus the specified Plan depth of concrete pavement. Prior to placing the concrete pavement, bring any such irregularities to the required tolerance by grinding or other means allowed by the Engineer. When utility appurtenances such as manhole covers and valve boxes are located in the Traveled Way, pave the Roadway before the utility appurtenances are adjusted to the finished grade. 5-04.3(14) Planing Bituminous Pavement Plane in such a manner that the underlying pavement is not torn, broken, or otherwise damaged by the planing operation. Delamination or raveling of the underlying pavement will not be construed as damage due to the Contractor’s operations. Pavement outside the limits shown in the Plans or designated by the Engineer that is damaged by the Contractor’s operations shall be repaired to the satisfaction of the Engineer at no additional cost to the Contracting Agency. For mainline planing operations, use equipment with automatic controls and with sensors for either or both sides of the equipment. The controls shall be capable of sensing the grade from an outside reference line, or a mat-referencing device. The automatic controls shall have a transverse slope controller capable of maintaining the mandrel at the desired transverse slope (expressed as a percentage) within plus or minus 0.1 percent. Remove all loose debris from the planed surface before opening the planed surface to traffic. The planings and other debris resulting from the planing operation shall become the property of the Contractor and be disposed of in accordance with Section 2-03.3(7)C, or as otherwise allowed by the Contract. 5-04.3(15) Sealing Pavement Surfaces Apply a fog seal where shown in the Plans. Construct the fog seal in accordance with Section 5-02.3. Unless otherwise approved by the Engineer, apply the fog seal prior to opening to traffic. 5-04.3(16) HMA Road Approaches Construct HMA approaches at the locations shown in the Plans or where staked by the Engineer, in accordance with Section 5-04. Page 5-58 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt 5-04.4 Measurement HMA Cl. ___ PG ___, HMA for ___ Cl. ___ PG ___, and Commercial HMA will be measured by the ton in accordance with Section 1-09.2, with no deduction being made for the weight of asphalt binder, mineral filler, or any other component of the HMA. If the Contractor elects to remove and replace HMA as allowed by Section 5-04.3(11), the material removed will not be measured. Roadway cores will be measured per each for the number of cores taken. Crack Sealing-LF will be measured by the linear foot along the line of the crack. Soil residual herbicide will be measured by the mile for the stated width to the nearest 0.01 mile or by the square yard, whichever is designated in the Proposal. Pavement repair excavation will be measured by the square yard of surface marked prior to excavation. Asphalt for fog seal will be measured by the ton, as provided in Section 5-02.4. Longitudinal joint seals between the HMA and cement concrete pavement will be measured by the linear foot along the line and slope of the completed joint seal. HMA sawcut and seal, and paved panel joint seal, will be measured by the linear foot along the line and slope of the completed joint seal. Planing bituminous pavement will be measured by the square yard. Temporary pavement marking will be measured by the linear foot as provided in Section 8-23.4. Water will be measured by the M gallon as provided in Section 2-07.4. 5-04.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “HMA Cl. ___ PG ___”, per ton. “HMA for Approach Cl. ___ PG ___”, per ton. “HMA for Preleveling Cl. ___ PG ___”, per ton. “HMA for Pavement Repair Cl. ___ PG ___”, per ton. “Commercial HMA”, per ton. The unit Contract price per ton for “HMA Cl. ___ PG ___”, “HMA for Approach Cl. ___ PG ___”, “HMA for Preleveling Cl. ___ PG ___”, “HMA for Pavement Repair Cl. ___ PG ___”, and “Commercial HMA” shall be full compensation for all costs, including anti- stripping additive, incurred to carry out the requirements of Section 5-04 except for those costs included in other items which are included in this Subsection and which are included in the Proposal. “Crack Sealing-FA”, by force account. 2020 Standard Specifications M 41-10 Page 5-59 Hot Mix Asphalt 5-04 “Crack Sealing-FA” will be paid for by force account as specified in Section 1-09.6. For the purpose of providing a common Proposal for all Bidders, the Contracting Agency has entered an amount in the Proposal to become a part of the total Bid by the Contractor. “Crack Sealing-LF”, per linear foot. The unit Contract price per linear foot for “Crack Sealing-LF” shall be full payment for all costs incurred to perform the Work described in Section 5-04.3(4)A. “Soil Residual Herbicide ____ ft. Wide”, per mile, or “Soil Residual Herbicide”, per square yard. The unit Contract price per mile or per square yard for “Soil Residual Herbicide” shall be full payment for all costs incurred to obtain, provide and install herbicide in accordance with Section 5-04.3(4)B. “Pavement Repair Excavation Incl. Haul”, per square yard. The unit Contract price per square yard for “Pavement Repair Excavation Incl. Haul” shall be full payment for all costs incurred to perform the Work described in Section 5-04.3(4)C with the exception, however, that all costs involved in the placement of HMA shall be included in the unit Contract price per ton for “HMA for Pavement Repair Cl. ___ PG ___”, per ton. “Asphalt for Fog Seal”, per ton. Payment for “Asphalt for Fog Seal” is described in Section 5-02.5. “Longitudinal Joint Seal”, per linear foot. The unit Contract price per linear foot for “Longitudinal Joint Seal” shall be full payment for all costs incurred to construct the longitudinal joint between HMA and cement concrete pavement, as described in Section 5-04.3(12)B. “HMA Sawcut And Seal”, per linear foot. The unit Contract price per linear foot for “HMA Sawcut And Seal” shall be full payment for all costs incurred to perform the Work described in Section 5-04.3(12)B1. “Paved Panel Joint Seal”, per linear foot. The unit Contract price per linear foot for “Paved Panel Joint Seal” shall be full payment for all costs incurred to perform the Work described in Section 5-04.3(12)B2. “Planing Bituminous Pavement”, per square yard. The unit Contract price per square yard for “Planing Bituminous Pavement” shall be full payment for all costs incurred to perform the Work described in Section 5-04.3(14). “Temporary Pavement Marking”, per linear foot. Payment for “Temporary Pavement Marking” is described in Section 8-23.5. Page 5-60 2020 Standard Specifications M 41-10 5-04 Hot Mix Asphalt “Water”, per M gallon. Payment for “Water” is described in Section 2-07.5. “Job Mix Compliance Price Adjustment”, by calculation. “Job Mix Compliance Price Adjustment” will be calculated and paid for as described in Section 5-04.3(9)B6 and 5-04.3(9)D1. “Compaction Price Adjustment”, by calculation. “Compaction Price Adjustment” will be calculated and paid for as described in Section 5-04.3(10)C3. “HMA Core – Bridge”, per each. The unit Contract price per each for “HMA Core – Bridge” shall be full payment for all costs, including traffic control, associated with taking HMA density cores in pavement that is on a bridge deck. “HMA Core – Roadway”, per each. The unit Contract price per each for “HMA Core – Roadway” shall be full payment for all costs, including traffic control, associated with taking HMA density cores in pavement that is not on a bridge deck. “Cyclic Density Price Adjustment”, by calculation. “Cyclic Density Price Adjustment” will be calculated and paid for as described in Section 5-04.3(10)B. 2020 Standard Specifications M 41-10 Page 5-61 Cement Concrete Pavement 5-05 5-05 Cement Concrete Pavement 5-05.1 Description This Work shall consist of constructing a pavement composed of cement concrete on a prepared Subgrade or base in accordance with these Specifications and in conformity with the lines, grades, thicknesses, and typical cross-sections shown in the Plans or established by the Engineer. 5-05.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Fine Aggregate 9-03 Coarse Aggregate 9-03 Combined Aggregate 9-03 Joint Filler 9-04.1 Joint Sealants 9-04.2 Corrosion Resistant Dowel Bars 9-07.5(2) Tie Bars 9-07.6 Concrete Patching Material 9-20.1 Curing Materials and Admixtures 9-23 Water 9-25 Epoxy Resins 9-26 Cementitious materials are considered to be the following: portland cement, blended hydraulic cement, fly ash, ground granulated blast furnace slag, and microsilica fume. 5-05.3 Construction Requirements 5-05.3(1) Concrete Mix Design for Paving The Contractor shall provide a concrete mix design for each design of concrete specified in the Contract. The Contractor shall use ACI 211.1 as a guide to determine proportions. Concrete strength, placement, and workability shall be the responsibility of the Contractor. Following approval of the Contractor’s proposal, all other requirements of Section 5-05 shall apply. 1. Materials – Materials shall conform to Section 5-05.2. Fine aggregate shall conform to Section 9-03.1(2), Class 1. Coarse aggregate shall conform to Section 9-03.1(4), AASHTO grading No. 467. An alternate combined gradation conforming to Section 9-03.1(5) may be proposed, that has a nominal maximum aggregate size equal to or greater than a 1½-inch sieve. Fly ash, if used, shall not exceed 35 percent by weight of the total cementitious material, shall conform to Section 9-23.9 and shall be limited to Class F with a maximum CaO content of 15 percent by weight. Page 5-62 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement Ground granulated blast furnace slag, if used, shall not exceed 30 percent by weight of the total cementitious material and shall conform to Section 9-23.10. When both ground granulated blast furnace slag and fly ash are included in the concrete mix, the total weight of both these materials is limited to 35 percent by weight of the total cementitious material. As an alternative to the use of fly ash, ground granulated blast furnace slag and cement as separate components, a blended hydraulic cement that meets the requirements of Section 9-01.2(1)B Blended Hydraulic Cements may be used. The water/cement ratio shall be calculated on the total weight of cementitious material. Cementitious materials are those listed in Section 5-05.2. The minimum cementitious material for any mix design shall be 564 pounds per cubic yard. 2. Submittals – The Contractor’s submittal shall include the mix proportions per cubic yard, test results from beams and cylinders, and the proposed sources for all ingredients including the fly ash. The mix shall be capable of providing a minimum flexural strength of 650 psi at 14 days. Evaluation of strength shall be based on statistically analyzed results of five beam specimens made according to WSDOT T 808 and tested according to WSDOT T 802 that demonstrate a quality level of not less than 80 percent analyzed in accordance with Section 1-06.2(2)D. In addition the Contractor shall fabricate, cure, and test five sets of cylinders, for evaluation of 28-day strengths, according to FOP for AASHTO T 22 and FOP for AASHTO T 23 using the same mix design as used in fabrication of the beams. Mix designs submitted by the Contractor shall provide a unique identification for each proposal and shall include test data confirming that concrete made in accordance with the proposed design will meet the requirements of these Specifications and the 28-day compressive strength result. Test data shall be from an independent testing lab or from a commercial concrete producer’s lab. If the test data is developed at a producer’s lab, the Engineer or a representative may witness all testing. 3. Mix Design Modifications – The Contractor may initiate adjustments to the aggregate proportions of the approved mix design. An adjustment in both the fine and coarse aggregate batch target weights of plus or minus 200 pounds per cubic yard will be allowed without resubmittal of the mix design. The adjusted aggregate weights shall become the new batch target weights for the mix design. 4. Conformance to Mix Design – Cement and coarse and fine aggregate weights shall be within the following tolerances of the batch target weights of the mix design: Concrete Batch Weights Cement +5%-1% Coarse Aggregate + 2%- 2% Fine Aggregate + 2%- 2% If the total cementitious material weight is made up of different components, these component weights shall be within the following tolerances: 2020 Standard Specifications M 41-10 Page 5-63 Cement Concrete Pavement 5-05 a. Cement weight plus 5 percent or minus 1 percent of that specified in the mix design. b. Fly ash and ground granulated blast furnace slag weight plus or minus 5 percent of that specified in the mix design. c. Microsilica weight plus or minus 10 percent of that specified in the mix design. Water shall not exceed the maximum water specified in the mix design. The Contractor may initiate minor adjustments to the approved mix proportions within the tolerances noted above without resubmitting the mix design. The Contractor shall notify the Engineer in writing of any proposed modification. A new mix design will designate a new lot. 5-05.3(2) Consistency The materials shall be mixed with sufficient water to produce a stiff concrete which will hold its shape when deposited upon the Subgrade. Concrete placed during wet weather must be mixed with sufficient water to produce a very stiff mixture. The consistency shall be such that separation of the mortar from the coarse aggregate will not occur in handling. The water/cementitious material ratio, by weight, shall not exceed 0.44. When slip-form paving equipment is used, the Contractor shall further control concrete consistency to ensure that edge slump conforms to the requirements of Section 5-05.3(11). 5-05.3(3) Equipment Equipment necessary for handling materials and performing all parts of the Work shall conform to the following requirements: 5-05.3(3)A Batching Plant and Equipment 1. General – 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, hopper, and separate scale for cement shall be included. The weighing hoppers shall be properly sealed and vented to preclude dusting during operation. The batching plant shall be equipped with a suitable batch counter that cannot be reset, which will correctly indicate the number of batches proportioned. 2. Bins and Hoppers – Bins with adequate separate compartments for fine aggregate and for each size of the coarse aggregate shall be provided in the batching plant. 5-05.3(3)B Mixing Equipment 1. General – Concrete may be mixed at a batching plant or wholly or in part in truck mixers. 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 and the speed of rotation of the mixing drum or blades. Page 5-64 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement 2. Batching Plant – Mixing shall be in an approved mixer capable of combining the aggregates, cement, and water into a thoroughly mixed and uniform weight within the specified mixing period. Mixers shall be cleaned at suitable intervals. The pickup and throw-over blades in the drum shall be repaired or replaced when they are worn down ¾ inch or more. The Contractor shall have available at the jobsite a copy of the manufacturer’s design, showing dimensions and arrangements of the blades in reference to original height and depth, or provide permanent marks on blades to show points of ¾ inch wear from new conditions. Drilled holes ¼ inch in diameter near each end and at midpoint of each blade are recommended. 3. Truck Mixers and Truck Agitators – Truck mixers used for mixing and hauling concrete, and truck agitators used for hauling plant-mixed concrete, shall conform to the requirements of Section 6-02.3(4)A. 4. Nonagitator Trucks – Bodies of nonagitating hauling equipment for concrete shall be smooth, mortar-tight, metal containers and shall be capable of discharging the concrete at a satisfactory controlled rate without segregation. Covers shall be provided when needed for protection. Plant-mixed concrete may be transported in nonagitated vehicles provided that concrete is in a workable condition when placed and: a. discharge is completed within 45 minutes after the introduction of mixing water to the cement and aggregates, or b. discharge is completed within 60 minutes after the introduction of mixing water to the cement and aggregates, provided the concrete mix temperature is 70°F or below during placement, or c. discharge is completed within 60 minutes after the introduction of mixing water to the cement and aggregates, provided the mix contains an approved set retarder at the manufacturer’s minimum dosage rate. 5-05.3(3)C Finishing Equipment The standard method of constructing concrete pavement on State Highways shall be with approved slip-form paving equipment designed to spread, consolidate, screed, and float-finish the freshly placed concrete in one complete pass of the machine so a dense and homogeneous pavement is achieved with a minimum of hand finishing. On other roads and on WSDOT projects requiring less than 1,000 square yards of cement concrete pavement or requiring individual placement areas of less than 1,000 square yards, irregular areas, intersections, and at locations inaccessible to slip-form paving equipment, cement concrete pavement may be placed with approved placement and finishing equipment utilizing stationary side forms. Hand screeding and float finishing of cement concrete pavement may only be utilized on small irregular areas as allowed by the Engineer. 2020 Standard Specifications M 41-10 Page 5-65 Cement Concrete Pavement 5-05 5-05.3(3)D Joint Sawing Equipment The Contractor shall provide approved power driven concrete saws for sawing joints, adequate in number of units and power to complete the sawing at the required rate. The Contractor shall provide at least one standby saw in good working order. An ample supply of saw blades shall be maintained at the site of the Work at all times during sawing operations. The Contractor shall provide adequate artificial lighting facilities for night sawing. All of this equipment shall be on the job both before and continuously during concrete placement. Sawing equipment shall be available immediately and continuously upon call by the Engineer on a 24-hour basis, including Saturdays, Sundays, and holidays. 5-05.3(3)E Smoothness Testing Equipment Inertial profilers shall meet all requirements of AASHTO M 328 and be certified in accordance with AASHTO R 56 within the preceding 12 months. The inertial profiler operator shall be certified as required by AASHTO R 56 within three years preceding profile measurement. Equipment or operator certification by other states or a profiler certification facility will be accepted provided the certification meets the requirements of AASHTO R 56. Documentation verifying certification by another state shall be submitted to the Engineer a minimum of 14 calendar days prior to profile measurement. Equipment certification documentation shall include the information required by part 8.5 and 8.6 of AASHTO R 56. Operator documentation shall include a statement from the certifying state that indicates the operator is certified to operate the inertial profiler to be used on the project. The decision whether another state’s certification meets the requirements of AASHTO R 56 shall be vested entirely in the Engineer. 5-05.3(4) Measuring and Batching Materials The batch plant site, layout, equipment, and provisions for transporting material shall ensure a continuous supply of material to the Work. 1. Measuring Materials a. Aggregates – The fine aggregate and each size of coarse aggregate shall be measured by weighing, the weight for the particular aggregates used being proportional to their respective bulk specific gravities. The weighing of each size of material shall be a separate and distinct operation. Corrections shall be made for variations in weight of materials due to the moisture content. The equipment for weighing aggregates shall conform to the requirements of Section 1-09.2. b. Cement – Cement shall be weighed on scales meeting the requirements of Section 1-09.2. Adequate provision shall be made to prevent loss of cement between the batch box and the mixer. Page 5-66 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement c. Water – Water may be measured either by volume or by weight. The accuracy of measuring the water shall be within a range of error of not over 1 percent. 2. Batching Materials – On all projects requiring more than 2,500 cubic yards of concrete for paving, the batching plant shall be equipped to proportion aggregates and cement by weight by means of automatic and interlocked proportioning devices of accepted type. 5-05.3(4)A Acceptance of Portland Cement or Blended Hydraulic Cement Concrete Pavement Acceptance of portland cement or blended hydraulic cement concrete pavement shall be as provided under statistical or nonstatistical acceptance. Determination of statistical or nonstatistical shall be based on Proposal quantities and shall consider the total of all Bid items involving of a specific class. Statistical acceptance will apply only to Contracts advertised, Awarded and administered by WSDOT, unless specifically provided otherwise in the Special Provisions. Contracting agencies other than WSDOT must specifically invoke statistical acceptance in their Special Provisions if it is desired. Statistical Acceptance, (1) applies only to WSDOT projects, (2) is administered under the provisions of Section 5-05.5, and (3) will be used for a class of mix when the Proposal quantities for that class of mix is 1,500 cubic yards or greater. Nonstatistical Acceptance will be used (1) for a class of mix when the Proposal quantities for that class of mix is less than 1,500 cubic yards and (2) all contracts advertised, Awarded and administered by agencies other than WSDOT. The point of acceptance will be in accordance with FOP for WAQTC TM 2 or at the point of discharge when a pump is used. Acceptance of Concrete. The concrete producer shall provide a certificate of compliance for each truckload of concrete in accordance with Section 6-02.3(5)B. For the purpose of acceptance sampling and testing, a lot is defined as having a maximum of 15 sublots that was produced for the same class of mix. The final lot may be increased to 25 sublots. All of the test results obtained from the same lot shall be evaluated collectively. The quantity represented by each sample will constitute a sublot. Sampling and testing shall be performed on a random basis at the frequency of one sample per sublot. Sublot size shall be determined to the nearest 10 cubic yards to provide not less than three uniform sized sublots with a maximum sublot size of 500 cubic yards. Acceptance testing for compliance of air content and 28-day compressive strength shall be conducted from samples prepared according to FOP for WAQTC TM 2. Air content shall be determined by conducting FOP for AASHTO T 152. Compressive strength shall be determined by FOP for AASHTO T 23 and FOP for AASHTO T 22. 2020 Standard Specifications M 41-10 Page 5-67 Cement Concrete Pavement 5-05 The Contractor shall provide cure boxes in accordance with Section 6-02.3(5)H, and protect concrete cylinders in cure boxes from excessive vibration and shock waves during the curing period in accordance with Section 6-02.3(6)D. Payment for cure boxes shall be in accordance with Section 6-02.5. Rejection of Concrete 1. Rejection by the Contractor – The Contractor may, prior to sampling, elect to remove any defective material and replace it with new material at no expense to the Contracting Agency. Any such new material will be sampled, tested, and evaluated for acceptance. 2. Rejection Without Testing – The Engineer may reject any load that appears defective prior to placement. Material rejected before placement shall not be incorporated into the pavement. No payment will be made for the rejected materials unless the Contractor requests that the rejected material be tested. If the Contractor elects to have the rejected materials tested, a sample will be taken and both the air content and strength shall be tested by WSDOT. Payment for rejected material will be based on the results of the one sample, which was taken and tested. If the rejected material fails either test, no payment will be made for the rejected material; in addition, the cost of sampling and testing at the rate of $250.00 per sample shall be borne by the Contractor. If the rejected material passes both tests, the mix will be compensated at a CPF of 1.00 and the cost of the sampling and testing will borne by the Contracting Agency. Statistical Acceptance The results of all acceptance testing performed in the field and the Composite Pay Factor (CPF) of the lot after three sublots have been tested will be available to the contractor through WSDOT’s website. The Specification limits as defined in Section 1-06.2(2)D shall be as follows. The lower Specification limit for Air Content shall be 3 percent, and the upper Specification limit for Air Content shall be 7 percent. The lower Specification limit for compressive strength shall be 4,000 psi. The price adjustment factor (fi) defined in Section 1-06.2(2)D shall be six for compressive strength and four for air content. If either the air content or compressive strength is not measured in accordance with this section its individual pay factor will be considered to be 1.00 in calculating the Composite Pay Factor. Page 5-68 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement Non-Statistical Acceptance Concrete will be accepted based on conformance to the requirement for air content and the compressive strength at 28 days for sublots as tested and determined by the Contracting Agency. The lower Specification limit for air content shall be 3 percent, and the upper Specification limit for air content shall be 7 percent. The lower Specification limit for compressive strength shall be 4,000 psi. Each sublot will be deemed to have met the specified compressive strength requirement when both of the following conditions are met: 1. Individual strength tests do not fall below the lower specification limit for strength by more than 12½ percent, or 500 psi, whichever is least. 2. An individual strength test averaged with the two preceding individual strength tests meets or exceeds the lower specification limit for strength. When compressive strengths fail to satisfy one or both of the above requirements, the Contractor may request acceptance of in-place concrete strength based on core results. This method will not be used if the Engineer determines coring would be harmful to the integrity of the Structure. Cores, if allowed, will be obtained by the Contractor in accordance with FOP for AASHTO T 24 and delivered to the Contracting Agency for testing in accordance with AASHTO T 22. If the concrete in the Structure will be dry under service conditions, the core will be air-dried at a temperature of between 60°F and 80°F and at a relative humidity of less than 60 percent for 7 days before testing, and will be tested air dry. Acceptance for each sublot by the core method requires that the average compressive strength of three cores be at least 85 percent of the specified strength with no one core less than 75 percent of the specified strength. When the Contractor requests strength analysis by coring, the results obtained will be accepted by both parties as conclusive and supersede all other strength data for the concrete sublot. If the Contractor elects to core, cores shall be obtained no later than 50 days after initial concrete placement. The Engineer will concur in the locations to be cored. Repair of cored areas shall be the responsibility of the Contractor. The cost incurred in coring and testing these cores, including repair of core locations, shall be borne by the Contractor. 5-05.3(5) Mixing Concrete The concrete may be mixed in a batching plant or in truck mixers. The mixer shall be of an approved type and capacity. Mixing time shall be measured from the time all materials are in the drum. Ready-mixed concrete shall be mixed and delivered in accordance with the requirements of Sections 6-02.3(4), 6-02.3(4)A, and 6-02.3(4)B. When mixed in a batching plant, the mixing time shall not be less than 50 seconds nor more than 90 seconds. 2020 Standard Specifications M 41-10 Page 5-69 Cement Concrete Pavement 5-05 The mixer shall be operated at a drum speed as shown on the manufacturer’s nameplate on the mixer. Any concrete mixed less than the specified time shall be discarded and disposed of by the Contractor at no expense to the Contracting Agency. The volume of concrete mixed per batch shall not exceed the mixer’s rated capacity, as shown on the manufacturer’s standard rating plate on the mixer. Each concrete mixing machine shall be equipped with a device for counting automatically the number of batches mixed during the day’s operation. Retempering concrete by adding water or by other means will not be permitted. 5-05.3(5)A Limitations of Mixing Concrete shall not be mixed, placed, or finished when the natural light is inadequate, as determined by the Engineer, unless an adequate and approved artificial lighting system is operated. Mixing and placing concrete shall be discontinued when a descending air temperature in the shade away from artificial heat reaches 40ºF and shall not be resumed until an ascending air temperature in the shade and away from artificial heat reaches 35ºF unless authorized in writing by the Engineer. When mixing and placing 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 shall be arranged to preclude the possible occurrence of overheated areas which might injure the materials. Unless otherwise authorized, the temperature of the mixed concrete shall be not less than 50ºF and not more than 90ºF at the time of discharge into the hauling conveyance. No concrete shall be mixed with frozen aggregates. 5-05.3(6) Surface Preparation The Subgrade surface shall be prepared and compacted a minimum of 3 feet beyond each edge of the area which is to receive concrete pavement in order to accommodate the slip- form equipment. Concrete shall not be placed during a heavy rainfall. Prior to placing concrete: 1. The surface shall be moist; 2. Excess water (e.g., standing, pooling or flowing) shall be removed from the surface. 3. The surface shall be clean and free of any deleterious materials. 4. The surface temperature shall not exceed 120°F or be frozen. Page 5-70 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement 5-05.3(7) Placing, Spreading, and Compacting Concrete 5-05.3(7)A Slip-Form Construction The concrete shall be distributed uniformly into final position by a self-propelled slip-form paver without delay. The alignment and elevation of the paver shall be regulated from outside reference lines established for this purpose, or by an electronic control system capable of controlling the line and grade within required tolerances. The paver shall vibrate the concrete for the full width and depth of the strip of pavement being placed and the vibration shall be adequate to provide a consistency of concrete that will stand normal to the surface with sharp well-defined edges. The sliding forms shall be rigidly held together laterally to prevent spreading of the forms. The plastic concrete shall be effectively consolidated by internal vibration with transverse vibrating units for the full width of pavement and/or a series of equally spaced longitudinal vibrating units. The space from the outer edge of the pavement to the outer longitudinal unit shall not exceed 9 inches. The spacing of internal units shall be uniform and not exceed 18 inches. The term internal vibration means vibration by vibrating units located within the specified thickness of pavement section. The rate of vibration of each vibrating unit shall be not less than 7,500 cycles per minute, and the amplitude of vibration shall be sufficient to be perceptible on the surface of the concrete along the entire length of the vibrating unit and for a distance of at least 1 foot. The frequency of vibration or amplitude shall be varied proportionately with the rate of travel to result in a uniform density and air content. The paving machine shall be equipped with a tachometer or other suitable device for measuring and indicating the actual frequency of vibrations. The concrete shall be held at a uniform consistency. The slip-form paver shall be operated with as nearly a continuous forward movement as possible and all operations of mixing, delivering, and spreading concrete shall be coordinated to provide uniform progress with stopping and starting of the paver held to a minimum. If, for any reason, it is necessary to stop the forward movement of the paver, the vibratory and tamping elements shall also be stopped immediately. No tractive force shall be applied to the machine, except that which is controlled from the machine. When concrete is being placed adjacent to an existing pavement, that part of the equipment which is supported on the existing pavement shall be equipped with protective pads on crawler tracks or rubber-tired wheels on which the bearing surface is offset to run a sufficient distance from the edge of the pavement to avoid breaking the pavement edge. 2020 Standard Specifications M 41-10 Page 5-71 Cement Concrete Pavement 5-05 5-05.3(7)B Stationary Side Form Construction Side form sections shall be straight, free from warps, bends, indentations, or other defects. Defective forms shall be removed from the Work. Metal side forms shall be used unless other forms are approved by the Engineer. Side forms may be built up by rigidly attaching a section to either top or bottom of forms. If such buildup is attached to the top of metal forms, the buildup shall be of metal. Side forms shall be of sufficient rigidity, both in the form and in the interlocking connection with adjoining forms, that springing will not occur under the weight of grading and paving equipment or from the pressure of concrete. The Contractor shall provide sufficient forms so that there will be no delay in placing the concrete due to lack of forms. Before placing side forms, the underlying material shall be at the proper grade. Side forms shall be placed to the required grade and alignment of the edge of the finished pavement. Wood wedges may be used to adjust the form elevation provided they do not extend into the concrete. The forms shall be firmly supported during the entire operation of placing, compacting, and finishing the pavement. Forms shall be drilled in advance of being placed to line and grade to accommodate tie bars where these are specified. Immediately in advance of placing concrete and after all Subgrade operations are completed, side forms shall be trued and maintained to the required line and grade for a distance sufficient to prevent delay in placing concrete. Side forms shall remain in place at least 12 hours after the concrete has been placed, and in all cases until the edge of the pavement no longer requires the protection of the forms. Curing compound shall be applied to the concrete immediately after the forms are removed. Side forms shall be thoroughly cleaned and oiled each time they are used and before concrete is placed against them. Concrete shall be spread, screeded, shaped, and consolidated by one or more self- propelled machines. These machines shall uniformly distribute and consolidate concrete without segregation so that completed pavement will conform to required cross section with a minimum of handwork. The number and capacity of machines furnished shall be adequate to perform the Work required at a rate equal to that of concrete delivery. Concrete for the full paving width shall be effectively consolidated by means of surface vibrators, in combination with internal vibrators, or by some other method of consolidation that produces equivalent results without segregation. Page 5-72 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement When vibrators are used to consolidate concrete, the rate of vibration shall be not less than 3,500 cycles per minute for surface vibrators and shall be not less than 7,000 cycles per minute for internal vibrators. Amplitude of vibration shall be sufficient to be perceptible on the surface of the concrete more than 1 foot from the vibrating element. The Contractor shall furnish a tachometer or other suitable device for measuring and indicating frequency of vibration. Power to vibrators shall be connected so that vibration ceases when forward or backward motion of the machine is stopped. 5-05.3(8) Joints Joints in cement concrete pavement will be designated as longitudinal and transverse contraction joints, longitudinal and transverse construction joints, or isolation joints, and shall be constructed as shown in the Plans and in accordance with the following provisions: All contraction joints shall be constructed at the locations, intervals, and depths shown in the Standard Plans. The faces of all joints shall be constructed perpendicular to the surface of the cement concrete pavement. 5-05.3(8)A Contraction Joints All transverse and longitudinal contraction joints shall be formed with suitable power- driven concrete saws. The Contractor shall provide sufficient sawing equipment capable of completing the sawing to the required dimensions and at the required rate to control cracking. The Contractor shall provide adequate artificial lighting facilities for night sawing. Joints shall not vary from the specified or indicated line by more than ¾ inch. Commencement of sawing transverse contraction joints will be dependent upon the setting time of the concrete and shall be done at the earliest possible time following placement of the concrete without tearing or raveling the adjacent concrete excessively. Longitudinal contraction joints shall be sawed as required to control cracking and as soon as practical after the initial control transverse contraction joints are completed. Any damage to the curing material during the sawing operations shall be repaired immediately after the sawing is completed. When cement concrete pavement is placed adjacent to existing cement concrete pavement, the vertical face of all existing working joints shall be covered with a bond- breaking material such as polyethylene film, roofing paper, or other material as approved by the Engineer. 2020 Standard Specifications M 41-10 Page 5-73 Cement Concrete Pavement 5-05 5-05.3(8)B Sealing Sawed Contraction Joints Sawed contraction joints shall be filled with a joint sealant filler conforming to the requirements of Section 9-04.2. Joints shall be thoroughly clean at the time of sealing and if the hot-poured type is used the joints shall be dry. Care shall be taken to avoid air pockets. The hot-poured compound shall be applied in two or more layers, if necessary. The hot-poured compound and the cold-poured compound shall be applied under sufficient pressure to fill the groove from bottom to top and the cured joint sealant shall be between ¼ and ⅝ inch below the top surface of the concrete. The joint filled with cold- poured compound shall then be covered with a strip of nonabsorbent paper at least twice as wide as the joint and the paper shall be left in place. 5-05.3(8)C Construction Joints When placing of concrete is discontinued for more than 45 minutes, a transverse construction joint shall be installed. Construction joints shall be as shown in the Standard Plans. Transverse construction joints shall be constructed between cement concrete pavement and reinforced concrete bridge approach slabs. All transverse and longitudinal construction joints, including the joint between new and existing pavement when widened, shall be sawed and sealed with joint filler conforming to the requirements of Sections 5-05.3(8)A and 9-04.2. 5-05.3(8)D Isolation Joints Premolded joint filler in accordance with Section 9-04.1(2) shall be placed as detailed in the Plans through the full depth of concrete pavement when drainage features are placed within the concrete pavement. 5-05.3(9) Vacant 5-05.3(10) Tie Bars and Corrosion Resistant Dowel Bars Tie bars shall be placed at all longitudinal contraction and construction joints, in accordance with the requirements shown in the Standard Plans. In addition, tie bars shall be installed when concrete Shoulders are placed as a separate operation or when widening existing pavement. Tie bars shall be placed at longitudinal construction joints between lanes in a manner that the individual bars are located at the required elevation and spaced as shown in the Standard Plans and in a manner that the vertical edge of the concrete is not deformed or otherwise damaged during placement of the bars. Placement tolerances for tie bars shall be within 1 inch of the middle of the concrete slab, within 1 inch of being centered over the joint and placed parallel or perpendicular to centerline within 1 inch of the vertical and horizontal plane. Page 5-74 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement Corrosion resistant dowel bars will be required for the construction joint at the end of paving operations each day and they shall be placed in accordance with the Standard Plans. Corrosion resistant dowel bars shall be placed at all transverse contraction joints as shown in the Contract or in accordance with the Standard Plans. All dowel bars shall have a parting compound, such as curing compound, grease or other Engineer approved equal applied to them prior to placement. Any dowel bar delivered to the project that displays rust/oxidation, pinholes, questionable blemishes, or deviates from the round shall be rejected. The Contractor shall furnish a Manufacturer’s Certificate of Compliance in accordance with Section 1-06.3, including mill test report verifying conformance to the requirements of Section 9-07.5(2) as well as written certification identifying the patching material, when applicable, used at cut dowel bar ends. Only one type of corrosion resistant dowel bars will be allowed per contract; intermixing of different corrosion resistant dowel bar types will not be allowed. Placement tolerances for dowel bars shall be within 1 inch of the middle of the concrete slab, within 1 inch of being centered over the transverse joint and parallel to centerline within ½ inch of the vertical and the horizontal plane. Cutting of stiffeners within the dowel bar cage is not allowed. When fresh concrete pavement is to be placed against pre-project existing cement concrete pavement, tie bars shall be drilled and set into the existing pavement with an epoxy bonding agent in accordance with the Standard Plans and specified tolerances for placement of tie bars. The epoxy-bonding agent shall be either Type I or IV epoxy resin as specified in Section 9-26. The Contractor may use any method for drilling the holes, provided the method selected does not damage the existing concrete. Any damage caused by the Contractor’s operations shall be repaired by the Contractor at no cost to the Contracting Agency in accordance with Section 1-07.13. The tie bar holes shall be clean before grouting. The bar shall be centered in the hole for the full length of embedment before grouting. The grout shall then be pumped into the hole around the bar in a manner that the back of the hole will be filled first. Blocking or shimming shall not impede the flow of the grout into the hole. Dams, if needed, shall be placed at the front of the holes to confine the grout. The dams shall permit the escape of air without leaking grout and shall not be removed until grout has cured in the hole. 2020 Standard Specifications M 41-10 Page 5-75 Cement Concrete Pavement 5-05 5-05.3(11) Finishing After the concrete has been given a preliminary finish by means of finishing devices incorporated in the slip-form paving equipment, the surface of the fresh concrete shall be checked by the Contractor with a straightedge device not less than 10 feet in length. High areas indicated by the straightedge device shall be removed by the hand-float method. Each successive check with the straightedge device shall lap the previous check path by at least ½ of the length of the straightedge. The requirements of this paragraph may be waived if it is successfully demonstrated that other means will consistently produce a surface with a satisfactory profile index and meeting the 10-foot straightedge requirement specified in Section 5-05.3(12). Any edge slump of the pavement, exclusive of specified edging, in excess of ¼ inch shall be corrected before the concrete has hardened. If edge slump on any 1 foot or greater length of hardened concrete exceeds 1 inch, the concrete shall be repaired as provided in Section 5-05.3(22). The standard method of surface finish shall be longitudinal tining. In advance of curing operations, where longitudinal tining is required, the pavement shall be given an initial and a final texturing. Initial texturing shall be performed with a burlap drag or broom device that will produce striations parallel with the centerline. Final texturing shall be performed with a wire comb tine device that will produce grooves parallel with the centerline. The wire comb tine device shall be operated within 5 inches, but not closer than 3 inches, of pavement edges. Burlap drags, brooms, and tine devices shall be installed on self-propelled equipment having external alignment control. The installation shall be such that, when texturing, the area of burlap in contact with the pavement surface shall be maintained constant at all times. Broom and tine devices shall be provided with positive elevation control. Downward pressure on pavement surface shall be maintained at all times during texturing so as to achieve uniform texturing without measurable variations in pavement profile. Self-propelled texturing machines shall be operated so that travel speed when texturing is maintained constant. Failure of equipment to conform to all provisions in this paragraph shall constitute cause for stopping placement of concrete until the equipment deficiency or malfunction is corrected. The wire comb of the final texturing device shall be rectangular in cross section, 3/32 to 1/8 inch wide, on ¾-inch centers, ± 1/8-inch, and of sufficient length, thickness, and resilience to form grooves approximately 1/8 inch deep in the fresh concrete surface. Final texture shall be uniform in appearance with substantially all of the grooves having a depth between 1/16 and 3/16 inch. On projects requiring less than 1,000 square yards of cement concrete pavement, for irregular areas or areas not accessible to slip-form pavers, the surface finish may be either longitudinal tined or transverse tined. Page 5-76 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement Transverse tining shall be done by texturing with a wire comb perpendicular to the centerline of the pavement. The wire comb tines shall be rectangular in cross section, 3/32 to 1/8 inch wide, on ½-inch centers ± 1/8 inch, and of sufficient length, thickness, and resilience to form grooves approximately 1/8 inch deep in the fresh concrete surface. Final texture shall be uniform in appearance with substantially all of the grooves having a depth between 1/16 to 3/16 inch. Finishing shall take place with the elements of the wire comb as nearly perpendicular to the concrete surface as is practical, to eliminate dragging the mortar. If the tining equipment has not been previously approved, a test section shall be constructed prior to approval of the equipment. Regardless of the surface finish, if the pavement has a raised curb without a formed concrete gutter, the texturing shall end 2 feet from the curb line. At the beginning and end of paving each day, the Contractor shall, with an approved stamp, indent the concrete surface near the right hand edge of the panel to indicate the date, month, and year of placement. At approximate 500-foot intervals where designated by the Engineer the Contractor shall, with an approved stamp, indent the concrete surface near the right hand edge of the pavement with the stationing of the Roadway. 5-05.3(12) Surface Smoothness Pavement surface smoothness for this project will include International Roughness Index (IRI) testing. The Contractor shall perform IRI testing on each through lane, climbing lane, and passing lane, greater than 0.25 mile in length and these lanes will be subject to incentive/disincentive adjustments. Ride quality will be evaluated using the Mean Roughness Index (MRI) calculated by averaging the IRI data for the left and right wheel path within the section. Ramps, shoulders and tapers will not be included in MRI testing for pavement smoothness and will not be subject to incentive adjustments. All Work is subject to parallel and transverse 10-foot straightedge requirements, corrective work and disincentive adjustments. Operate the inertial profiler in accordance with AASHTO R 57. Collect two longitudinal traces, one in each wheel path. Collect profile data after completion of all concrete paving on the project in a continuous pass including areas excluded from pay adjustments. Provide notice to the Engineer a minimum of seven calendar days prior to testing. Within 30 calendar days after the Contractor’s testing, the Engineer may perform verification testing. If the verification testing shows a difference in MRI greater than the percentages shown in Table 2 of AASHTO R 54 the following resolution process will be followed: 1. The profiles, equipment and procedures will be evaluated to determine the cause of the difference. 2020 Standard Specifications M 41-10 Page 5-77 Cement Concrete Pavement 5-05 2. If the cause of the discrepancy cannot be resolved the pavement shall be retested with both profilers at a mutually agreed time. The two profilers will test the section within 30 minutes of each other. If the retest shows a difference in MRI equal or greater than the percentages shown in Table 2 of AASHTO R 54 the Engineer’s test results will be used to establish pay adjustments. Surface smoothness of travel lanes not subject to MRI testing will be measured with a 10-foot straightedge no later than 5:00 p.m. of the day following the placing of the concrete. The completed surface of the wearing course shall not vary more than 1/8 inch from the lower edge of a 10-foot straightedge placed on the surface parallel to the centerline. Smoothness perpendicular to the centerline will be measured with a 10-foot straightedge across all lanes with the same cross slope, including shoulders when composed of cement concrete pavement. The overlapping 10-foot straightedge measurement shall be discontinued at a point 6 inches from the most extreme outside edge of the finished cement concrete pavement. The completed surface of the wearing course shall not vary more than ¼ inch from the lower edge of a 10-foot straightedge placed on the surface perpendicular to the centerline. Any deviations in excess of the above tolerances shall be corrected. The Contractor shall evaluate profiles for acceptance, incentive payments, disincentive payments, or corrective action using the current version of ProVAL and provide the results including the profile data in unfiltered electronic Engineering Research Division (ERD) file format to the Engineer within 2 calendar days of completing testing each section of pavement. If the profile data files are created using an export option in the manufacturer’s software where filter settings can be specified, use the filter settings that were used to create data files for certification. Analyze the entire profile. Exclude any areas specifically identified in the Contract. Exclude from the analysis the first 100 feet after the start of the paving operations and last 100 feet prior to the end of the paving operation, the first 100 feet on either side of bridge Structures and bridge approach slab. Report the MRI results in inches per mile for each 52.8 foot section and horizontal distance measurements in project stationing to the nearest foot. Include pay adjustments in the results. The Engineer will verify the analysis. Corrective work for pavement smoothness may be taken by the Contractor prior to MRI testing. After completion of the MRI testing the Contractor shall measure the smoothness of each 52.8-foot section with an MRI greater than 125 inches per mile with a 10-foot straightedge within 14 calendar days or as allowed by the Engineer. The Contractor shall identify all locations that require corrective work and provide the straight edge measurements at each location that exceeds the allowable limit to the Engineer. If all measurements in a 52.8-foot section comply with smoothness requirements, the Contractor shall provide the maximum measurement to the Engineer and a statement that corrective work is not required. Unless allowed by the Engineer, corrective work shall be taken by the Contractor for pavement identified by the Contractor or Engineer that does not meet the following requirements: Page 5-78 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement 1. The completed surface shall be of uniform texture, smooth, uniform as to crown and grade, and free from defects of all kinds. 2. The completed surface shall not vary more than ⅛ inch from the lower edge of a 10-foot straightedge placed on the surface parallel to the centerline. 3. The completed surface shall vary not more than ¼ inch in 10 feet from the rate of transverse slope shown in the Plans. All corrective work shall be completed at no additional expense, including traffic control, to the Contracting Agency. Corrective work shall not begin until the concrete has reached its design strength unless allowed by the Engineer. Pavement shall be repaired by one or more of the following methods: 1. Diamond grinding; repairs shall not reduce pavement thickness by more than ¼ inch less than the thickness shown in the Plans. When required by the Engineer, the Contractor shall verify the thickness of the concrete pavement by coring. Thickness reduction due to corrective work will not be included in thickness measurements for calculating the Thickness Deficiency in Section 5-05.5(1)A. 2. Removal and replacement of the cement concrete pavement. 3. By other method allowed by the Engineer. For repairs following MRI testing the repaired area shall be checked by the Contractor with a 10-foot straightedge to ensure it no longer requires corrective work. With concurrence of the Engineer an inertial profiler may be used in place of the 10-foot straight edge. If correction of the roadway as listed above either will not or does not produce satisfactory results as to smoothness or serviceability the Engineer may accept the completed pavement and a credit will be calculated in accordance with Section 5-05.5. The credit will be in addition to the price adjustment for MRI. Under these circumstances, the decision whether to accept the completed pavement or to require corrective work as described above shall be vested entirely in the Engineer. 5-05.3(13) Curing Immediately after the finishing operations have been completed and as soon as marring of the concrete will not occur, the entire surface of the newly placed concrete shall be cured in accordance with one of the following methods the Contractor may elect. 5-05.3(13)A Curing Compound Liquid membrane-forming concrete curing compound Type 2 meeting the requirements of Section 9-23.2 shall be applied to the entire area of the exposed surface of the concrete with an approved mechanical spray machine. The spray fog shall be protected from the wind with an adequate shield. It shall be applied uniformly at the rate of one gallon to not more than 150-square feet. 2020 Standard Specifications M 41-10 Page 5-79 Cement Concrete Pavement 5-05 The compound shall be applied with equipment of the pressure tank or pump type equipped with a feed tank agitator which ensures continuous agitation of the compound during spraying operations. The nozzle shall be of the two-line type with sufficient air to properly atomize the compound. The curing compound shall not be applied during or immediately after rainfall. If it becomes necessary to leave the pavement uncoated overnight, it shall be covered with polyethylene sheeting, which shall remain in place until weather conditions are favorable for the application of the curing compound. In the event that rain falls on the newly coated pavement before the film has dried sufficiently to resist damage, or in the event of damage to the film from any cause, the Contractor shall apply a new coat of curing compound in one or two applications to the affected area at the rate which, in the opinion of the Engineer, will result in a film of curing value equal to that specified in the original coat. Before placing the curing compound in the spray tank, it shall be thoroughly agitated as recommended by the Manufacturer. The compound shall not be diluted by the addition of solvents nor be altered in any manner. If the compound has become chilled to the extent that it is too viscous for proper stirring or application or if portions of the vehicle have been precipitated from solution, it shall be heated to restore proper fluidity but it shall not be heated above 100ºF. All curing compound shall have approval prior to placing in the spray tanks. The curing compound shall be applied immediately after the concrete has been finished and after any bleed water that has collected on the surface has disappeared, or at a time designated by the Engineer. If hair checking develops in the pavement before finishing is completed, the Engineer may order the application of the curing compound at an earlier stage, in which event any concrete cut from the surface in finishing operations shall be removed entirely from the pavement. If additional mortar is then needed to fill torn areas, it shall be obtained ahead of the spraying operations. All areas cut by finishing tools subsequent to the application of the curing compound shall immediately be given new applications at the rate specified above. The curing compound, after application, shall be protected by the Contractor from injury until the pavement has reached a minimum compressive strength of 2,500 psi. All traffic, either by foot or otherwise, shall be considered as injurious to the film of the applied compound. The Contractor shall provide on the job a sufficient quantity of white polyethylene sheeting to cover all the pavement laid in 3 hours of maximum operation. This sheeting shall be reserved exclusively for the protection of the pavement in case of rain or breakdown of the spray equipment used for applying the curing compound. The protective sheeting shall be placed over the pavement when ordered, and in the manner specified by the Engineer. Page 5-80 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement Areas from which it is impossible to exclude traffic shall be protected by a covering of sand or earth not less than 1 foot in thickness or by other suitable and effective means. The protective covering shall be placed no earlier than 24 hours after application of the compound. The Contractor shall assume all liabilities for and protect the Contracting Agency from any damages or claims arising from the use of materials or processes described herein. 5-05.3(13)B White Polyethylene Sheeting The sheeting shall be placed over the pavement immediately after finishing operations are completed, or at a time designated by the Engineer. The sheeting shall be laid so that individual sheets overlap at least 2 feet, and the lapped areas shall be held in close contact with the pavement by weighting with earth or boards to prevent movement by the wind. The sheeting shall extend downward to cover the edges of the pavement and shall be secured to the Subgrade with a continuous bank of earth or surfacing material. Any holes occurring in the sheeting shall be patched immediately to the satisfaction of the Engineer. The sheeting shall be maintained against injury and remain in place until the pavement has reached a minimum compressive strength of 2,500 psi. 5-05.3(13)C Wet Curing Wet curing shall be accomplished by applying a continuous fog or mist spray to the entire pavement surface until it has reached a minimum compressive strength of 2,500 psi. If water runoff is not a concern, continuous sprinkling is acceptable. Sprinkling shall not begin until the concrete has achieved initial set as determined by AASHTO T 197 or other approved method. 5-05.3(14) Cold Weather Work When the air temperature is expected to reach the freezing point during the day or night and the pavement has not reached 50 percent of its design strength or 2,500 psi which ever is greater the concrete shall be protected from freezing. The Contractor shall, at no expense to the Contracting Agency, provide a sufficient supply of straw, hay, grass, earth, blankets, or other suitable blanketing material and spread it over the pavement to a sufficient depth to prevent freezing of the concrete. The Contractor shall be responsible for the quality and strength of the concrete thus cured. Any concrete injured by frost action or freezing shall be removed and replaced at the Contractor’s expense in accordance with these Specifications. 2020 Standard Specifications M 41-10 Page 5-81 Cement Concrete Pavement 5-05 5-05.3(15) Concrete Pavement Construction in Adjacent Lanes Unless otherwise shown in the Plans or in the Special Provisions, the pavement shall be constructed in multiple lanes; that is, two or more adjacent lanes paved in a single operation. Longitudinal contraction joints shall be used between adjacent lanes that are paved concurrently, and construction joints shall be used when lanes are paved separately. Tie bars shall be installed during initial lane construction. The Contractor shall replace, at no expense to the Contracting Agency, any panels on the new pavement that are cracked or broken as a result of the Contractor’s operations. 5-05.3(16) Protection of Pavement The Contractor shall protect the pavement and its appurtenances from any damage. Protection shall include personnel to direct traffic and the erection and maintenance of warning signs, lights, barricades, temporary take-down bridges across the pavement with adequate approaches, and whatever other means may be necessary to accommodate local traffic and to protect the pavement during the curing period or until opened to traffic as determined by the Engineer. The operation of construction equipment on the new pavement will not be allowed until the pavement has developed a compressive strength of 2,500 psi as determined from cylinders, made at the time of placement, cured under comparable conditions, and tested in accordance with FOP for AASHTO T 22. Exceptions would be one track from a slip- form paving machine when paving adjacent lanes or light vehicles required for sawing operations or taking cores. Placement of Shoulder material may commence when the pavement has developed a compressive strength of 1,800 psi as determined from cylinders made at the time of placement, cured under comparable conditions, and tested in accordance with AASHTO T22 as long as construction equipment is not operated on the new pavement. A continuous barrier of the design shown in the Plans shall be constructed and maintained along the edge of the pavement being constructed and adjacent to the portion of the Roadway used for traffic. The barriers shall be left in place until the new pavement is ready to be opened to traffic and shall then be removed by the Contractor. Any damage to the pavement occurring prior to final acceptance shall be replaced or repaired in accordance with Section 5-05.3(22). 5-05.3(17) Opening to Traffic The pavement may be opened to traffic when the concrete has developed a compressive strength of 2,500 psi as determined from cylinders, made at the time of placement, cured under comparable conditions, and tested in accordance with FOP for AASHTO T 22. Fabrication, curing, and testing of cylinders to measure early strength shall be the responsibility of the Contractor. The Contractor shall obtain the services of an independent Laboratory to perform these activities and these laboratories shall be approved by the Engineer. At the Contractor’s option, the time for opening pavement may Page 5-82 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement be determined through the use of the maturity test in accordance with ASTM C1074. The Contractor shall develop the maturity-strength relationship and provide maturity curves along with supporting data for approval by the Engineer. The Contractor shall furnish all equipment, including thermal or maturity meter, thermocouples, wire, and qualified personnel to monitor maturity and provide information to the Engineer. Field procedures to monitor maturity shall be submitted to the Engineer for approval prior to use. The pavement shall not be opened to traffic until the maturity-strength relationship shows the pavement has a compressive strength of 2,500 psi and approved by the Engineer. The pavement shall be cleaned prior to opening to traffic. All costs associated with early-strength cylinders shall be at the Contractor’s expense. 5-05.3(18) Vacant 5-05.3(19) Vacant 5-05.3(20) Vacant 5-05.3(21) Vacant 5-05.3(22) Repair of Defective Pavement Slabs Broken slabs, slabs with random cracks, nonworking contraction joints near cracks, edge slumping and spalls along joints and cracks shall be replaced or repaired as specified at no expense to the Contracting Agency, and shall be accomplished prior to completion of joint sealing. Pavement slabs containing more than one crack shall be entirely removed and replaced. Pavement slabs containing a single crack shall be removed and replaced such that the minimum dimension of the removed slab is 6 feet long and full panel width. The portion of the panel to remain in place shall have a minimum dimension of 6 feet in length and full panel width, otherwise entire removal and replacement of the slab is required. There shall be no new joints closer than 3 feet to an existing transverse joints. Saw cutting full pavement depth is required along all longitudinal joints and at transverse locations. Tie bars and dowel bars shall be used in accordance Section 5-05.3(10). Spalls and edge slumping shall be repaired by making vertical saw cuts at least 3 inches outside the affected area and to a minimum depth of 2 inches. Spall repairs that encounter dowel bars or are within 6 inches of a dowel bar will not be permitted. These spall areas shall be repaired by replacing a half or full panel as permitted by the Engineer. Removal of the existing pavement shall not damage any pavement to be left in place. If jackhammers are used for removing pavement, they shall not weigh more than 30 pounds, and chipping hammers shall not weigh more than 15 pounds. All power- driven hand tools used for the removal of pavement shall be operated at angles less than 45 degrees as measured from the surface of the pavement to the tool. The patch limits shall extend beyond the spalled area a minimum of 3 inches. Repair areas shall be kept square or rectangular. Repair areas that are within 12 inches of another repair area shall be combined. 2020 Standard Specifications M 41-10 Page 5-83 Cement Concrete Pavement 5-05 The Contractor shall remove material within the perimeter of the saw cut to a depth of 2 inches, or to sound concrete as determined by the Engineer. The surface patch area shall be sandblasted and all loose material removed. All sandblasting residue shall be removed. When a partial depth repair is placed directly against an adjacent longitudinal joint, a bond-breaking material such as polyethylene film, roofing paper, or other material as approved by the Engineer shall be placed between the existing concrete and the area to be patched. Patches that abut working transverse joints or cracks require placement of a compressible insert. The new joint or crack shall be formed to the same width as the existing joint or crack. The compressible joint material shall be placed into the existing joint 1 inch below the depth of repair. The compressible insert shall extend at least 3 inches beyond each end of the patch boundaries. Patches that abut the lane/shoulder joint require placement of a formed edge, along the slab edge, even with the surface. The patching material shall be mixed, placed, consolidated, finished, and cured according to manufacturer’s recommendations. Slab/patch interfaces that will not receive pavement grinding shall be sealed (painted) with a 1:1 cement-water grout along the patch perimeter. The Contractor shall reseal all joints in accordance with Section 5-05.3(8)B. Opening to traffic shall meet the requirements of Section 5-05.3(17). Low areas which grinding cannot feasibly remedy, shall be sandblasted, filled with epoxy bonded mortar, and textured by grinding. The epoxy bonding agent shall meet the requirements of Section 9-26.1(1)B for Type II epoxy. 5-05.4 Measurement Cement concrete pavement will be measured by the cubic yard for the completed pavement. The volume will be determined from measurements taken as listed below. 1. The width measurement will be the width of the pavement shown on the typical cross-section in the Plans, additional widening where called for, or as otherwise specified in writing by the Engineer. 2. The length will be measured along the center of each Roadway or ramp. 3. The depth shall be determined in accordance with Section 5-05.5(1). The depth utilized to calculate the volume shall not exceed the Plan depth plus 0.04 feet. The volume of cement concrete pavement in each thickness lot shall equal the measured length × width × thickness measurement. Page 5-84 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement Corrosion resistant dowel bar will be measured per each for the actual number of bars used in the completed Work. Tie bar with drill hole will be measured per each for the actual number of bars used in the completed Work. Tie bars with drill holes in cement concrete pavement placed under the Contract will not be measured. The ride smoothness compliance adjustment calculation is the volume of pavement, in cubic yards, represented by the profilograph. The calculation for cement concrete compliance adjustment is the volume of concrete represented by the CPF and the Thickness deficiency adjustment. 5-05.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Cement Conc. Pavement”, per cubic yard. The unit Contract price per cubic yard for “Cement Conc. Pavement” shall be full compensation for all costs incurred to carry out the requirements of Section 5-05, except for those costs included in other items, which are included in this Subsection and are included in the Proposal. All costs associated with performing the magnetic pulse induction thickness testing shall be included in the unit Contract price per cubic yard for “Cement Conc. Pavement”. “Corrosion Resistant Dowel Bar”, per each. The unit Contract price per each for “Corrosion Resistant Dowel Bar” shall be full payment for furnishing, and installing corrosion resistant dowel bars and any costs for drilling holes, placing dowel bars with baskets, furnishing and installing parting compound and all other costs associated with completing the installation of corrosion resistant dowel bars. “Tie Bar with Drill Hole”, per each. The unit Contract price per each, “Tie Bar with Drill Hole” shall be full payment for furnishing, and installing tie bars and any costs for drilling holes, and all other costs associated with installation of tie bars. All costs for tie bars with drill holes in cement concrete pavement placed under the Contract shall be included in the unit Contract price per cubic yard for “Cement Conc. Pavement”. “Ride Smoothness Compliance Adjustment”, by calculation. 2020 Standard Specifications M 41-10 Page 5-85 Cement Concrete Pavement 5-05 Smoothness Compliance Adjustments will be based on the requirements in Section 5-05.3(12) and the following calculations: 1. Final MRI acceptance and incentive/disincentive payments for pavement smoothness will be calculated as the average of the ten 52.8-foot sections in each 528 feet in accordance with the price adjustment schedule. a. For sections of a lane that are a minimum of 52.8 feet and less than 528 feet, the price adjustment will be calculated using the average of the 52.8 foot MRI values and the price adjustment prorated for the length of the section. b. MRI values per 52.8-feet that were measured prior to corrective work will be included in the 528 foot price adjustment for sections with corrective work. 2. In addition to the price adjustment for MRI a smoothness compliance adjustment will be calculated in the sum of minus $1000.00 for each and every section of single traffic lane 52.8 feet in length in that does not meet the 10-foot straight edge requirements in Section 5-05.3(12) after corrective Work. Page 5-86 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement Price Adjustment Schedule MRI for each 528 ft. section in. / mi. Pay Adjustment Schedule $ / 0.10 mi. < 30 2400 30 2400 31 2320 32 2240 33 2160 34 2080 35 2000 36 1920 37 1840 38 1760 39 1680 40 1600 41 1520 42 1440 43 1360 44 1280 45 1200 46 1120 47 1040 48 960 49 880 50 800 51 720 52 640 53 560 54 480 55 400 56 320 57 240 58 160 59 80 60 0 61 0 62 0 63 0 64 0 65 0 66 0 67 0 68 0 69 0 70 0 71 0 72 0 73 0 74 0 75 0 76 -80 77 -160 Price Adjustment Schedule MRI for each 528 ft. section in. / mi. Pay Adjustment Schedule $ / 0.10 mi. 78 -240 79 -320 80 -400 81 -480 82 -560 83 -640 84 -720 85 -800 86 -880 87 -960 88 -1040 89 -1120 90 -1200 91 -1280 92 -1360 93 -1440 94 -1520 95 -1600 96 -1680 97 -1760 98 -1840 99 -1920 100 -2000 101 -2080 102 -2160 103 -2240 104 -2320 105 -2400 106 -2480 107 -2560 108 -2640 109 -2720 110 -2800 111 -2880 112 -2960 113 -3040 114 -3120 115 -3200 116 -3280 117 -3360 118 -3440 119 -3520 120 -3600 121 -3680 122 -3760 123 -3840 124 -3920 ≥125 -4000 2020 Standard Specifications M 41-10 Page 5-87 Cement Concrete Pavement 5-05 “Cement Concrete Compliance Adjustment”, by calculation. Payment for “Cement Concrete Compliance Adjustment” will be calculated by multiplying the unit Contract price for the cement concrete pavement, times the volume for adjustment, times the percent of adjustment determined from the calculated CPF and the Deficiency Adjustment listed in Section 5-05.5(1)A. 5-05.5(1) Pavement Thickness Cement concrete pavement shall be constructed in accordance with the thickness requirements in the Plans and Specifications. Tolerances allowed for Subgrade construction and other provisions, which may affect thickness, shall not be construed to modify such thickness requirements. Thickness measurements in each lane shall comply with the following: Thickness Testing of Cement Concrete Pavement Thickness Lot Size 15 panels maximum Thickness test location determined by Engineer will select testing locations in accordance with WSDOT TM 716 method B. Sample method AASHTO T 359 Sample preparation performed by Contractor provides, places, and secures disks in the presence of the Engineer1 Measurement method AASHTO T 359 Thickness measurement performed by Contractor, in the presence of the Engineer2 1Reflectors shall be located at within 0.5 feet of the center of the panel. The Contractor shall supply a sufficient number of 300 mm-diameter round reflectors meeting the requirements of AASHTO T 359 to accomplish the required testing. 2The Contractor shall provide all equipment and materials needed to perform the testing. Thickness measurements shall be rounded to the nearest 0.01 foot. Each thickness test location where the pavement thickness is deficient by more than 0.04 foot, shall be subject to price reduction or corrective action as shown in Table 2. Table 2 Thickness Deficiency 0.04’ < Thickness Deficiency ≤ 0.06’10 0.06’ < Thickness deficiency ≤ 0.08’25 Thickness deficiency > 0.08’Remove and replace the panels or the panels may be accepted with no payment at the discretion of the Engineer. Page 5-88 2020 Standard Specifications M 41-10 5-05 Cement Concrete Pavement The price reduction shall be computed by multiplying the percent price reduction in Table 2 by the unit Contract price by the volume of pavement represented by the thickness test lot. Additional cores may be taken by the Contractor to determine the limits of an area that has a thickness deficiency greater than 0.04 feet. Cores shall be taken at the approximate center of the panel. Only the panels within the limits of the deficiency area as determined by the cores will be subject to a price reduction or corrective action. The cores shall be taken in the presence of the Engineer and delivered to the Engineer for measurement. All costs for the additional cores including filling the core holes with patching material meeting the requirements of Section 9-20 will be the responsibility of the Contractor. 5-05.5(1)A Vacant 5-05.5(1)B Vacant 2020 Standard Specifications M 41-10 Page 6-1 Division 6 Structures 6-01 General Requirements for Structures 6-01.1 Description This section relates to structural and incidental items used in any or all types of existing or proposed Structures. These provisions supplement the detailed Specifications supplied for any given Structure. These provisions apply only when relevant and when they do not conflict with the Plans or Special Provisions. 6-01.2 Foundation Data Foundation data in the Plans (from test borings, test pits, or other sources) were obtained only to guide the Department in planning and designing the project. These data reasonably represent the best information available to the Department concerning conditions and materials at the test sites at the time the investigations were made. 6-01.3 Clearing the Site The Contractor shall clear the entire site of the proposed Structure to the limits staked by the Engineer. 6-01.4 Appearance of Structures To achieve a more pleasing appearance, the Engineer may require the Contractor to adjust the height and alignment of bridge railings, traffic barrier, and structural curbs. 6-01.5 Vacant 6-01.6 Load Restrictions on Bridges Under Construction Bridges under construction shall remain closed to all traffic, including construction equipment, until the Substructure and the Superstructure, through the bridge deck, are complete for the entire Structure, except as provided herein. Completion includes release of all falsework, removal of all forms, and attainment of the minimum design concrete strength and specified age of the concrete in accordance with these Specifications. Once the Structure is complete, Section 1-07.7 shall govern all traffic loading, including construction traffic (equipment). If necessary and safe to do so, and if the Contractor requests it through a Type 2E Working Drawing, the Engineer may allow traffic on a bridge prior to completion. The maximum distributed load at each construction equipment support shall not exceed the design load by more than 33 percent. The written request shall: 1. Describe the extent of the Structure completion at time of the proposed equipment loading; Page 6-2 2020 Standard Specifications M 41-10 6-01 General Requirements For Structures 2. Describe the loading magnitude, arrangement, movement, and position of traffic (equipment) on the bridge, including but not limited to the following: a. Location of construction equipment, including outriggers, spreader beams and supports for each, relative to the bridge framing plan (bridge girder layout); b. Mechanism of all load transfer (load path) to the bridge; 3. Provide stress calculations under the design criteria specified in the AASHTO LRFD Bridge Design Specifications, current edition, including at a minimum the following: a. Supporting calculations showing that the flexural and shear stresses in the main load carrying members due to the construction load are within the allowable stresses; b Supporting calculations showing that the flexural and shear stresses in the bridge deck due to the construction load are within the allowable stresses; 4. Provide supporting material properties, catalogue cuts, and other information describing the construction equipment and all associated outriggers, spreader beams, and supports; and 5. State that the Contractor assumes all risk for damage. 6-01.7 Navigable Streams The Contractor shall keep navigable streams clear so that water traffic may pass safely, providing and maintaining all lights and signals required by the U.S. Coast Guard. The Contractor shall also comply with all channel depth and clearance line requirements of the U.S. Corps of Engineers. This may require removing material deposited in the channel during construction. 6-01.8 Approaches to Movable Spans No bridge deck or sidewalk slab on the approach span at either end of a movable span may be placed until after the movable span has been completed, adjusted and closed. 6-01.9 Working Drawings All Working Drawings required for bridges and other Structures shall conform to Section 1-05.3. 6-01.10 Utilities Supported by or Attached to Bridges Installation of utility pipes and conduit systems shall conform to the details shown in the Plans and as specified in the utility agreement between the utility company and the Contracting Agency. All utility pipes and conduit systems supported by or attached to bridges shall be labeled with Type I reflective sheeting conforming to Section 9-28.12, and the following: 2020 Standard Specifications M 41-10 Page 6-3 General Requirements For Structures 6-01 Content Label Background Color Lettering Utility Color Electrical Power Red Black Gas, Oil, Steam, Petroleum, and other gaseous materials Yellow Black CATV, Telecommunication, Alarm, and Signal Orange Black Potable Water Blue White Reclaimed Water, Irrigation, Slurry Purple White Sewer and Storm Drain Green White The purple color background for the label for reclaimed water, irrigation, and slurry, shall be generated by placing transparent film over white reflective material. The purple tint of the transparent film shall match SAE AMS Standard 595, Color No. 37100. The label text shall identify the utility contents and include the One-Number Locator Service phone number 1-800-424-5555. The minimum length of the label color field shall be the longer of either 1 letter width beyond each end of the label text, or the length specified below: Minimum Pipe O.D. (inches) Maximum Pipe O.D. (inches) Minimum Length of Label Color Field (inches) Letter Height (inches) ¾1¼8 ½ 1½2 8 ¾ 2½6 12 1¼ 8 10 24 2½ 12 32 3½ Utility pipes and conduit systems shall be labeled on both sides of each bridge pier, and adjacent to each entrance hatch into a box girder cell. For utility pipes and conduit systems within bridge spans exceeding 300 feet, labels shall also be applied to the utility pipes and conduit systems between the piers at a maximum spacing of 300 feet. The label shall be visible at a normal eye height. 6-01.11 Name Plates The Contractor shall install no permanent plates or markers on a Structure unless the Plans show it. 6-01.12 Final Cleanup When the Structure is completed, the Contractor shall leave it and the entire site in a clean and orderly condition. Structure decks shall be clean. Temporary buildings, falsework, piling, lumber, equipment, and debris shall be removed. The Contractor shall level and fine grade all excavated material not used for backfill, and shall fine grade all slopes and around all piers, bents, and abutments. Page 6-4 2020 Standard Specifications M 41-10 6-01 General Requirements For Structures 6-01.13 Vacant 6-01.14 Premolded Joint Filler When the Plans call for premolded joint filler, the Contractor shall fasten it with galvanized wire nails to 1 side of the joint. The nails must be no more than 6 inches apart and shall be 1½ inches from the edges over the entire joint area. The nails shall be at least 1½ inches longer than the thickness of the filler. The Contractor may substitute for the nails any adhesive acceptable to the Engineer. This adhesive, however, shall be compatible with the material specified in Section 9-04.1(2) and capable of bonding the filler to portland cement concrete. 6-01.15 Normal Temperature Bridge Plans state dimensions at a normal temperature of 64ºF. Unless otherwise noted, these dimensions are horizontal or vertical. 6-01.16 Repair of Defective Work 6-01.16(1) General When using repair procedures that are described elsewhere in the Contract Documents, the Working Drawing submittal requirements of this section shall not apply to those repairs unless noted otherwise. Repair procedures for defective Work shall be submitted as Type 2 Working Drawings. Type 2E Working Drawings shall be submitted when required by the Engineer. As an alternative to submitting Type 2 or 2E Working Drawings, defective Work within the limits of applicability of a pre-approved repair procedure may be repaired using that procedure. Repairs using a pre-approved repair procedure shall be submitted as a Type 1 Working Drawing. Pre-approved repair procedures shall consist of the following: • The procedures listed in Section 6-01.16(2) • For precast concrete, repair procedures in the annual plant approval process documents that have been approved for use by the Contracting Agency. All Working Drawings for repair procedures shall include: • A description of the defective Work including location, extent and pictures • Materials to be used in the repair. Repairs using manufactured products shall include written manufacturer recommendations for intended uses of the product, surface preparation, mixing, aggregate extension (if applicable), ambient and surface temperature limits, placement methods, finishing and curing. • Construction procedures • Plan details of the area to be repaired • Calculations for Type 2E Working Drawings 2020 Standard Specifications M 41-10 Page 6-5 General Requirements For Structures 6-01 Material manufacturer’s instructions and recommendations shall supersede any conflicting requirements in pre-approved repair procedures. The Engineer shall be notified prior to performing any repair procedure and shall be given an opportunity to inspect the repair work being performed. 6-01.16(2) Pre-Approved Repair Procedures 6-01.16(2)A Concrete Spalls and Poor Consolidation (Rock Pockets, Honeycombs, Voids, Etc.) This repair shall be limited to the following areas: • Areas that are not on top Roadway surfaces (with or without an overlay) including but not limited to concrete bridge decks, bridge approach slabs or cement concrete pavement • Areas that are not underwater • Areas that are not on precast barrier, except for the bottom 4 inches (but not to exceed 1 inch above blockouts) • Areas that do not affect structural adequacy as determined by the Engineer. The repair procedure is as follows: 1. Remove all loose and unsound concrete. Impact breakers shall not exceed 15 pounds in weight when removing concrete adjacent to reinforcement or other embedments and shall not exceed 30 pounds in weight otherwise. Operate impact breakers at angles less than 45 degrees as measured from the surface of the concrete to the tool and moving away from the edge of the defective Work. Concrete shall be completely removed from exposed surfaces of existing steel reinforcing bars. If half or more of the circumference of any steel reinforcing bar is exposed, if the reinforcing bar is loose or if the bond to existing concrete is poor then concrete shall be removed at least ¾ inch behind the reinforcing bar. Do not damage any existing reinforcement. Stop work and allow the Engineer to inspect the repair area after removing all loose and unsound concrete. Submit a modified repair procedure when required by the Engineer. 2. Square the edges of the repair area by cutting an edge perpendicular to the concrete surface around the repair area. The geometry of the repair perimeter shall minimize the edge length and shall be rectangular with perpendicular edges, avoiding reentrant corners. The depth of the cut shall be a minimum of ¾ inch, but shall be reduced if necessary to avoid damaging any reinforcement. For repairs on vertical surfaces, the top edge shall slope up toward the front at a 1-vertical-to-3- horizontal slope. Page 6-6 2020 Standard Specifications M 41-10 6-01 General Requirements For Structures 3. Remove concrete within the repair area to a depth at least matching the cut depth at the edges. Large variations in the depth of removal within short distances shall be avoided. Roughen the concrete surface. The concrete surface should be roughened to at least Concrete Surface Profile (CSP) 5 in accordance with ICRI Guideline No. 310.2R, unless a different CSP is recommended by the patching material manufacturer. 4. Inspect the concrete repair surface for delaminations, debonding, microcracking and voids using hammer tapping or a chain drag. Remove any additional loose or unsound concrete in accordance with steps 1 through 3. 5. Select a patching material in accordance with Section 9-20.2 that is appropriate for the repair location and thickness. The concrete patching material shall be pumpable or self-consolidating as required for the type of placement that suits the repair. The patching material shall have a minimum compressive strength at least equal to the specified compressive strength of the concrete. 6. Prepare the concrete surface and reinforcing steel in accordance with the patching material manufacturer’s recommendations. At a minimum, clean the concrete surfaces (including perimeter edges) and reinforcing steel using oil-free abrasive blasting or high-pressure (minimum 5,000 psi) water blasting. All dirt, dust, loose particles, rust, laitance, oil, film, microcracked/bruised concrete or foreign material of any sort shall be removed. Damage to the epoxy coating on steel reinforcing bars shall be repaired in accordance with Section 6-02.3(24)H. 7. Construct forms if necessary, such as for patching vertical or overhead surfaces or where patching extends to the edge or corner of a placement. 8. When recommended by the patching material manufacturer, saturate the concrete in the repair area and remove any free water at the concrete surface to obtain a saturated surface dry (SSD) substrate. When recommended by the patching material manufacturer, apply a primer, scrub coat or bonding agent to the existing surfaces. Epoxy bonding agents, if used, shall be Type II or Type V in accordance with Section 9-26.1. 9. Place and consolidate the patching material in accordance with the manufacturer’s recommendations. Work the material firmly into all surfaces of the repair area with sufficient pressure to achieve proper bond to the concrete. 10. The patching material shall be textured, cured and finished in accordance with the patching material manufacturer’s recommendations and/or the requirements for the repaired component. Protect the newly placed patch from vibration in accordance with Section 6-02.3(6)D. 11. When the completed repair does not match the existing concrete color and will be visible to the public, a sand and cement mixture that is color matched to the existing concrete shall be rubbed, brushed, or applied to the surface of the patching material and the concrete. 2020 Standard Specifications M 41-10 Page 6-7 Concrete Structures 6-02 6-02 Concrete Structures 6-02.1 Description This Work consists of the construction of all Structures (and their parts) made of portland cement or blended hydraulic cement concrete with or without reinforcement, including bridge approach slabs. Any part of a Structure to be made of other materials shall be built as these Specifications require elsewhere. 6-02.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Concrete 9-03.1 Gravel Backfill 9-03.12 Joint and Crack Sealing Materials 9-04 Reinforcing Steel 9-07 Epoxy-Coated Reinforcing Steel 9-07 Pigmented Sealer Materials 9-08.3(1) Exposed Aggregate Concrete Coatings and Sealers 9-08.3(2) Permeon Treatment 9-08.3(3) Grout 9-20.3 Mortar 9-20.4 Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Ground Granulated Blast Furnace Slag 9-23.10 Microsilica Fume 9-23.11 Plastic Waterstop 9-24 Water 9-25 Fabricated Bridge Bearing Assemblies 9-31 6-02.3 Construction Requirements 6-02.3(1) Classification of Structural Concrete The class of concrete to be used shall be as noted in the Plans and these Specifications. The class includes the specified minimum compressive strength in psi at 28 days (numerical class) and may include a letter suffix to denote structural concrete for a specific use. Letter suffixes include A for bridge approach slabs, D for bridge decks, P for piling and shafts, and W for underwater. The numerical class without a letter suffix denotes structural concrete for general purposes. Page 6-8 2020 Standard Specifications M 41-10 6-02 Concrete Structures Concrete of a numerical class greater than 4000 shall conform to the requirements specified for either Class 4000 (if general-purpose) or for the appropriate Class 4000 with a letter suffix, as follows: 1. Mix design and proportioning specified in Sections 6-02.3(2), 6-02.3(2)A and 6-02.3(2)A1. 2. Consistency requirements specified in Section 6-02.3(4)C. 3. Temperature and time for placement requirements specified in Section 6-02.3(4)D. 4. Curing requirements specified in Section 6-02.3(11). The Contractor may request, in writing, permission to use a different class of concrete with either the same or a higher compressive strength than specified. The substitute concrete shall be evaluated for acceptance based on the specified class of concrete. The Engineer will respond in writing. The Contractor shall bear any added costs that result from the change. 6-02.3(2) Proportioning Materials The soluble chloride ion content shall be determined by the concrete supplier and included with the mix design. The soluble chloride ion content shall be determined by (1) testing mixed concrete cured at least 28 days or (2) totaled from tests of individual concrete ingredients (cement, aggregate, admixtures, water, fly ash, ground granulated blast furnace slag, and other supplementary cementing materials). Chloride ion limits for admixtures and water are provided in Sections 9-23 and 9-25. Soluble chloride ion limits for mixed concrete shall not exceed the following percent by mass of cement when tested in accordance with AASHTO T260: Category Acid-Soluble Water-Soluble Prestressed concrete 0.08 0.06 Reinforced concrete 0.10 0.08 Unless otherwise specified, the Contractor shall use Type I or II portland cement or blended hydraulic cement in all concrete as defined in Section 9-01.2(1). The use of fly ash is required for Class 4000P concrete, except that ground granulated blast furnace slag may be substituted for fly ash at a 1:1 ratio. The use of fly ash and ground granulated blast furnace slag is optional for all other classes of concrete and may be substituted for portland cement at a 1:1 ratio as noted in the table below. 2020 Standard Specifications M 41-10 Page 6-9 Concrete Structures 6-02 Cementitious Requirement for Concrete Class of Concrete Minimum Cementitious Content (Pounds) Minimum percent Replacement of Fly Ash or Ground Granulated Blast Furnace Slag for Portland Cement Maximum percent Replacement of Fly Ash for Portland Cement Maximum percent Replacement of Ground Granulated Blast Furnace Slag for Portland Cement 4000 564 *35 50 4000A 564 *20 30 4000P 600 15 35 50 4000W 564 *35 50 3000 564 *35 50 Commercial Concrete **564 *35 50 Pumpable Lean Concrete ******** Lean Concrete ****145 *35 50 *No minimum specified. **For Commercial Concrete, the minimum cementitious content is only required for sidewalks, curbs, and gutters. ***No maximum specified. ****Maximum of 200 pounds When both ground granulated blast furnace slag and fly ash are included in the concrete mix, the total weight of both these materials is limited to 40 percent by weight of the total cementitious material for concrete class 4000A, and 50 percent by weight of the total cementitious material for all other classes of concrete. The water/cement ratio shall be calculated on the total weight of cementitious material. Cementitious materials are those listed in Section 5-05.2. With the Engineer’s written concurrence, microsilica fume may be used in all classifications of Class 4000, Class 3000, and commercial concrete and is limited to a maximum of 10 percent of the cementitious material. As an alternative to the use of fly ash, ground granulated blast furnace slag and cement as separate components, a blended hydraulic cement that meets the requirements of Section 9-01.2(1)B Blended Hydraulic Cements may be used. 6-02.3(2)A Contractor Mix Design The Contractor shall provide a mix design in writing to the Engineer for all classes of concrete specified in the Plans except for lean concrete, commercial concrete and concrete class EA. No concrete shall be placed until the Engineer has reviewed the mix design. The required average 28-day compressive strength shall be selected in accordance with ACI 301, Chapter 4, Section 4.2.3.3. ACI 211.1 shall be used to determine proportions. All proposed concrete mixes except Class 4000D shall meet the requirements in Cementitious Requirement for Concrete in Section 6-02.3(2). Page 6-10 2020 Standard Specifications M 41-10 6-02 Concrete Structures The Contractor’s submittal of a mix design shall be on WSDOT Form 350-040 and shall provide a unique identification for each mix design and shall include the mix proportions per cubic yard, the proposed sources, the average 28-day compressive strength for which the mix is designed, the fineness modulus, and the water cement ratio. The mix design submittal shall also include test results no older than one year showing that the Aggregates do not contain Deleterious Substances in accordance with Section 9-03. Concrete placeability, workability, and strength shall be the responsibility of the Contractor. The Contractor shall notify the Engineer in writing of any mix design modifications. Fine aggregate shall conform to Section 9-03.1(2) Class 1 or Class 2. Coarse aggregate shall conform to Section 9-03. An alternate combined aggregate gradation conforming to Section 9-03.1(5) may also be used. The nominal maximum size aggregate for Class 4000P shall be ⅜ inch. The nominal maximum size aggregate for Class 4000A shall be 1 inch. Nominal maximum size for concrete aggregate is defined as the smallest standard sieve opening through which the entire amount of the aggregate is permitted to pass. A retarding admixture is required in concrete Class 4000P. Air content for concrete Class 4000D shall conform to Section 6-02.3(2)A1. For all other concrete, air content shall be a minimum of 4.5 percent and a maximum of 7.5 percent for all concrete placed above the finished ground line unless noted otherwise. 6-02.3(2)A1 Contractor Mix Design for Concrete Class 4000D All Class 4000D concrete shall conform to the following requirements: 1. Aggregate shall use combined gradation in accordance with Section 9-03.1(5) with a nominal maximum aggregate size of 1½ inches. 2. Permeability shall be less than 2,000 coulombs at 56 days in accordance with AASHTO T277. 3. Freeze-thaw durability shall be provided by one of the following methods: a. The concrete shall maintain an air content between 4.5 and 7.5 percent. b. The concrete shall maintain a minimum air content that achieves a durability factor of 90 percent, minimum, after 300 cycles in accordance with AASHTO T 161, Procedure A. This air content shall not be less than 3.0 percent. Test samples shall be obtained from concrete batches of a minimum of 3.0 cubic yards. 4. Shrinkage at 28 days shall be less than 0.032 percent in accordance with AASHTO T 160. 5. Density shall be measured in accordance with ASTM C138. 2020 Standard Specifications M 41-10 Page 6-11 Concrete Structures 6-02 The Contractor shall submit the mix design in accordance with Section 6-02.3(2)A. The submittal shall include test reports for all tests listed above that follow the reporting requirements of the AASHTO/ASTM procedures. Mix designs using shrinkage reducing admixture shall state the specific quantity required. Samples for testing may be obtained from either laboratory or concrete plant batches. If concrete plant batches are used, the minimum batch size shall be 3.0 cubic yards. Testing samples of mixes using shrinkage reducing admixture shall use the admixture amount specified in the mix design submittal. The Contractor shall submit the mix design to the Engineer at least 30 calendar days prior to the placement of concrete in the bridge deck. 6-02.3(2)A2 Contractor Mix Design for Self-Consolidating Concrete Self-consolidating concrete (SCC) is concrete that is able to flow under its own weight and completely fill the formwork without the need for vibration while maintaining homogeneity, even in the presence of dense reinforcement. SCC shall be capable of being pumped, and of flowing through the steel reinforcing bar cage without segregation or buildup of differential head inside or outside of the steel reinforcing bar cage. Type III cement may be used in SCC. SCC may be used for the following concrete Structure elements: 1. All cast-in-place concrete elements except bridge decks, bridge approach slabs, and any cast-in-place concrete element excluded by the Special Provisions. 2. Prestressed concrete girders in accordance with Sections 6-02.3(25). 3. All precast concrete elements identified in Section 6-02.3(27)A. The mix design submittal shall include items specified in Section 6-02.3(2)A and results of the following tests conducted on concrete that has slump flow within the slump flow range defined below: 1. Slump Flow. a. The mix design shall specify the target slump flow in inches, in accordance with WSDOT FOP for ASTM C1611. The slump flow range is defined as the target slump flow plus or minus 2-inches. b. The visual stability index (VSI) shall be less than or equal to 1, in accordance with ASTM C1611, Appendix X1, using Filling Procedure B. c. The T50 flow rate results shall be less than 6-seconds in accordance with ASTM C1611, Appendix X1, using Filling Procedure B. 2. Column Segregation. a. The maximum static segregation shall be 10-percent in accordance with ASTM C1610. b. The Maximum Hardened Visual Stability Index (HVSI) shall be 1 in accordance with AASHTO PP 58. Page 6-12 2020 Standard Specifications M 41-10 6-02 Concrete Structures 3. J ring test results for passing ability shall be less than or equal to 1.5-inches in accordance with the WSDOT FOP for ASTM C1621. 4. Rapid assessment of static segregation resistance of self-consolidating concrete using penetration test in accordance with ASTM C1712 shall be less than or equal to 15 mm. 5. Air content shall be tested in accordance with WSDOT Test Method T 818, and shall conform to Section 6-02.3(2)A. 6. Concrete unit weight results in pounds per cubic foot shall be recorded in accordance with AASHTO T 121, except that the concrete shall not be consolidated in the test mold. 7. The temperature of all concrete laboratory test samples shall be tested in accordance with AASHTO T 309 and shall conform to the placement limits specified in Section 6-02.3(4)D. 8. The modulus of elasticity in pounds per square inch at 28 days shall be recorded in accordance with ASTM C469. In lieu of a Contractor-Provided mix design for SCC for Section 6-02.3(27)A Structure elements 3, 7 and 8, a representative full-size example Structure element shall be cast for inspection by the Contracting Agency in accordance with Section 6-02.3(27)B as a component of the precast fabricating facility’s annual plant approval process. 6-02.3(2)B Commercial Concrete Commercial concrete shall have a minimum compressive strength at 28 days of 3,000 psi in accordance with AASHTO T 22. Commercial concrete placed above the finished ground line shall be air entrained and have an air content from 4.5 percent to 7.5 percent in accordance with FOP for AASHTO T 152. Commercial concrete does not require mix design or source approvals for cement, aggregate, and other admixtures. Where concrete Class 3000 is specified for items such as, culvert headwalls, plugging culverts, concrete pipe collars, pipe anchors, monument cases, Type PPB, PS, I, FB and RM signal standards, pedestals, cabinet bases, guardrail anchors, fence post footings, sidewalks, concrete curbs, curbs and gutters, and gutters, the Contractor may use commercial concrete. If commercial concrete is used for sidewalks, concrete curbs, curbs and gutters, and gutters, it shall have a minimum cementitious material content of 564 pounds per cubic yard of concrete, shall be air entrained, and the tolerances of Section 6-02.3(5)C shall apply. 2020 Standard Specifications M 41-10 Page 6-13 Concrete Structures 6-02 6-02.3(2)C Concrete Class EA Concrete for members and surfaces specified to receive an exposed aggregate finish shall be Class EA. Concrete Class EA shall conform to the following requirements: 28 day compressive strength 3,600 psi (minimum) Cement 610 pounds per cubic yard Fine Aggregate Class 1 880 pounds per cubic yard Coarse Aggregate Grading No. 67 2,160 pounds per cubic yard Water (maximum)270 pounds per cubic yard Water/Cement Ratio (maximum)0.44 A Type A water reducing admixture conforming to Section 9-23.6 shall be used in accordance with Section 6-02.3(3). Air content shall conform to Section 6-02.3(2)A. Mixing water shall be the minimum required for satisfactory placement and shall not exceed the specified amount. Aggregate weights are based on a specific gravity of 2.67. Adjustments in the mix design will be made by the Engineer as necessary to correct for actual bulk specific gravity of the aggregates, moisture content of the aggregates, and to ensure proper consistency, workability, and correct cement content per cubic yard of concrete. 6-02.3(2)D Lean Concrete Lean concrete shall meet the cementitious requirements of Section 6-02.3(2) and have a maximum water/cement ratio of 2. 6-02.3(3) Admixtures Concrete admixtures shall be added to the concrete mix at the time of batching the concrete or in accordance with the manufacturer’s written procedure and as accepted by the Engineer. A copy of the manufacturer’s written procedure shall be furnished to the Engineer prior to use of any admixture. Any deviations from the manufacturer’s written procedures shall be submitted as a Type 2 Working Drawing. Admixtures shall not be added to the concrete with the modified procedures until the Engineer has concurred in writing. When the Contractor is proposing to use admixtures from different admixture manufacturers they shall provide evidence to the Engineer that the admixture will be compatible and not adversely affect the air void system of the hardened concrete. Test results complying with ASTM C457 shall be provided as the evidence to satisfy this requirement. Admixture combinations which have been previously tested and which are in compliance with ASTM C457 shall be listed in the Qualified Products List (QPL). Proposed combinations not found in the QPL shall meet this requirement. Accelerators shall not be used. Page 6-14 2020 Standard Specifications M 41-10 6-02 Concrete Structures Accelerating admixtures conforming to Sections 9-23.6(4) or 9-23.6(6) and used in accordance with the manufacturer’s recommendations may be used in cast-in-place concrete, except as required here. Accelerating admixtures shall not be used in bridge decks, all concrete superstructures, crossbeams, columns, mass concrete, or new bridge approach slabs and expansion joints that are not part of a repair. Concrete placements with the least dimension greater than 6 feet shall be considered mass concrete. Concrete placement with the least dimension greater than 3 feet, but less than or equal than 6 feet, shall require the approval of the Engineer for the use of accelerating admixtures. Shafts shall not be considered mass concrete. Chloride based accelerating admixtures shall not be used. Air entrained cement shall not be used to air entrain concrete. 6-02.3(4) Ready-Mix Concrete All concrete, except lean concrete shall be batched in a prequalified manual, semi- automatic, or automatic plant as described in Section 6-02.3(4)A. The Engineer is not responsible for any delays to the Contractor due to problems in getting the plant certified. 6-02.3(4)A Qualification of Concrete Suppliers Batch Plant Prequalification requires a certification by the National Ready Mix Concrete Association (NRMCA). Information concerning NRMCA certification may be obtained from the NRMCA at 900 Spring Street, Silver Springs, MD 20910 or online at www. nrmca.org. The NRMCA certification shall be valid for a 2-year period from the date of certificate. The following documentation shall be submitted to the Engineer; a copy of the current NRMCA Certificate of Conformance, the concrete mix design(s) (WSDOT Form 350-040), along with copies of the truck list, batch plant scale certification, admixture dispensing certification, and volumetric water batching devices (including water meters) verification. For central-mixed concrete, the mixer shall be equipped with a timer that prevents the batch from discharging until the batch has been mixed for the prescribed mixing time. A mixing time of 1 minute will be required after all materials and water have been introduced into the drum. Shorter mixing time may be allowed if the mixer performance is tested in accordance with (AASHTO M157 Annex A1 Concrete Uniformity Requirements). Tests shall be conducted by an independent testing lab or by a commercial concrete producer’s lab. If the tests are performed by a producer’s lab, the Engineer or a representative will witness all testing. For shrink-mixed concrete, the mixing time in the stationary mixer shall not be less than 30 seconds or until the ingredients have been thoroughly blended. For transit-mixed or shrink-mixed concrete, the mixing time in the transit mixer shall be a minimum of 70 revolutions at the mixing speed designated by the manufacturer of the mixer. Following mixing, the concrete in the transit mixer may be agitated at the manufacturer’s designated agitation speed. A maximum of 320 revolutions (total of mixing and agitation) will be permitted prior to discharge. 2020 Standard Specifications M 41-10 Page 6-15 Concrete Structures 6-02 All transit-mixers shall be equipped with an operational revolution counter and a functional device for measurement of water added. All mixing drums shall be free of concrete buildup and the mixing blades shall meet the minimum Specifications of the drum manufacturer. A copy of the manufacturer’s blade dimensions and configuration shall be on file at the concrete producer’s office. A clearly visible metal data plate (or plates) attached to each mixer and agitator shall display: (1) the maximum concrete capacity of the drum or container for mixing and agitating, and (2) the rotation speed of the drum or blades for both the agitation and mixing speeds. Mixers and agitators shall always operate within the capacity and speed-of-rotation limits set by the manufacturer. Any mixer, when fully loaded, shall keep the concrete uniformly mixed. All mixers and agitators shall be capable of discharging the concrete at a steady rate. Only those transit- mixers which meet the above requirements will be allowed to deliver concrete to any Contracting Agency project covered by these Specifications. In transit-mixing, mixing shall begin within 30 seconds after the cement is added to the aggregates. Central-mixed concrete, transported by truck mixer/agitator, shall not undergo more than 250 revolutions of the drum or blades before beginning discharging. To remain below this limit, the suppler may agitate the concrete intermittently within the prescribed time limit. When water or admixtures are added after the load is initially mixed, an additional 30 revolutions will be required at the recommended mixing speed. For each project, at least biannually, or as required, the Plant Manager will examine mixers and agitators to check for any buildup of hardened concrete or worn blades. If this examination reveals a problem, or if the Engineer wishes to test the quality of the concrete, slump tests may be performed with samples taken at approximately the ¼ and ¾ points as the batch is discharged. The maximum allowable slump difference shall be as follows: If the average of the two slump tests is < 4 inches, the difference shall be < 1 inch or if the average of the two slump tests is >4 inches, the difference shall be < 1½ inches. If the slump difference exceeds these limits, the equipment shall not be used until the faulty condition is corrected. However, the equipment may continue in use if longer mixing times or smaller loads produce batches that pass the slump uniformity tests. All concrete production facilities will be subject to verification inspections at the discretion of the Engineer. Verification inspections are a check for: current scale certifications; accuracy of water metering devices; accuracy of the batching process; and verification of coarse aggregate quality. If the concrete producer fails to pass the verification inspection, the following actions will be taken: 1. For the first violation, a written warning will be provided. Page 6-16 2020 Standard Specifications M 41-10 6-02 Concrete Structures 2. For the second violation, the Engineer will give written notification and the Contracting Agency will assess a price reduction equal to 15 percent of the invoice cost of the concrete that is supplied from the time of the infraction until the deficient condition is corrected. 3. For the third violation, the concrete supplier is suspended from providing concrete until all such deficiencies causing the violation have been permanently corrected and the plant and equipment have been reinspected and meets all the prequalification requirements. 4. For the fourth violation, the concrete supplier shall be disqualified from supplying concrete for 1 year from the date of disqualification. At the end of the suspension period the concrete supplier may request that the facilities be inspected for prequalification. 6-02.3(4)B Jobsite Mixing For small quantities of concrete, the Contractor may mix concrete on the job site provided the Contractor has requested in writing and received written permission from the Engineer. The Contractor’s written request shall include a mix design, batching and mixing procedures, and a list of the equipment performing the job-site mixing. All job site mixed concrete shall be mixed in a mechanical mixer. If the Engineer permits, hand mixing of concrete will be permitted for pipe collars, pipe plugs, fence posts, or other items receiving the concurrence of the Engineer, provided the hand mixing is done on a watertight platform in a way that distributes materials evenly throughout the mass. Mixing shall continue long enough to produce a uniform mixture. No hand mixed batch shall exceed ½ cubic yard. Concrete mixed at the jobsite is never permitted for placement in water. 6-02.3(4)C Consistency The maximum slump for concrete shall be: 1. 3½ inches for vibrated concrete placed in all bridge decks, bridge approach slabs, and flat slab bridge Superstructures. 2. 4½ inches for all other vibrated concrete. 3. 7 inches for non-vibrated concrete. (Includes Class 4000P) 4. 9 inches for shafts when using Class 4000P, provided the water cement ratio does not exceed 0.44 and a water reducer is used meeting the requirements of Section 9-23.6. 5. 5½ inches for all concrete placed in curbs, gutters, and sidewalks. When a high range water reducer is used, the maximum slump listed in 1, 2, 3, and 5 above, may be increased an additional 2 inches. For self-consolidating concrete (SCC), the slump requirements specified above do not apply, and are instead replaced by the target slump flow and slump flow range specified as part of the SCC mix design. 2020 Standard Specifications M 41-10 Page 6-17 Concrete Structures 6-02 6-02.3(4)D Temperature and Time For Placement Concrete temperatures shall remain between 55°F and 90°F while it is being placed, except that Class 4000D concrete temperatures shall remain between 55°F and 75°F during placement. The upper limit for placement for Class 4000D concrete may be increased to a maximum of 80°F if allowed by the Engineer. Precast concrete that is heat cured in accordance with Section 6-02.3(25)D shall remain between 50°F and 90°F while being placed. The batch of concrete shall be discharged at the project site no more than 1½ hours after the cement is added to the concrete mixture. The time to discharge may be extended to 1¾ hours if the temperature of the concrete being placed is less than 75°F. With the concurrence of the Engineer and as long as the temperature of the concrete being placed is below 75°F, the maximum time to discharge may be extended to 2 hours. When conditions are such that the concrete may experience an accelerated initial set, the Engineer may require a shorter time to discharge. The time to discharge may be extended upon written request from the Contractor. This time extension will be considered on a case by case basis and requires the use of specific retardation admixtures and the concurrence of the Engineer. 6-02.3(5) Acceptance of Concrete 6-02.3(5)A General Concrete for the following applications will be accepted based on a Certificate of Compliance to be provided by the supplier as described in Section 6-02.3(5)B: 1. Lean concrete. 2. Commercial concrete. 3. Class 4000P concrete for Roadside Steel Sign Support Foundations. 4. Class 4000P concrete for Type II, III, and CCTV Signal Standard Foundations that are 12’-0” or less in depth. 5. Class 4000P concrete for Type IV and V Strain Pole Foundations that are 12’-0” or less in depth. 6. Class 4000P concrete for Steel Light Standard Foundations Types A & B. Concrete Class EA will be accepted based on conformance to the requirements specified in Section 6-02.3(2)C for proportioning, temperature, and 28 day compressive strength. Slip-form barrier concrete will be accepted based on conformance to the requirements for temperature, air content and compressive strength at 28 days for sublots as tested and determined by the Contracting Agency. All other concrete will be accepted based on conformance to the requirement for temperature, slump, air content for concrete placed above finished ground line, and the specified compressive strength at 28 days for sublots as tested and determined by the Contracting Agency. A sublot is defined as the material represented by an individual strength test. An individual strength test is the average compressive strength of cylinders from the same sample of material. Page 6-18 2020 Standard Specifications M 41-10 6-02 Concrete Structures Each sublot will be deemed to have met the specified compressive strength requirement when both of the following conditions are met: 1. Individual strength tests do not fall below the specified strength by more than 12½ percent or 500 psi, whichever is least. 2. An individual strength test averaged with the two preceding individual strength tests meets or exceeds specified strength (for the same class and exact mix I.D. of concrete on the same Contract). When compressive strengths fail to satisfy one or both of the above requirements, the Contractor may: 1. Request acceptance based on the Contractor/Suppliers strength test data for cylinders made from the same truckload of concrete as the Contracting Agency cylinders; provided: a. The Contractor’s test results are obtained from testing cylinders fabricated, handled, and stored for 28 days in accordance with FOP for AASHTO T 23 and tested in accordance with AASHTO T 22. The test cylinders shall be the same size cylinders as those cast by the Contracting Agency. b. The technician fabricating the cylinders is qualified by either ACI, Grade 1 or WAQTC to perform this Work. c. The Laboratory performing the tests in accordance with AASHTO T 22 has an equipment calibration/certification system, and a technician training and evaluation process in accordance with AASHTO R-18. d. Both the Contractor and Contracting Agency have at least 15 test results from the same mix to compare. The Contractor’s results could be used if the Contractor’s computed average of all their test results is within one standard deviation of the Contracting Agency’s average test result. The computed standard deviation of the Contractor’s results must also be within plus or minus 200 psi of the Contracting Agency’s standard deviation. 2. Request acceptance of in-place concrete strength based on core results. This method will not be used if the Engineer determines coring would be harmful to the integrity of the Structure. Cores, if allowed, will be obtained by the Contractor in accordance with AASHTO T 24 and delivered to the Contracting Agency for testing in accordance with AASHTO T 22. If the concrete in the Structure will be dry under service conditions, the core will be air dried at a temperature of between 60°F and 80°F and at a relative humidity of less than 60 percent for 7 days before testing, and will be tested air dry. Acceptance for each sublot by the core method requires that the average compressive strength of three cores be at least 85 percent of the specified strength with no one core less than 75 percent of the specified strength. When the Contractor requests strength analysis by coring, the results obtained will be accepted by both parties as conclusive and supersede all other strength data for the concrete sublot. 2020 Standard Specifications M 41-10 Page 6-19 Concrete Structures 6-02 If the Contractor elects to core, cores shall be obtained no later than 50 days after initial concrete placement. The Engineer will concur in the locations to be cored. Repair of cored areas shall be the responsibility of the Contractor. The cost incurred in coring and testing these cores, including repair of core locations, shall be borne by the Contractor. 6-02.3(5)B Certification of Compliance The concrete producer shall provide a Certificate of Compliance for each truckload of concrete. The Certificate of Compliance shall verify that the delivered concrete is in compliance with the mix design and shall include: Manufacturer plant (batching facility) Contracting Agency Contract number Date Time batched Truck No. Initial revolution counter reading Quantity (quantity batched this load) Type of concrete by class and producer design mix number Cement producer, type, and Mill Certification No. (The mill test number as required by Section 9-01.3 is the basis for acceptance of cement.) Fly ash (if used) brand and Class Accepted aggregate gradation designation Mix design weight per cubic yard and actual batched weights for: Cement Fly ash (if used) Coarse concrete aggregate and moisture content (each size) Fine concrete aggregate and moisture content Water (including free moisture in aggregates) Admixtures brand and total quantity batched Air-entraining admixture Water-reducing admixture Other admixture For concretes that use combined aggregate gradation, the Certificate of Compliance shall include the aggregate components and moisture contents for each size in lieu of the aggregate information described above. In lieu of providing a machine produced record containing all of the above information, the concrete producer may use the Contracting Agency-provided printed forms, which shall be completed for each load of concrete delivered to the project. For commercial concrete, the Certificate of Compliance shall include, as a minimum, the batching facility, date, and quantity batched per load. Page 6-20 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(5)C Conformance to Mix Design Cement, coarse and fine aggregate weights shall be within the following tolerances of the mix design: Batch Volumes less than or equal to 4 cubic yards Batch Volumes more than 4 cubic yards Cement +5%-1%Cement +5%-1% Aggregate +10%-2%Aggregate +2%-2% If the total cementitious material weight is made up of different components, these component weights shall be within the following tolerances: 1. Cement weight plus 5 percent or minus 1 percent of that specified in the mix design. 2. Fly ash and ground granulated blast furnace slag weight plus or minus 5 percent of that specified in the mix design. 3. Microsilica weight plus or minus 10 percent of that specified in the mix design. Water shall not exceed the maximum water specified in the mix design. 6-02.3(5)D Test Methods Acceptance testing will be performed by the Contracting Agency in accordance with the WSDOT Materials Manual M 46-01. The test methods to be used with this Specification are: AASHTO T 22 Compressive Strength of Cylindrical Concrete Specimens FOP for AASHTO T 23 Making and Curing Concrete Test Specimens in the Field FOP for AASHTO T 119 Slump of Hydraulic Cement Concrete FOP for WAQTC TM 2 Sampling Freshly Mixed Concrete FOP for AASHTO T 152 Air Content of Freshly Mixed Concrete by the Pressure Method FOP for AASHTO T 231 Capping Cylindrical Concrete Specimens FOP for AASHTO T 309 Temperature of Freshly Mixed Portland Cement Concrete ASTM C1611 Standard Test Method for Slump Flow of Self-Consolidating Concrete (Inverted Mold Method only) ASTM C1621 Standard Test Method for Passing Ability of Self- Consolidating Concrete by J-Ring (Inverted Mold Method only) 2020 Standard Specifications M 41-10 Page 6-21 Concrete Structures 6-02 6-02.3(5)E Point of Acceptance Determination of concrete properties for acceptance will be made based on samples taken as follows: Bridge decks, overlays, bridge approach slabs, and barriers at the discharge of the placement system. All other placements at the truck discharge. It shall be the Contractor’s responsibility to provide adequate and representative samples of the fresh concrete to a location designated by the Engineer for the testing of concrete properties and making of cylinder specimens. Samples shall be provided as directed in Sections 1-06.1 and 1-06.2. Once the Contractor has turned over the concrete for acceptance testing, no more mix adjustment will be allowed. The concrete will either be accepted or rejected. 6-02.3(5)F Water/Cement Ratio Conformance The actual water cement ratio shall be determined from the certified proportions of the mix, adjusting for on the job additions. No water may be added after acceptance testing or after placement has begun, except for concrete used in slip forming. For slip-formed concrete, water may be added during placement but shall not exceed the maximum water cement ratio in the mix design, and shall meet the requirements for consistency as described in Section 6-02.3(4)C. If water is added, an air and temperature test shall be taken prior to resuming placement to ensure that Specification conformance has been maintained. 6-02.3(5)G Sampling and Testing for Temperature, Consistency, and Air Content Concrete properties shall be determined from concrete as delivered to the project and as accepted by the Contractor for placement. The Contracting Agency will perform acceptance testing on all concrete for temperature and air content, if applicable. Concrete that is not self-consolidating concrete will be tested for slump. The following additional acceptance tests will be performed on self-consolidating concrete: 1. Slump flow within the target slump flow range. 2. J ring passing ability less than or equal to 1.5 inches. 3. VSI less than or equal to 1. Sampling and testing will be performed before concrete placement from the first load. Concrete shall not be placed until all tests have been completed by the Engineer, and the results indicate that the concrete is within acceptable limits. If the concrete is not within acceptable limits, sampling and testing will continue before concrete placement for each load until one load meets all of the applicable acceptance requirements. After one test indicates that the concrete is within specified limits, the concrete may be placed and the sampling and testing frequency may decrease to one for every 100 cubic yards. Sampling shall be performed in accordance with FOP for WAQTC TM 2 and random samples shall Page 6-22 2020 Standard Specifications M 41-10 6-02 Concrete Structures be selected in accordance with WSDOT T 716. After the first acceptable load of concrete, up to ½ cubic yard may be placed from subsequent loads to be tested prior to testing for acceptance. When the results for any subsequent acceptance test indicates that the concrete as delivered and approved by the Contractor for placement does not conform to the specified limits, the sampling and testing frequency will be resumed for each load. Whenever one subsequent test indicates that the concrete is within the specified limits, the random sampling and testing frequency of one for every 100 cubic yards may resume. Sampling and testing for a placement of one class of concrete consisting of 50 cubic yards or less will be as listed above, except that after one set of tests indicate that the concrete is within specified limits, the remaining concrete to be placed may be accepted by visual inspection. 6-02.3(5)H Sampling and Testing for Compressive Strength and Initial Curing Acceptance testing for compressive strength shall be conducted at the same frequency as the acceptance tests for temperature, consistency, and air content. The Contractor shall provide and maintain a sufficient number of cure boxes in accordance with FOP for AASHTO T 23 for curing concrete cylinders. The cure boxes shall be readily accessible and no more than 500 feet from the point of acceptance testing, unless otherwise allowed by the Engineer. The Contractor shall also provide, maintain and operate all necessary power sources and connections needed to operate the cure boxes. The cure boxes shall be in-place and functioning at the specified temperature for curing cylinders prior to concrete placement. Concrete cylinders shall be cured in the cure boxes in accordance with FOP for AASHTO T 23. The cure boxes shall have working locks and the Contractor shall provide the Engineer with one key to each of the locks. Once concrete cylinders are placed in the cure box, the cure box shall not be disturbed until the cylinders have been removed. The Contractor shall retain the cure box Temperature Measuring Device log and provide it to the Engineer upon request. The Contractor shall protect concrete cylinders in cure boxes from excessive vibration and shock waves during the curing period in accordance with Section 6-02.3(6)D. All cure box costs shall be incidental to the associated item of work. 6-02.3(5)I Test Section for Cast-In-Place SCC Unless otherwise approved by the Engineer, the Contractor shall construct a test section of the element being constructed of cast-in-place SCC. The Contractor shall confirm, through the SCC placement operation in the test section, the SCC flows the distance required, completely filling the forms and encapsulating the reinforcement as required without leaving voids and pockets and causing segregation of the SCC mix. The test section forms, reinforcing steel and concrete placing operations shall be identical to those to be used in the production elements. 2020 Standard Specifications M 41-10 Page 6-23 Concrete Structures 6-02 For horizontal elements, the test section shall simulate the flow of concrete for the maximum distance anticipated during production concrete placement. The depth and width of the test section for horizontal element may be smaller than the actual depth and width of the element to be cast. For vertical elements, the test section shall be a minimum of 33-percent of the height of the tallest element to be constructed. The Contractor shall submit Type 2 Working Drawings consisting of formwork and reinforcement details of the test section and SCC placement procedures. After removing the forms, the test section will be inspected for signs of honeycombs, cracks, aggregate segregation, sedimentation, cold joints, and other surface and concrete placement defects. If such defects are present, the Contractor shall revise the formwork and SCC placement procedures as necessary to eliminate such defects. Acceptance of the test section and the SCC mix design is contingent on acceptable visual inspection, and a minimum of two 4-inch minimum diameter core samples taken from the placement location and the furthest-most limits of the concrete as identified by the Engineer. The number of core locations will be specified by the Engineer. The difference in average unit weight of the locations represented by the core samples shall be less than 5-percent. The Contractor shall use the same SCC placement procedures confirmed by the Engineer accepted test section for casting the production members. 6-02.3(5)J Vacant 6-02.3(5)K Rejecting Concrete Rejection Without Testing – The Engineer, prior to sampling, may reject any batch or load of concrete that appears defective in composition; such as cement content or aggregate proportions. Rejected material shall not be incorporated in the Structure. 6-02.3(5)L Concrete With Non-Conforming Strength Concrete with cylinder compressive strengths (fc) that fail to meet acceptance level requirements shall be evaluated for structural adequacy. If the material is found to be adequate, payment shall be adjusted in accordance with the following formula: Pay adjustment = 2(f’c – fc)(UP)(Q) f’cWhere: f’c = Specified minimum compressive strength at 28 days. fc = Compressive strength at 28 days as determined by AASHTO Test Methods. UP = Unit Contract price per cubic yard for the class of concrete involved. Q = Quantity of concrete represented by an acceptance test based on the required frequency of testing. Page 6-24 2020 Standard Specifications M 41-10 6-02 Concrete Structures Concrete that fails to meet minimum acceptance levels using the coring method will be evaluated for structural adequacy. If the material is found to be adequate, payment shall be adjusted in accordance with the following formula: Pay adjustment = 3.56(.85f’c – f cores)(UP)(Q) f’cWhere: f’c = Specified minimum compressive strength at 28 days. f cores = Compressive strength of the cores as determined by AASHTO T 22. UP = Unit Contract price per cubic yard for the class of concrete involved. Q = Quantity of concrete represented by an acceptance test based on the required frequency of testing. Where these Specifications designate payment for the concrete on other than a per cubic yard basis, the unit Contract price of concrete shall be taken as $300 per cubic yard for concrete Class 4000, 5000, and 6000. For concrete Class 3000, the unit contract price for Concrete shall be $160 per cubic yard. 6-02.3(6) Placing Concrete The Contractor shall not place concrete: 1. On frozen or ice-coated ground or Subgrade; 2. Against or on ice-coated forms, reinforcing steel, structural steel, conduits, precast members, or construction joints; 3. Under rainy conditions; placing of concrete shall be stopped before the quantity of surface water is sufficient to affect or damage surface mortar quality or cause a flow or wash the concrete surface; 4. In any foundation until the Engineer has accepted its depth and character; 5. In any form until the Engineer has accepted it and the placement of any reinforcing in it; or 6. In any Work area when vibrations from nearby Work may harm the concrete’s initial set or strength. When a foundation excavation contains water, the Contractor shall pump it dry before placing concrete. If this is impossible, an underwater concrete seal shall be placed that complies with Section 6-02.3(6)B. This seal shall be thick enough to resist any uplift. All foundations, forms, and contacting concrete surfaces shall be moistened with water just before the concrete is placed. Any standing water on the foundation, on the concrete surface, or in the form shall be removed. The Contractor shall place concrete in the forms as soon as possible after mixing. The concrete shall always be plastic and workable. For this reason, the Engineer may reduce the time to discharge even further. Concrete placement shall be continuous, with no interruption longer than 30 minutes between adjoining layers unless the Engineer allows a longer time. The Type 2 Working Drawing submittal shall include justification that the concrete mix design will remain fluid for interruptions longer than 30 minutes between 2020 Standard Specifications M 41-10 Page 6-25 Concrete Structures 6-02 placements. Each layer shall be placed and consolidated before the preceding layer takes initial set. After initial set, the forms shall not be jarred, and projecting ends of reinforcing bars shall not be disturbed. In girders or walls, concrete shall be placed in continuous, horizontal layers 1½ to 2½ feet deep. Compaction shall leave no line of separation between layers. In each part of a form, the concrete shall be deposited as near its final position as possible. Any method for placing and consolidating shall not segregate aggregates or displace reinforcing steel. Any method shall leave a compact, dense, and impervious concrete with smooth faces on exposed surfaces. Plastering is not permitted. Any section of defective concrete shall be removed at the Contractor’s expense. To prevent aggregates from separating, the length of any conveyor belt used to transport concrete shall not exceed 300 feet. If the mix needs protection from sun or rain, the Contractor shall cover the belt. When concrete pumps are used for placement, a Contractor’s representative shall, prior to use on the first placement of each day, visually inspect the pumps water chamber for water leakage. No pump shall be used that allows free water to flow past the piston. If a concrete pump is used as the placing system, the pump priming slurry shall be discarded before placement. Initial acceptance testing may be delayed until the pump priming slurry has been eliminated from the concrete being pumped. Eliminating the priming slurry from the concrete may require that several cubic yards of concrete are discharged through the pumping system and discarded. Use of a concrete pump requires a reserve pump (or other backup equipment) at the site. If the concrete will drop more than 5 feet, it shall be deposited through a sheet metal (or other accepted) conduit. If the form slopes, the concrete shall be lowered through accepted conduit to keep it from sliding down one side of the form. No aluminum conduits or tremies shall be used to pump or place concrete. Before placing bridge deck concrete on steel spans, the Contractor shall release the falsework under the bridge and let the span swing free on its supports. Concrete in flat slab bridges shall be placed in one continuous operation for each span or series of continuous spans. Concrete for bridge decks and the stems of T-beams or box-girders shall be placed in separate operations if the stem of the beam or girder is more than 3 feet deep. First the beam or girder stem shall be filled to the bottom of the slab fillets. Bridge deck concrete shall not be placed until enough time has passed to permit the earlier concrete to shrink (at least 12 hours). If stem depth is 3 feet or less, the Contractor may place concrete in 1 continuous operation if the Engineer concurs. Between expansion or construction joints, concrete in beams, girders, bridge decks, piers, columns, walls, and traffic and pedestrian barriers, etc., shall be placed in a continuous operation. Page 6-26 2020 Standard Specifications M 41-10 6-02 Concrete Structures No traffic or pedestrian barrier shall be placed until after the bridge deck is complete for the entire Structure. No concrete barriers shall be placed until the falsework has been released and the span supports itself. The Contractor may choose not to release the deck overhang falsework prior to the barrier placement. The Contractor shall submit Type 2E Working Drawings consisting of calculations indicating the loads induced into the girder webs due to the barrier weight and any live load placed on the Structure do not exceed the design capacity of the girder component. This analysis is not required for bridges with concrete Superstructures. No barrier, curb, or sidewalk shall be placed on steel or prestressed concrete girder bridges until the bridge deck reaches a compressive strength of at least 3,000 psi. The Contractor may construct traffic and pedestrian barriers by the slipform method. However, the barrier may not deviate more than ¼ inch when measured by a 10-foot straightedge held longitudinally on the front face, back face, and top surface. Electrical conduit within the barrier shall be constructed in accordance with the requirements of Section 8-20.3(5). When placing concrete in arch rings, the Contractor shall ensure that the load on the falsework remains symmetrical and uniform. Unless otherwise allowed by the Engineer, arch ribs in open spandrel arches shall be placed in sections. Small key sections between large sections shall be filled after the large sections have shrunk. 6-02.3(6)A Weather and Temperature Limits to Protect Concrete 6-02.3(6)A1 Hot Weather Protection The Contractor shall provide concrete within the specified temperature limits. Cooling of the coarse aggregate piles by sprinkling with water is permitted provided the moisture content is monitored, the mixing water is adjusted for the free water in the aggregate and the coarse aggregate is removed from at least 1 foot above the bottom of the pile. Sprinkling of fine aggregate piles with water is not allowed. Refrigerating mixing water, or replacing all or part of the mixing water with crushed ice is permitted, provided the ice is completely melted by placing time. If air temperature exceeds 90°F, the Contractor shall use water spray or other accepted methods to cool all concrete-contact surfaces to less than 90°F. These surfaces include forms, reinforcing steel, steel beam flanges, and any others that touch the concrete. 6-02.3(6)A2 Cold Weather Protection Concrete shall be maintained at or above a temperature of 40°F during the first seven days of the Cold Weather Protection Period and at or above a temperature of 35°F during the remainder of the Cold Weather Protection Period. Cold weather protection requirements do not apply to concrete in shafts and piles placed below the ground line. 2020 Standard Specifications M 41-10 Page 6-27 Concrete Structures 6-02 Prior to placing concrete in cold weather, the Contractor shall submit a Type 2 Working Drawing with a written procedure for cold weather concreting. The procedure shall detail how the Contractor will adequately cure the concrete and prevent the concrete temperature from falling below the minimum temperature. Extra protection shall be provided for areas especially vulnerable to freezing (such as exposed top surfaces, corners and edges, thin sections, and concrete placed into steel forms). Concrete placement will only be allowed if the Contractor’s cold weather protection plan has been accepted by the Engineer. Prior to concrete placement, the Contractor shall review the 7-day temperature predictions for the job site from the Western Region Headquarters of the National Weather Service (www.wrh.noaa.gov). When temperatures below 35°F are predicted, the Contractor shall: 1. Install temperature sensors in each concrete placement. One sensor shall be installed for every 100 cubic yards of concrete placed. Sensors shall be installed at locations directed by the Engineer, and shall be placed 1.5 inches from the face of concrete. 2. Immediately after concrete placement, temperature sensors shall be installed on the concrete surface at locations directed by the Engineer. One sensor shall be installed for every 100 cubic yards of concrete placed. Temperatures shall be measured and recorded a minimum of every hour for the duration of the Cold Weather Protection Period. Temperature data shall be submitted to the Engineer as a Type 1 Working Drawing within three days following the end of the Cold Weather Protection Period. For each day that the concrete temperature falls below 40°F during the first seven days of the Cold Weather Protection Period, no curing time is awarded for that day and the Cold Weather Protection Period is extended for one additional day. If the concrete temperature falls below 35°F during the Cold Weather Protection Period, the concrete may be rejected by the Engineer. 6-02.3(6)B Placing Concrete in Foundation Seals If the Plans require a concrete seal, the Contractor shall place the concrete underwater inside a watertight cofferdam, tube, or caisson. Seal concrete shall be placed in a compact mass in still water. It shall remain undisturbed and in still water until fully set. While seal concrete is being deposited, the water elevation inside and outside the cofferdam shall remain equal to prevent any flow through the seal in either direction. The cofferdam shall be vented at the vent elevation shown in the Plans. The thickness of the seal is based upon this vent elevation. The seal shall be at least 18 inches thick unless the Plans show otherwise. The Engineer may change the seal thickness during construction which may require redesign of the footing and the pier shaft or column. Although seal thickness changes may result in the use of more or less concrete, reinforcing steel, and excavation, payment will remain as originally defined in unit Contract prices. Page 6-28 2020 Standard Specifications M 41-10 6-02 Concrete Structures To place seal concrete underwater, the Contractor shall use a concrete pump or tremie. The tremie shall have a hopper at the top that empties into a watertight tube at least 10 inches in diameter. The discharge end of the tube on the tremie or concrete pump shall include a device to seal out water while the tube is first filled with concrete. Tube supports shall permit the discharge end to move freely across the entire Work area and to drop rapidly to slow or stop the flow. One tremie may be used to concrete an area up to 18 feet per side. Each additional area of this size requires one additional tremie. Throughout the underwater concrete placement operation, the discharge end of the tube shall remain submerged in the concrete and the tube shall always contain enough concrete to prevent water from entering. The concrete placement shall be continuous until the Work is completed, resulting in a seamless, uniform seal. If the concreting operation is interrupted, the Engineer may require the Contractor to prove by core drilling or other tests that the seal contains no voids or horizontal joints. If testing reveals voids or joints, the Contractor shall repair them or replace the seal at no expense to the Contracting Agency. Concrete Class 4000W shall be used for seals, and it shall meet the consistency requirements of Section 6-02.3(4)C. 6-02.3(6)C Dewatering Concrete Seals and Foundations After a concrete seal is constructed, the Contractor shall pump the water out of the cofferdam and place the rest of the concrete in the dry. This pumping shall not begin until the seal has set enough to withstand the hydrostatic pressure (3 days for gravity seals and 10 days for seals containing piling or shafts). The Engineer may extend these waiting periods to ensure structural safety or to meet a condition of the operating permit. If weighted cribs are used to resist hydrostatic pressure at the bottom of the seal, the Contractor shall anchor them to the foundation seal. Any method used (such as dowels or keys) shall transfer the entire weight of the crib to the seal. No pumping shall be done during or for 24 hours after concrete placement unless done from a suitable sump separated from the concrete Work by a watertight wall. Pumping shall be done in a way that rules out any chance of concrete being carried away. 6-02.3(6)D Protection Against Vibration Freshly placed concrete shall not be subjected to excessive vibration and shock waves during the curing period until it has reached a 2,000 psi minimum compressive strength for structural concrete and lower-strength classes of concrete. After the first 5 hours from the time the concrete has been placed and consolidated, the Contractor shall keep all vibration producing operations at a safe horizontal distance from the freshly placed concrete by following either the prescriptive safe distance method or the monitoring safe distance method. These requirements for the protection of freshly placed concrete against vibration shall not apply for plant cast concrete, nor shall they apply to the vibrations caused by the traveling public. 2020 Standard Specifications M 41-10 Page 6-29 Concrete Structures 6-02 6-02.3(6)D1 Prescriptive Safe Distance Method After the concrete has been placed and consolidated, the Contractor shall keep all vibration producing operations at a safe horizontal distance from the freshly placed concrete as follows: Minimum Compressive Strength, f’c Safe Horizontal Distance1 Equipment Class L2 Equipment Class H3 < 1,000 psi 75 feet 125 feet 1,000 to < 1,400 psi 30 feet 50 feet 1,400 to 2,000 psi 15 feet 25 feet 1The safe horizontal distance shall be reduced to 10 feet for small rubber tire construction equipment like backhoes under 50,000 pounds, concrete placing equipment, and legal Highway vehicles if such equipment travels at speeds of:  • ≤ 5 mph on relatively smooth Roadway surfaces or  • ≤ 3 mph on rough Roadway surfaces (i.e., with potholes) 2Equipment Class L (Low Vibration) shall include tracked dozers under 85,000 pounds, track vehicles, trucks (unless excluded above), hand-operated jack hammers, cranes, auger drill rig, caisson drilling, vibratory roller compactors under 30,000 pounds, and grab-hammers. 3Equipment Class H (High Vibration) shall include pile drivers, vibratory hammers, machine-operated impact tools, pavement breakers, and other large pieces of equipment. After the concrete has reached a minimum compressive strength specified above, the safe horizontal distance restrictions would no longer apply. 6-02.3(6)D2 Monitoring Safe Distance Method The Contractor may monitor the vibration producing operations in order to decrease the safe horizontal distance requirements of the prescriptive safe distance method. If this method is chosen, all construction operations that produce vibration or shock waves in the vicinity of freshly placed concrete shall be monitored by the Contractor with monitoring equipment sensitive enough to detect a minimum peak particle velocity (PPV) of 0.10 inches per second. Monitoring devices shall be placed on or adjacent to the freshly placed concrete when the measurements are taken. During the time subsequent to the concrete placement, the Contractor shall cease all vibration or shock producing operations in the vicinity of the newly placed concrete when the monitoring equipment detects excessive vibration and shock waves defined as exceeding the following PPVs: Minimum Compressive Strength, f’c Maximum PPV < 1,000 psi 0.10 in/sec 1,000 to < 1,400 psi 1.0 in/sec 1,400 to 2,000 psi 2.0 in/sec After the concrete has reached a minimum compressive strength specified above, the safe horizontal distance restrictions would no longer apply. Page 6-30 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(7) Tolerances Unless noted otherwise, concrete construction tolerances shall be in accordance with this section. Tolerances in this section do not apply to cement concrete pavement. Horizontal deviation of roadway crown points, cross-slope break points, and curb, barrier or railing edges from alignment or work line: ±1.0 inch Deviation from plane: ±0.5 inch in 10 feet Deviation from plane for roadway surfaces: ±0.25 inch in 10 feet Deviation from plumb or specified batter: ±0.5 inch in 10 feet, but not to exceed a total of ±1.5 inches Vertical deviation from profile grade for roadway surfaces: ±1 inch Vertical deviation of top surfaces (except roadway surfaces): ±0.75 inch Thickness of bridge decks and other structural slabs not at grade: ±0.25 inch Length, width and thickness of elements such as columns, beams, crossbeams, diaphragms, corbels, piers, abutments and walls, including dimensions to construction joints in initial placements: +0.5 inch, -0.25 inch Length, width and thickness of spread footing foundations: +2 inches, -0.5 inch Horizontal location of the as-placed edge of spread footing foundations: The greater of ±2% of the horizontal dimension of the foundation perpendicular to the edge and ±0.5 inch. However, the tolerance shall not exceed ±2 inches. Location of opening, insert or embedded item at concrete surface: ±0.5 inch Cross-sectional dimensions of opening: ±0.5 inch Bridge deck, bridge approach slab, and bridge traffic barrier expansion joint gaps with a specified temperature range, measured at a stable temperature: ±0.25 inch Horizontal deviation of centerline of bearing pad, oak block or other bearing assembly: ±0.125 inch Horizontal deviation of centerline of supported element from centerline of bearing pad, oak block or other bearing assembly ±0.25 inch Vertical deviation of top of bearing pad, oak block or other bearing assembly: ±0.125 inch 6-02.3(8) Vacant 2020 Standard Specifications M 41-10 Page 6-31 Concrete Structures 6-02 6-02.3(9) Vibration of Concrete The Contractor shall supply enough vibrators to consolidate the concrete (except that placed underwater) according to the requirements of this section. Each vibrator shall: 1. Be designed to operate while submerged in the concrete, 2. Vibrate at a rate of at least 7,000 pulses per minute, and 3. Receive the Engineer’s acceptance on its type and method of use. Immediately after concrete is placed, vibration shall be applied in the fresh batch at the point of deposit. In doing so, the Contractor shall: 1. Space the vibrators evenly, no farther apart than twice the radius of the visible effects of the vibration; 2. Ensure that vibration intensity is great enough to visibly affect a weight of 1-inch slump concrete across a radius of at least 18 inches; 3. Insert the vibrators slowly to a depth that will effectively vibrate the full depth of each layer, penetrating into the previous layer on multilayer pours; 4. Protect partially hardened concrete (i.e., nonplastic, which prevents vibrator penetration when only its own weight is applied) by preventing the vibrator from penetrating it or making direct contact with steel that extends into it; 5. Not allow vibration to continue in one place long enough to form pools of grout; 6. Continue vibration long enough to consolidate the concrete thoroughly, but not so long as to segregate it; 7. Withdraw the vibrators slowly when the process is complete; and 8. Not use vibrators to move concrete from one point to another in the forms. When vibrating and finishing top surfaces that will be exposed to weather or wear, the Contractor shall not draw water or laitance to the surface. In high lifts, the top layer shall be shallow and made up of a concrete mix as stiff as can be effectively vibrated and finished. To produce a smooth, dense finish on outside surfaces, the Contractor shall hand tamp the concrete. Vibration of SCC shall only be used as described below or as approved by the Engineer: 1. To prevent the formation of a cold joint in between placement of successive batches of SCC. 2. Near the end of an SCC placement to aid in leveling the SCC in the forms. When vibration of SCC is allowed, the magnitude and duration of the applied vibration shall be kept as minimal as possible. Page 6-32 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(10) Bridge Decks and Bridge Approach Slabs 6-02.3(10)A Pre-Deck Pour Meeting A pre-deck pour meeting shall be held 5 to 10 working days before placing deck concrete to discuss construction procedures, personnel, equipment to be used, concrete sampling and testing and deck finishing and curing operations. Those attending shall include, at a minimum, the superintendent, foremen in charge of placing and finishing concrete, and representatives from the concrete supplier and the concrete pump truck supplier. If the project includes more than one bridge deck, and if the Contractor’s key personnel change between concreting operations, or at request of the Engineer, additional conferences shall be held before each deck placement. 6-02.3(10)B Screed Rail Supports The Contractor shall place screed rails outside the finishing area. When screed rails cannot be placed outside the finishing area as determined by the Engineer, they shall rest on adjustable supports that can be removed with the least possible disturbance to the screeded concrete. The supports shall rest on structural members or on forms rigid enough to resist deflection. Supports shall be removable to at least 2 inches below the finished surface. For staged constructed bridge decks, the finishing machine screed rails shall not be supported on the completed portion of deck and shall deflect with the portion of structure under construction. Screed rails (with their supports) shall be strong enough and stiff enough to permit the finishing machine to operate effectively on them. All screed rails shall be placed and secured for the full length of the deck/slab before the concreting begins. If the Engineer concurs in advance, the Contractor may move rails ahead onto previously set supports while concreting progresses. However, such movable rails and their supports shall not change the set elevation of the screed. On steel truss and girder spans, screed rails and bulkheads may be placed directly on transverse steel floorbeams, with the strike-board moving at right angles to the centerline of the Roadway. 6-02.3(10)C Finishing Equipment The finishing machine shall be self-propelled and be capable of forward and reverse movement under positive control. The finishing machine shall be equipped with augers and a rotating cylindrical single or double drum screed. The finishing machine shall have the necessary adjustments to produce the required cross section, line, and grade. The finishing machine shall be capable of raising the screeds, augers, and any other parts of the finishing mechanical operation to clear the screeded surface, and returning to the specified grade under positive control. Unless otherwise allowed by the Engineer, a finishing machine manufacturer technical representative shall be on site to assist the first use of the machine on the Contract. For bridge deck widening of 20 feet or less, and for bridge approach slabs, or where jobsite conditions do not allow the use of the conventional configuration finishing 2020 Standard Specifications M 41-10 Page 6-33 Concrete Structures 6-02 machines, or modified conventional machines as described above, the Contractor may submit a Type 2 Working Drawing proposing the use of a hand-operated motorized power screed such as a “Texas” or “Bunyan” screed. This screed shall be capable of finishing the bridge deck and bridge approach slab to the same standards as the finishing machine. On bridge decks, the Contractor may use hand-operated strike-boards only when the Engineer concurs for special conditions where self-propelled or motorized hand-operated screeds cannot be employed. These boards shall be sturdy and able to strike off the full placement width without intermediate supports. Strike-boards, screed rails, and any specially made auxiliary equipment shall receive the Engineer’s concurrence before use. All finishing requirements in these Specifications apply to hand-operated finishing equipment. 6-02.3(10)D Concrete Placement, Finishing, and Texturing 6-02.3(10)D1 Test Slab Using Bridge Deck Concrete After the Contractor receives the Engineer’s acceptance of the Class 4000D concrete mix design, and a minimum of seven calendar days prior to the first placement of bridge deck concrete, the Contractor shall construct a test slab using concrete of the accepted mix design. The test slab may be constructed on grade, shall have a minimum thickness of 8-inches, shall have minimum plan dimensions of 10-feet along all four edges, and shall be square or rectangular. During construction of the test slab, the Contractor shall demonstrate concrete sampling and testing, use of the concrete temperature monitoring system, the concrete fogging system, concrete placement system, and the concrete finishing operation. The Contractor shall conduct the demonstration using the same type of equipment to be used for the production bridge decks, except that the Contractor may elect to finish the test slab with a hand-operated strike-board. After the construction of the test slab and the demonstration of bridge deck construction operations is complete, the Contractor shall remove and dispose of the test slab in accordance with Sections 2-02.3 and 2-03.3(7)C. 6-02.3(10)D2 Preparation for Concrete Placement Before placing bridge approach slab concrete, the subgrade shall be constructed in accordance with Sections 2-06 and 5-05.3(6). Before any concrete is placed, the finishing machine shall be operated over the entire length of the deck/slab to check screed deflection. Concrete placement may begin only if the Engineer accepts after this test. Immediately before placing concrete, the Contractor shall check (and adjust if necessary) all falsework and wedges to minimize settlement and deflection from the added mass of the concrete deck/slab. The Contractor shall also install devices, such as telltales, by which the Engineer can readily measure settlement and deflection. Page 6-34 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(10)D3 Concrete Placement The placement operation shall cover the full width of the bridge deck or the full width between construction joints. The Contractor shall locate any construction joint over a beam or web that can support the deck/slab on either side of the joint. The joint shall not occur over a pier unless the Plans permit. Each joint shall be formed vertically and in true alignment. The Contractor shall not release falsework or wedges supporting bridge deck placement sections on either side of a joint until each side has aged as these Specifications require. Placement of concrete for bridge decks and bridge approach slabs shall comply with Section 6-02.3(6). In placing the concrete, the Contractor shall: 1. Place it (without segregation) against concrete placed earlier, as near as possible to its final position, approximately to grade, and in shallow, closely spaced piles; 2. Consolidate it around reinforcing steel by using vibrators before strike-off by the finishing machine; 3. Not use vibrators to move concrete; 4. Not revibrate any concrete surface areas where workers have stopped prior to screeding; 5. Remove any concrete splashed onto reinforcing steel in adjacent segments before concreting them; 6. Maintain a slight excess of concrete in front of the screed across the entire width of the placement operation; 7. Operate the finishing machine to create a surface that is true and ready for final finish without overfinishing or bringing excessive amounts of mortar to the surface; and 8. Leave a thin, even film of mortar on the concrete surface after the last pass of the finishing machine pan. Workers shall complete all post screeding operations without walking on the concrete. This may require work bridges spanning the full width of the deck/slab. After removing the screed supports, the Contractor shall fill the voids with concrete (not mortar). If the surface left by the finishing machine is porous, rough, or has minor irregularities, the Contractor shall float the surface of the concrete. Floating shall leave a smooth and even surface. Float finishing shall be kept to the minimum number of passes necessary to seal the surface. The floats shall be at least 4-feet long. Each transverse pass of the float shall overlap the previous pass by at least half the length of the float. The first floating shall be at right angles to the strike-off. The second floating shall be at right angles to the centerline of the span. A smooth riding surface shall be maintained across construction joints. 2020 Standard Specifications M 41-10 Page 6-35 Concrete Structures 6-02 The edge of completed roadway slabs at expansion joints and compression seals shall have a ⅜-inch radius. After floating, but while the concrete remains plastic, the Contractor shall test the entire deck/slab for flatness (allowing for crown, camber, and vertical curvature). The testing shall be done with a 10-foot straightedge held on the surface. The straightedge shall be advanced in successive positions parallel to the centerline, moving not more than one half the length of the straightedge each time it advances. This procedure shall be repeated with the straightedge held perpendicular to the centerline. An acceptable surface shall be one free from deviations of more than ⅛-inch under the 10-foot straightedge. If the test reveals depressions, the Contractor shall fill them with freshly mixed concrete, strike off, consolidate, and refinish them. High areas shall be cut down and refinished. Retesting and refinishing shall continue until a surface conforming to the requirements specified above is produced. 6-02.3(10)D4 Vacant 6-02.3(10)D5 Bridge Deck Concrete Finishing and Texturing Except as otherwise specified for portions of bridge decks receiving an overlay or sidewalk under the same Contract, the Contractor shall texture the surface of the bridge deck as follows: The Contractor shall texture the bridge deck using diamond tipped saw blades mounted on a power driven, self-propelled machine that is designed to texture concrete surfaces. The grooving equipment shall provide grooves that are ⅛" ± 1/64" wide, 3/16" ± 1/16" deep, and spaced at ¾" ± ⅛". The bridge deck shall not be textured with a metal tined comb. The Contractor shall submit a Type 2 Working Drawing consisting of the type of grooving equipment to be used. The Contractor shall demonstrate that the method and equipment for texturing the bridge deck will not chip, spall or otherwise damage the deck. Unless otherwise allowed by the Engineer, the Contractor shall texture the concrete bridge deck surface either in a longitudinal direction, parallel with centerline or in a transverse direction, perpendicular with centerline. The Contractor shall texture the bridge deck surface to within 3-inches minimum and 24-inches maximum of the edge of concrete at expansion joints, within 1-foot minimum and 2-feet maximum of the curb line, and within 3-inches minimum and 9-inches maximum of the perimeter of bridge drain assemblies. The Contractor shall contain and collect all concrete dust and debris generated by the bridge deck texturing process, and shall dispose of the collected concrete dust and debris in accordance with Section 2-03.3(7)C. Page 6-36 2020 Standard Specifications M 41-10 6-02 Concrete Structures If the Plans call for placement of a sidewalk or an HMA or concrete overlay on the bridge deck, the Contractor shall produce the final finish of these areas by dragging a strip of damp, seamless burlap lengthwise over the bridge deck or by brooming it lightly. Approximately 3-feet of the drag shall contact the surface, with the least possible bow in its leading edge. It shall be kept wet and free of hardened lumps of concrete. When the burlap drag fails to produce the required finish, the Contractor shall replace it. When not in use, it shall be lifted clear of the bridge deck. After the bridge deck has cured, the surface shall conform to the surface smoothness requirements specified in Section 6-02.3(10)D3. The surface texture on any area repaired to address out-of-tolerance surface smoothness shall match closely that of the surrounding bridge deck area at the completion of the repair. Methods used to remove high spots shall cut through the mortar and aggregate without breaking or dislodging the aggregate or causing spalls. 6-02.3(10)D6 Bridge Approach Slab Finishing and Texturing Bridge approach slabs that are being built as part of a bridge construction project shall be textured in accordance with Section 6-02.3(10)D5. All other bridge approach slabs shall be textured using metal tined combs in the transverse direction, except bridge approach slabs receiving an overlay in the same Contract shall be finished as specified in Section 6-02.3(10)D5 only. The comb shall be made of a single row of metal tines. It shall leave striations in the fresh concrete approximately 3/16-inch deep by ⅛-inch wide and spaced approximately ½-inch apart. The Engineer will decide actual depths at the site. If the comb has not been accepted, the Contractor shall obtain the Engineer’s acceptance by demonstrating it on a test section. The Contractor may operate the combs manually or mechanically, either singly or with several placed end to end. The timing and method used shall produce the required texture without displacing larger particles of aggregate. Texturing shall end 2-feet from curb lines. This 2-foot untextured strip shall be hand finished with a steel trowel. Surface smoothness, high spots, and low spots shall be addressed as specified in Section 6-02.3(10)D5. The surface texture on any area cut down or built up shall match closely that of the surrounding bridge approach slab area. The entire bridge approach slab shall provide a smooth riding surface. 6-02.3(10)E Sidewalk Concrete for sidewalk shall be well compacted, struck off with a strike-board, and floated with a wooden float to achieve a surface that does not vary more than ⅛ inch under a 10- foot straightedge. An edging tool shall be used to finish all sidewalk edges and expansion joints. The final surface shall have a granular texture that will not turn slick when wet. 2020 Standard Specifications M 41-10 Page 6-37 Concrete Structures 6-02 6-02.3(10)F Bridge Approach Slab Orientation and Anchors Bridge approach slabs shall be constructed full bridge deck width from outside usable Shoulder to outside usable Shoulder at an elevation to match the Structure. Unless otherwise shown in the Plans, the pavement end of the bridge approach slab shall be constructed normal to the Roadway centerline. The bridge approach slabs shall be modified as shown in the Plans to accommodate the grate inlets at the bridge ends if the grate inlets are required. Bridge approach slab anchors shall be installed as detailed in the Plans, and the anchor rods, couplers, and nuts shall conform to Section 9-06.5(1). The steel plates shall conform to ASTM A36. All metal parts of the approach expansion anchor shall receive one coat of paint conforming to Section 9-08.1(2)F or be galvanized in accordance with AASHTO M232. The pipe shall be any nonperforated PE or PVC pipe of the diameter specified in the Plans. Polystyrene shall conform to Section 9-04.6. The anchors shall be installed parallel both to profile grade and centerline of Roadway. The Contractor shall secure the anchors to ensure that they will not be misaligned during concrete placement. For Method B anchor installations, the epoxy bonding agent used to install the anchors shall be Type IV conforming to Section 9-26.1. The compression seal shall be as noted in the Contract documents. Dowel bars shall be installed in the bridge approach slabs in accordance with the requirements of the Standard Plans and Section 5-05.3(10). The compression seal shall be a 2½ inch wide gland and shall conform to Section 9-04.1(4). 6-02.3(11) Curing Concrete After placement, concrete surfaces shall be cured as follows: 1. Bridge sidewalks, roofs of cut and cover tunnels – curing compound covered by white, reflective type sheeting or continuous wet curing. Curing by either method shall be for at least 10 days. 2. Bridge decks — See Section 6-02.3(11)B. 3. Bridge approach slabs (Class 4000A concrete) – Two coats of curing compound and continuous wet cure for at least 10 days. 4. Concrete barriers and rail bases – See Section 6-02.3(11)A. 5. All other concrete surfaces – Continuous wet cure for at least 3 days. During the continuous wet cure, the Contractor shall keep all exposed concrete surfaces saturated with water. Formed concrete surfaces shall be kept in a continuous wet cure by leaving the forms in place. If forms are removed during the continuous wet cure period, the Contractor shall treat the concrete as an exposed concrete surface. Runoff water shall be collected and disposed of in accordance with all applicable regulations. In no case shall runoff water be allowed to enter any lakes, streams, or other surface waters. Page 6-38 2020 Standard Specifications M 41-10 6-02 Concrete Structures When curing Class 4000A, two coats of curing compound that complies with Section 9-23.2 shall be applied immediately (not to exceed 15 min.) after tining any portion of the bridge approach slab. The continuous wet cure shall be established as soon as the concrete has set enough to allow covering without damaging the finish. For all other concrete requiring curing compound, the Contractor shall apply two coats (that complies with Section 9-23.2) to the fresh concrete. The compound shall be applied immediately after finishing. Application of the second coat shall run at right angles to that of the first. The two coats shall total at least 1 gallon per 150 square feet and shall obscure the original color of the concrete. If any curing compound spills on construction joints or reinforcing steel, the Contractor shall clean it off before the next concrete placement. If the Plans call for an asphalt overlay on the bridge approach slab, the Contractor shall use the clear curing compound (Type 1, Class B), applying at least 1 gallon per 150 square feet to the concrete surface. Otherwise, the Contractor shall use white pigmented curing compound (Type 2), agitating it thoroughly just before and during application. If other materials are to be bonded to the surface, the Contractor shall remove the curing compound by sandblasting or acceptable high pressure water washing. The Contractor shall have on the site, back-up spray equipment, enough workers, and a bridge from which they will apply the curing compound. The Engineer may require the Contractor to demonstrate (at least 1 day before the scheduled concrete placement) that the crew and equipment can apply the compound acceptably. The Contractor shall cover the top surfaces with white, reflective sheeting, leaving it in place for at least 10 days. Throughout this period, the sheeting shall be kept in place by taping or weighting the edges where they overlap. When accelerating admixtures are used, the concrete shall be cured in accordance with these specifications or until the concrete has reached 70 percent of the mix design 28-day strength, but not less than 3 days. 6-02.3(11)A Curing and Finishing Concrete Traffic and Pedestrian Barrier The Contractor shall supply enough water and workers to cure and finish concrete barrier as required in this section. Unit contract prices shall cover all curing and finishing costs. 6-02.3(11)A1 Fixed-Form Barrier The edge chamfers shall be formed by attaching chamfer strips to the barrier forms. After troweling and edging a barrier (while the forms remain in place), the Contractor shall: 1. Brush the top surface with a fine bristle brush; 2. Cover the top surface with heavy, quilted blankets; and 3. Spray water on the blankets and forms at intervals short enough to keep them thoroughly wet for 3 days. 2020 Standard Specifications M 41-10 Page 6-39 Concrete Structures 6-02 After removing the forms, the Contractor shall: 1. Remove all lips and edgings with sharp tools or chisels; 2. Fill all holes with mortar conforming to Section 9-20.4(2); 3. True up corners of openings; 4. Remove concrete projecting beyond the true surface by stoning or grinding; 5. Cover the barrier with heavy, quilted blankets (not burlap); 6. Keep the blankets continuously wet for at least 7 days. The Contractor may do the finishing Work described in steps 1 through 4 above during the second (the 7-day) curing period if the entire barrier is kept covered except the immediate Work area. Otherwise, no finishing Work may be done until at least 10 days after pouring. After the 10-day curing period, the Contractor shall remove from the barrier all form- release agent, mud, dust, and other foreign substances in either of two ways: (1) by light sandblasting and washing with water, or (2) by spraying with a high-pressure water jet. The water jet equipment shall use clean fresh water and shall produce (at the nozzle) at least 1,500 psi with a discharge of at least 3 gpm. The water jet nozzle shall have a 25-degree tip and shall be held no more than 9 inches from the surface being washed. After cleaning, the Contractor shall use brushes to rub mortar conforming to Section 9-20.4(2) at a ratio of 1:1 cement/aggregate ratio into air holes and small crevices on all surfaces except the brushed top. As soon as the mortar takes its initial set, the Contractor shall rub it off with a piece of sacking or carpet. The barrier shall then be covered with wet blankets for at least 48 hours. No curing compound shall be used on fixed-form concrete barrier. The completed surface of the concrete shall be even in color and texture. 6-02.3(11)A2 Slip-Form Barrier The edge radius shall be formed by attaching radius strips to the barrier slip form. The Contractor shall finish slip-form barrier by: (1) steel troweling to close all surface pockmarks and holes; and (2) for plain surface barrier, lightly brushing the front and back face with vertical strokes and the top surface with transverse strokes. After finishing, the Contractor shall cure the slip-form barrier by using either Method A (curing compound) or B (wet blankets) described below. Method A – Under the curing compound method, the Contractor shall: 1. Spray two coats of clear curing compound (Type 1) on the concrete surface after the free water has disappeared. (Coverage of combined coats shall equal at least 1 gallon per 150 square feet.) 2. No later than the morning after applying the curing compound, cover the barrier with white, reflective sheeting for at least 10 days. Page 6-40 2020 Standard Specifications M 41-10 6-02 Concrete Structures 3.After the 10-day curing period, remove the curing compound as necessary by light sandblasting or by spraying with a high-pressure water jet to produce an even surface appearance. The water jet equipment shall use clean fresh water and shall produce (at the nozzle) at least 2,500 psi with a discharge of at least 4 gpm. The water jet nozzle shall have a 25-degree tip and shall be held no more than 9 inches from the surface being cleaned. The Contractor may propose to use a curing compound/concrete sealer. The Engineer will evaluate the proposal and if found acceptable, will accept the proposal in writing. As a minimum, the Contractor’s proposal shall include: •Product identity •Manufacturer’s recommended application rate •Method of application and necessary equipment •Material Safety Data Sheet (MSDS) •Sample of the material for testing Allow 14 working days for evaluating the proposal and testing the material. Method B – Under the wet cure method, the Contractor shall: 1.Provide an initial cure period by continuous fogging or mist spraying for at least the first 24 hours. 2.After the initial cure period, cover the barrier with a heavy quilted blanket. 3.Keep the blankets continuously wet for at least 10 days. (No additional finishing is required at the end of the curing period.) 6-02.3(11)B Curing Bridge Deck 6-02.3(11)B1 Equipment The Contractor shall maintain a wet sheen, without developing pooling or sheeting water, using a fogging apparatus consisting of pressure washers with a minimum nozzle output of 1,500 psi, or other means accepted by the Engineer. The Contractor shall submit a Type 2 Working Drawing consisting of the bridge deck curing plan a minimum 14 calendar days prior to the pre-concreting conference. The Contractor’s plan shall describe the sequence and timing that will be used to fog the bridge deck, apply pre-soaked burlap, install soaker hoses and cover the deck with white reflective sheeting. 6-02.3(11)B2 Curing The fogging apparatus shall be in place and charged for fogging prior to beginning concrete placement for the bridge deck. The Contractor shall presoak all burlap to be used to cover the deck during curing. 2020 Standard Specifications M 41-10 Page 6-41 Concrete Structures 6-02 Immediately after the finishing machine passes over finished concrete, the Contractor shall implement the following tasks: 1. The Contractor shall fog the bridge deck while maintaining a wet sheen without developing pooling or sheeting water. 2. The Contractor shall apply the presoaked burlap to the top surface to fully cover the deck without damaging the finish, other than minor marring of the concrete surface. The Contractor shall not apply curing compound. 3. The Contractor shall continue to keep the burlap wet by fog spraying until the burlap is covered by soaker hoses and white reflective sheeting. The Contractor shall place the soaker hoses and white reflective sheeting after the concrete has achieved initial set. The Contractor shall charge the soaker hoses frequently so as to keep the burlap covering the entire deck wet during the course of curing. As an alternative to tasks 2 and 3 above, the Contractor may propose a curing system using proprietary curing blankets specifically manufactured for bridge deck curing. The Contractor shall submit a Type 2 Working Drawing consisting of details of the proprietary curing blanket system, including product literature and details of how the system is to be installed and maintained. The wet curing regime as described shall remain in place for at least 14 consecutive calendar days. 6-02.3(12) Construction Joints 6-02.3(12)A Construction Joints in New Construction If the Engineer allows, the Contractor may add, delete, or relocate construction joints shown in the Plans. Any request for such changes shall be in writing, accompanied by a drawing that depicts them. The Contractor will bear any added costs that result from such changes. All construction joints shall be formed neatly with grade strips or other accepted methods. The Contracting Agency will not accept irregular or wavy pour lines. All joints shall be horizontal, vertical, or perpendicular to the main reinforcement. The Contractor shall not use an edger on any construction joint, and shall remove any lip or edging before making the adjacent pour. If the Plans require a roughened surface on the joint, the Contractor shall strike it off to leave grooves at right angles to the length of the member. Grooves shall be installed using one of the following options: 1. Grooves shall be ½ to 1 inch wide, ¼ to ½ inch deep, and spaced equally at twice the width of the groove. Grooves shall terminate approximately 1½-inches from the face of concrete. 2. Grooves shall be 1 to 2 inches wide, a minimum of ½-inch deep, and spaced a maximum of three times the width of the groove. Grooves shall terminate approximately 1½-inches from the face of concrete. Page 6-42 2020 Standard Specifications M 41-10 6-02 Concrete Structures If the Engineer allows, the Contractor may use an alternate method to produce a roughened surface on the joint, provided that such an alternate method leaves a roughened surface of at least a ¼-inch amplitude. If the first strike-off does not produce the required roughness, the Contractor shall repeat the process before the concrete reaches initial set. The final surface shall be clean and without laitance or loose material. If the Plans do not require a roughened surface, the Contractor shall include shear keys at all construction joints. These keys shall provide a positive, mechanical bond. Shear keys shall be formed depressions and the forms shall not be removed until the concrete has been in place at least 12 hours. Forms shall be slightly beveled to ensure ready removal. Raised shear keys are not allowed. Shear keys for the tops of beams, at tops and bottoms of boxed girder webs, in diaphragms, and in crossbeams shall: 1. Be formed with 2 by 8-inch wood blocks; 2. Measure 8 inches lengthwise along the beam or girder stem; 3. Measure 4 inches less than the width of the stem, beam, crossbeam, etc. (measured transverse of the stem); and 4. Be spaced at 16 inches center to center. Unless the Plans show otherwise, in other locations (not named above), shear keys shall equal approximately ⅓ of the joint area and shall be approximately 1½ inches deep. Before placing fresh concrete against cured concrete, the Contractor shall thoroughly clean and saturate the cured surface. All loose particles, dust, dirt, laitance, oil, or film of any sort shall be removed by method(s) as accepted by the Engineer. The cleaned surface shall be saturated with water for a minimum of four hours before the fresh concrete is placed. Before placing the reinforcing mat for footings on seals, the Contractor shall: (1) remove all scum, laitance, and loose gravel and sediment; (2) clean the construction joint at the top of the seals; and (3) chip off any high spots on the seals that would prevent the footing steel from being placed in the position required by the Plans. 6-02.3(12)B Construction Joints Between Existing and New Construction If the Plans or Special Provisions require a roughened surface on the joint, the Contractor shall thoroughly roughen the existing surface to a uniformly distributed ¼-inch minimum amplitude surface profile, with peaks spaced at a maximum of 1 inch. If the Plans or Special Provisions do not require a roughened surface on the joint, the Contractor shall remove all loose particles, dust, dirt, laitance, oil, or film of any sort. Before placing fresh concrete against existing concrete, the Contractor shall thoroughly clean and saturate the existing surface. All loose particles, dust, dirt, laitance, oil, or film of any sort shall be removed. The cleaned surface shall be saturated with water for a minimum of 4 hours before the fresh concrete is placed. 2020 Standard Specifications M 41-10 Page 6-43 Concrete Structures 6-02 6-02.3(13) Expansion Joints This section outlines the requirements of specific expansion joints shown in the Plans. The Plans may require other types of joints, seals, or materials than those described here. Joints made of a vulcanized, elastomeric compound (with neoprene as the only polymer) shall be installed with a lubricant adhesive as recommended by the manufacturer. The length of a seal shall match that required in the Plans without splicing or stretching. Open joints shall be formed with a template made of wood, metal, or other suitable material. Insertion and removal of the template shall be done without chipping or breaking the edges or otherwise damaging the concrete. Any part of an expansion joint running parallel to the direction of expansion shall provide a clearance of at least ½ inch (produced by inserting and removing a spacer strip) between the two surfaces. The Contractor shall ensure that the surfaces are precisely parallel to prevent any wedging from expansion and contraction. All poured rubber joint sealer (and any required primer) shall conform with Section 9-04.2(2). 6-02.3(13)A Strip Seal Expansion Joint System The Contractor shall submit Type 2 Working Drawings consisting of the strip seal expansion joint shop drawings. These plans shall include, at a minimum, the following: 1. Plan, elevation, and sections of the joint system and all components, with dimensions and tolerances. 2. All material designations. 3. Manufacturer’s written installation procedure. The installation procedure shall indicate how the extrusions set into the two sides of the joint will be allowed to move independently of one another. 4. Corrosion protection system used on the metal components. 5. Locations of welded shear studs, lifting mechanisms, temperature setting devices, and construction adjustment devices. 6. Method of sealing the system to prevent leakage of water through the joint. 7. Details of the temporary supports for the steel extrusions while the encapsulating concrete of the headers is placed and cured. 8. The gland installation procedure, including the means and methods used to install the gland and assure correct seating of the gland within the steel extrusions. The strip seal shall be removable and replaceable. The metal components shall conform to ASTM A36, ASTM A992, or ASTM A572, and shall be protected against corrosion by one of the following methods: 1. Zinc metallized in accordance with Section 6-07.3(14). Page 6-44 2020 Standard Specifications M 41-10 6-02 Concrete Structures 2. Hot-dip galvanized in accordance with AASHTO M111. 3. Paint in accordance with Section 6-07.3(9). The color of the top coat shall be SAE AMS Standard 595 Color No. 26357. The surfaces embedded in concrete shall be painted only with a shop primer coat of paint conforming to Section 9-08.1(2)C. If the gland is installed in the field, the Contractor shall have the services of a strip seal expansion joint system manufacturer’s technical representative physically present at the job site. The manufacturer’s technical representative shall train the Contractor’s personnel performing the field installation of the gland, provide technical assistance for installing the gland, and observe and inspect the installation of at least the first complete joint. The strip seal gland shall be continuous for the full length of the joint with no splices permitted, unless otherwise shown in the Plans. Other than items shown in the Plans, threaded studs used for construction adjustments are the only items that may be welded to the steel shapes provided they are removed by grinding after use, and the area repaired by application of an accepted corrosion protection system. After the joint system is installed, the joint shall be flooded with water and inspected, from below the joint, for leakage. If leakage is observed, the joint system shall be repaired by the Contractor, as recommended by the manufacturer. 6-02.3(13)B Compression Seal Expansion Joint System Compression seal glands shall conform to Section 9-04.1(4) and be sized as shown in the Plans. The compression seal expansion joint system shall be installed in accordance with the manufacturer’s written recommendations. The Contractor shall submit a Type 1 Working Drawing consisting of the manufacturer’s written installation procedure and repair procedures if leakage testing fails. After the joint system is installed, the joint area shall be flooded with water and inspected, from below the joint, for leakage. If leakage is observed, the joint system shall be repaired by the Contractor, as recommended by the manufacturer. 6-02.3(14) Finishing Concrete Surfaces All concrete shall show a smooth, dense, uniform surface after the forms are removed. If it is porous, the Contractor shall bear the cost of repairing it. The Contractor shall clean and refinish any stained or discolored surfaces. Subsections A and B (below) describe two classes of surface finishing. 6-02.3(14)A Class 1 Surface Finish The Contractor shall apply a Class 1 finish to all surfaces of concrete members to the limits designated in the Contract Plans. 2020 Standard Specifications M 41-10 Page 6-45 Concrete Structures 6-02 The Contractor shall follow steps 1 through 8 below. When steel forms have been used and when the surface of filled holes matches the texture and color of the area around them, the Contractor may omit steps 3 through 8. To create a Class 1 surface, the Contractor shall: 1. Remove all bolts and all lips and edgings where form members have met; 2. Fill all holes greater than ¼ inch and float to an even, uniform finish with mortar conforming to Section 9-20.4(2) at a 1:2 cement/aggregate ratio; 3. Thoroughly wash the surface of the concrete with water; 4. Brush on a mortar conforming to Section 9-20.4(2) at a 1:1 cement/aggregate ratio, working it well into the small air holes and other crevices in the face of the concrete; 5. Brush on no more mortar than can be finished in 1 day; 6. Rub the mortar off with burlap or a piece of carpet as soon as it takes initial set (before it reaches final set); 7. Fog-spray water over the finish as soon as the mortar paint has reached final set; and 8. Keep the surface damp for at least 2 days. If the mortar becomes too hard to rub off as described in step 6, the Contractor shall remove it with a Carborundum stone and water. Random grinding is not permitted. 6-02.3(14)B Class 2 Surface Finish The Contractor shall apply a Class 2 finish to all above-ground surfaces not receiving a Class 1 finish as specified above unless otherwise indicated in the Contract. Surfaces covered with fill do not require a surface finish. To produce a Class 2 finish, the Contractor shall remove all bolts and all lips and edgings where form members have met and fill all form tie holes. 6-02.3(14)C Pigmented Sealer for Concrete Surfaces The Contractor shall submit a Type 1 Working Drawing consisting of the pigmented sealer manufacturer’s written instructions covering, at a minimum, the following: 1. Surface preparation. 2. Application methods. 3. Requirements for concrete curing prior to sealer application. 4. Temperature, humidity and precipitation limitations for application. 5. Rate of application and number of coats to apply. All surfaces specified in the Plans to receive pigmented sealer shall receive a Class 2 surface finish (except that concrete barrier surfaces shall be finished in accordance with Section 6-02.3(11)A). The Contractor shall not apply pigmented sealer from a batch greater than 12 months past the initial date of color sample acceptance of that batch by the Engineer. Page 6-46 2020 Standard Specifications M 41-10 6-02 Concrete Structures The pigmented sealer color or colors for specific concrete surfaces shall be as specified in the Special Provisions. The final appearance shall be even and uniform without blotchiness, streaking or uneven color. Surface finishes deemed unacceptable by the Engineer shall be re-coated in accordance with the manufacturer’s recommendations at no additional expense to the Contracting Agency. For concrete surfaces such as columns, retaining walls, pier walls, abutments, concrete fascia panels, and noise barrier wall panels, the pigmented sealer shall extend to 1 foot below the finish ground line, unless otherwise shown in the Plans. Pigmented Sealer Materials shall be a product listed in the current WSDOT Qualified Products List (QPL). If the pigmented sealer material is not listed in the current WSDOT QPL, a sample shall be submitted to the State Materials Laboratory in Tumwater for evaluation and acceptance in accordance with Section 9-08.3. 6-02.3(14)D Concrete Surface Finishes Produced by Form Liners The concrete finishes listed in the table below shall be accomplished by the use of either a form liner selected from the products listed in the WSDOT Qualified Products List (QPL), or a form liner accepted by the the State Bridge and Structures Architect and the Engineer. For acceptance of form liners not listed in the current WSDOT QPL, the Contractor shall submit Type 3 Working Drawings consisting of catalog cuts, other descriptive supporting information and a 2-foot square physical sample of the form liner. Concrete Finish Horizontal joints in elastomeric form liners are permitted on surfaces greater than 8 feet in height1 provided that the minimum form liner panel dimensions are: Height (ft)Width (ft) Fractured Basalt Finish 8 2 Fractured Fin Finish 8 8 Fractured Granite Finish 8 8 Variable Depth Random Board Finish 8 8 3/4 Inch Random Board Finish 8 8 Ribbed Finish 8 8 Striated Finish 8 8 Ashlar Stone Finish 8 8 Block Finish 8 8 Split Face Finish 8 6 River Rock Finish 4 8 Cascadian Stone Finish 4 8 14 feet in height for River Rock Finish and Cascadian Stone Finish Variable Depth Random Board Finish shall utilize an elastomeric form liner. 2020 Standard Specifications M 41-10 Page 6-47 Concrete Structures 6-02 3/4 Inch Random Board Finish shall utilize either an elastomeric or a plastic form liner. When specified in Contract documents to use wooden form liners, the concrete surface finish shall be achieved with reusable wooden form liners meeting the requirements of this Section and Section 6-02.3(14)D1. For Cascadian Stone Finish, no partial rocks will be allowed in the finished pattern. Horizontal and vertical joints shall be adjusted as needed. Form liners shall be placed with the pillars, fins, board lines and faux mortar/other joints normal to grade for barrier applications and vertical for all other applications. Horizontal and vertical joints in ABS, plastic, or elastomeric form liners shall be spliced in accordance with the manufacturer’s printed instructions. The Contractor shall submit a Type 1 Working Drawing consisting of the manufacturer’s joint splice instructions. Horizontal joints in elastomeric form liners are permitted in accordance with the requirements in the table above. Horizontal splicing of ABS and plastic form liners to achieve the required height is not permitted and there shall be no horizontal joints. Once the forms are removed, the Contractor shall treat the joint areas by patching or light sandblasting as required by the Engineer to ensure that the joints are not visible. The concrete formed with ABS and plastic form liners shall be given a light sandblast to remove the glossy finish. Form liners shall be cleaned, reconditioned, and repaired before each use. Form liners with repairs, patches, or defects which, in the opinion of the Engineer, would result in adverse effects to the concrete finish shall not be used. Care shall be taken to ensure uniformity of color throughout the textured surface. A change in form release agent will not be allowed. All surfaces formed by the form liner shall also receive a Class 2 surface finish. Form ties shall be a type that leaves a clean hole when removed. All spalls and form tie holes shall be filled as specified for a Class 2 surface finish. 6-02.3(14)D1 3/4 Inch Random Board Finish Using Wooden Form Liners The reusable wooden form liners shall conform to Section 6-02.3(17)J and the texture pattern shown in the Plans. The texture pattern shall be accomplished with 3/4 inch thick battens in varying widths applied to the surface of the forms. The edge of all battens shall be sloped 15 degrees to facilitate form removal. The Contractor shall submit a Type 3 Working Drawing consisting of a concrete panel test section, with the 3/4 inch random board texture to be used and based on the pattern shown in the Plans. The test section shall be constructed using the forms and materials intended to construct the permanent structures. The test section shall be composed of two ten foot by ten foot form sections which shall be assembled to make a ten foot by 20 foot concrete surface section, and shall include the wall top treatment, and one horizontal joint treatment. Page 6-48 2020 Standard Specifications M 41-10 6-02 Concrete Structures All cracks, holes, slits, gaps, and apertures in forms shall be plugged and caulked with molding plaster to remain completely watertight and withstand the pressures of concrete placement. Joints between the form units shall be sealed with silicone or latex caulking compound. Butt joints may be sealed with non-absorptive sponge tape. Construction joints and expansion joints shall be incorporated into the pattern of the face treatment. Forms and form ties shall be designed to permit removal without damaging the finish. Prying against the face of the concrete will not be allowed. Storage of formwork and form materials shall be in a manner to prevent damage or distortion. Any damage to formwork during placing, removal, or storage shall be repaired by the Contractor at no additional expense to the Contracting Agency. 6-02.3(14)E Exposed Aggregate Finish 6-02.3(14)E1 Submittals The Contractor shall submit Type 2 Working Drawings consisting of the following items: 1. Written description of the equipment to be used and procedure to be followed in producing the exposed aggregate finish. 2. A copy of the manufacturer’s written instructions for applying the retardant coating and the clear sealer. 3. Type of nozzle, nozzle pressure, type and gradation of abrasive, blasting techniques, safety procedures, and containment methods and procedures used with all abrasive blasting and water blasting operations. 4. The method and materials used to collect, contain, and dispose of the concrete surface mortar removed from the finish surface, and the chemical agent residue and abrasives used to remove the concrete surface mortar. 5. For formed applications, a sample panel, equal either to the size of one concrete barrier panel minimum for barrier applications, or a four-foot by eight-foot panel for non-barrier applications, cast in a vertical position on the site and constructed in accordance with the procedure outlined in the Type 2 Working Drawing submittal. 6-02.3(14)E2 Producing Exposed Aggregate Finish The Contractor shall produce all exposed aggregate concrete in accordance with procedure and equipment outlined in the Type 2 Working Drawing submittal. The exposed aggregate shall achieve the same final effect as demonstrated on the sample panel accepted by the Engineer. Formwork shall be cleaned, reconditioned, and repaired before each use. Formwork with repairs, patches or defects which, in the opinion of the Engineer, would result in adverse effects to the concrete finish shall not be used. Forms and form joints shall remain completely watertight. Butt joints and joints between form units used on surfaces which are to receive an exposed aggregate finish shall be tongue and grooved, or splined and shall be sealed with a caulking compound. 2020 Standard Specifications M 41-10 Page 6-49 Concrete Structures 6-02 As an alternative to using tongue and grooved or splined joints, a closed cell polyvinylchloride foam sealer of 3/16 inch thickness with pressure-sensitive adhesive on one or both sides may be used to seal the butt joints between form units. The foam sealer shall be recessed by an amount such that when the form units are compressed to their final position, the foam sealer will be flush with the face of the form units. Adjacent formwork panels, if used, shall be in line and no offset shall occur between panels. Forms for the exposed aggregate surface for members not yet supporting loads, including the members own load, may be removed as required to effect the exposed aggregate surface, provided the concrete has a minimum age of twelve hours and is of sufficient strength and hardness so as not to be damaged by the form removal operations and provided that curing and protection operations are maintained. Removal of forms on the remaining concrete surfaces shall be in accordance with Section 6-02.3(17)N. After the forms are stripped, the surface mortar shall be removed from the areas specified to receive the exposed aggregate finish. The exposed aggregate finish shall be obtained by either one or a combination of the two methods described in Sections 6-02.3(14)E3 and 6-02.3(14)E4 as necessary to provide the specified exposed aggregate finish. 6-02.3(14)E3 Retardant Coating Method A retardant coating conforming to Section 9-08.3(2)A shall be applied to the formwork where concrete surfaces with exposed aggregate finish are shown in the Plans. For cast-in-place concrete the retardant shall have an effective life of not less than the length of time required for the Class EA concrete to be in place prior to the removal of forms plus 12 hours. For slip-formed concrete barrier and horizontal to near-horizontal applications, the retardant shall have an effective life of not less than 24 hours. The Contractor shall remove the surface mortar two to three hours after applying the retardant coating. Retardant shall be applied in accordance with the manufacturer’s instructions to remove the surface mortar. The sealer and form release agent used on the form shall be compatible with the retardant and shall not react with the retardant to produce an undesirable effect on the exposed aggregate finish. The sealer and form release agent to be used on the form shall be as recommended by the manufacturer of the retardant. Surface mortar shall be removed using one of the following methods: 1. Light abrasive blasting 2. Washing with water under pressure, avoiding excessive pressure which loosens individual aggregate particles. 3. A combination of both methods. Page 6-50 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(14)E4 Abrasive Blasting Method As soon as forms are stripped, the exposed aggregate areas shall be abrasive blasted to remove the surface mortar. For slip-formed concrete barrier and horizontal to near- horizontal applications, this shall be done once the concrete has attained a minimum age of 12 hours and is of sufficient strength and hardness to prevent damage. Adjacent materials and finishes shall be protected from dust, dirt and other damage during abrasive blasting operations. Corners and edge of patterns shall be carefully blasted using back-up boards to maintain a uniform corner or edge line. The abrasive blast finishing shall be done in as continuous an operation as possible, utilizing the same work crew to maintain continuity of finish on each surface or area of work. The type and gradation of abrasive grit used, the type of nozzle, nozzle pressure, and blasting techniques shall be as specified in the Type 2 Working Drawing submittal, and as required to expose the aggregate. The Contractor shall be responsible for safety of the workers and shall equip each with air-fed helmets. The Contractor shall provide suitable enclosures for the collection of grit and dust from the abrasive blasting operation. After receiving the Engineer’s acceptance of the exposed aggregate finish, a 10 percent muriatic acid wash shall be applied to the exposed aggregate surfaces. Surfaces shall be flushed thoroughly with water following a 5 to 10 minute interaction period between the acid solution and the surface. All stains and streaks on the exposed aggregate surface shall be removed before applying the clear sealer. 6-02.3(14)E5 Applying Clear Sealer Two seal coatings of clear sealer conforming to Section 9-08.3(2)B shall be applied to the exposed aggregate surfaces in accordance with the manufacturer’s recommended procedure. 6-02.3(14)E6 Containment When producing exposed aggregate finish on concrete surfaces over water, the Contractor shall exercise care and use suitable means to collect and dispose of abrasives and chemical agents, and the resulting concrete surface mortar debris used in or resulting from the finishing of the exposed aggregate surfaces to prevent their entry into the environment surrounding the Structure. 2020 Standard Specifications M 41-10 Page 6-51 Concrete Structures 6-02 6-02.3(14)F Permeon Treatment The Contractor shall apply permeon treatment to all concrete surfaces specified in the Plans to receive permeon treatment. The Contractor shall use SAE AMS Standard 595 Color Number 30219 as the target color. The target color is intended as a reference for hue, and is not intended as a reference for opacity or luster. The Contractor is advised that this target color is based on the concentration formula and application rate identified in the QPL for each product. The concentration formula and application rate for products not listed in the QPL will be determined by the Engineer. The permeon treatment shall be applied only by personnel approved by the manufacturer to apply the product. The Contractor shall furnish certificates of approval from the manufacturer, for the personnel scheduled to perform the work, to the Engineer prior to beginning the treatment operation. The concrete shall be cured for the time period recommended by the manufacturer prior to receiving the permeon treatment coating. The Contractor shall clean and prepare the concrete surfaces in accordance with the recommendations of the manufacturer for the use of the treatment product. The Contractor shall apply the permeon treatment to the surfaces specified, in accordance with the recommendations of the manufacturer for the use of the treatment product. The Contractor shall prevent permeon treatment from reaching surfaces not specified to receive the permeon treatment. The Contractor shall prevent pigmented sealer from reaching surfaces that have received permeon treatment. Should pigmented sealer reach surfaces that have received permeon treatment, the pigmented sealer shall be removed and the permeon treatment repaired in accordance with Section 1-07.13. 6-02.3(15) Date Numerals Standard date numerals shall be placed where shown in the Plans. The date shall be for the year in which the Structure is completed. When an existing Structure is widened or when traffic barrier is placed on an existing Structure, the date shall be for the year in which the original Structure was completed. Unit Contract prices shall cover all costs relating to these numerals. 6-02.3(16) Plans for Falsework and Formwork The Contractor shall submit all plans for falsework and formwork as Type 2E Working Drawings. A submittal is not required for footing or retaining wall formwork if the concrete placement is 4 feet or less in height. Page 6-52 2020 Standard Specifications M 41-10 6-02 Concrete Structures The design of falsework and formwork shall be based on: 1. Applied loads and conditions which are no less severe than those described in Section 6-02.3(17)A; 2. Allowable stresses and deflections which are no greater than those described in Section 6-02.3(17)B; 3. Special loads and requirements no less severe than those described in Section 6-02.3(17)C; 4. Conditions required by other Sections of 6-02.3(17). The falsework and formwork plans shall be scale drawings showing the details of proposed construction, including: sizes and properties of all members and components; spacing of bents, posts, studs, wales, stringers, wedges and bracing; rates of concrete placement, placement sequence, direction of placement, and location of construction joints; identification of falsework devices and safe working loads as well as identification of any bolts or threaded rods used with the devices including their diameter, length, type, grade, and required torque. The falsework plans shall show the proximity of falsework to utilities or any nearby Structures including underground Structures. Formwork accessories shall be identified according to Section 6-02.3(17)H. All assumptions, dimensions, material properties, and other data used in making the structural analysis shall be noted on the drawing. The Contractor shall furnish associated design calculations to the Engineer as part of the submittal. The design calculations shall include the structural and geotechnical design of the foundation and shall show the stresses and deflections in all load-carrying members that are part of the falsework system. Construction details which may be shown in the form of sketches on the calculation sheets shall be shown in the falsework or formwork drawings as well. Falsework or formwork plans will not be accepted in cases where it is necessary to refer to the calculation sheets for information needed for complete understanding of the falsework and formwork plans or how to construct the falsework and formwork. 6-02.3(16)A Vacant 6-02.3(16)B Pre-Contract Review of Falsework and Formwork Plans The Contractor may request pre-contract review of formwork plans for abutments, wingwalls, diaphragms, retaining walls, columns, girders and beams, box culverts, railings, and bulkheads. Plans for falsework supporting the bridge deck for interior spans between precast prestressed concrete girders may also be submitted for pre-contract review. To obtain pre-contract review, the Contractor shall electronically submit drawings and design calculations in PDF format directly to: BridgeConstructionSupport@wsdot.wa.gov The Bridge and Structures Office, Construction Support Engineer will return the falsework or formwork plan to the Contractor with review notes, an effective date of review, and any revisions needed prior to use. 2020 Standard Specifications M 41-10 Page 6-53 Concrete Structures 6-02 For each contract on which the pre-reviewed falsework or formwork plans will be used, the Contractor shall submit a copy to the Engineer. Construction shall not begin until the Engineer has given concurrence. If the falsework or formwork being constructed has any deviations to the preapproved falsework or formwork plan, the Contractor shall submit plan revisions for review and approval in accordance with Section 6-02.3(16). 6-02.3(17) Falsework and Formwork Formwork and falsework are both structural systems. Formwork contains the lateral pressure exerted by concrete placed in the forms. Falsework supports the vertical and/ or the horizontal loads of the formwork, reinforcing steel, concrete, and live loads during construction. The Contractor shall set falsework, to produce in the finished Structure, the lines and grades indicated in the Contract Plans. The setting of falsework shall allow for shrinkage, settlement, falsework girder camber, and any structural camber the Plans or the Engineer require. Concrete forms shall be mortar tight, true to the dimensions, lines, and grades of the Structure. Curved surfaces shown in the Contract Plans shall be constructed as curved surfaces and not chorded, except as allowed in Section 6-02.3(17)J. Concrete formwork shall be of sufficient strength and stiffness to prevent overstress and excess deflection as defined in Section 6-02.3(17)B. The rate of depositing concrete in the forms shall not exceed the placement rate in the formwork plan Working Drawing. The interior form shape and dimensions shall also ensure that the finished concrete will conform with the Contract Plans. If the new Structure is near or part of an existing one, the Contractor shall not use the existing Structure to suspend or support falsework unless the Plans or Special Provisions state otherwise. For prestressed girder and T-beam bridge widenings or stage construction, the bridge deck and the diaphragm forms may be supported from the existing Structure or previous stage, if accepted by the Engineer. For steel plate girder bridge widenings or stage construction, only the bridge deck forms may be supported from the existing Structure or previous stage, if accepted by the Engineer. See Section 6-02.3(17)E for additional conditions. On bridge decks, forms designed to stay in place made of steel or precast concrete panels shall not be used. For post-tensioned Structures, both falsework and forms shall be designed to carry the additional loads caused by the post-tensioning operations. The Contractor shall construct supporting falsework in a way that leaves the Superstructure free to contract and lift off the falsework during post-tensioning. Forms that will remain inside box girders to support the placement of the bridge deck concrete shall, by design, resist girder contraction as little as possible. See Section 6-02.3(26) for additional conditions. Page 6-54 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(17)A Design Loads The design load for falsework shall consist of the sum of dead and live vertical loads, and a design horizontal load. The minimum total design load for any falsework shall not be less than 100 lbs/sf for combined live and dead load regardless of Structure thickness. The entire Superstructure cross-section, except traffic barrier, shall be considered to be placed at one time for purposes of determining support requirements and designing falsework girders for their stresses and deflections, except as follows: For concrete box girder bridges, the girder stems, diaphragms, crossbeams, and connected bottom slabs, if the stem wall is placed more than 5 days prior to the top slab, may be considered to be self supporting between falsework bents at the time the top slab is placed, provided that the distance between falsework bents does not exceed four times the depth of the portion of the girder placed in the preceding concrete placements. Falsework bents shall be designed for the entire live load and dead load, including all load transfer that takes place during post-tensioning, and braced for the design horizontal load. Dead loads shall include the weight of all successive placements of concrete, reinforcing steel, forms and falsework, and all load transfer that takes place during post-tensioning. The weight of concrete with reinforcing steel shall be assumed to be not less than 160 pounds per cubic foot. Live loads shall consist of a minimum uniform load of not less than 25 psf, applied over the entire falsework plan area, plus the greater of: 1. Actual weights of the deck finishing equipment applied at the rails, or; 2. A minimum load of 75 pounds per linear foot applied at the edge of the bridge deck. The design horizontal load to be resisted by the falsework bracing system in any direction shall be: The sum of all identifiable horizontal loads due to equipment, construction sequence, side-sway caused by geometry or eccentric loading conditions, or other causes, and an allowance for wind plus an additional allowance of 1 percent of the total dead load to provide for unexpected forces. In no case shall the design horizontal load be less than 3 percent of the total dead load. The minimum horizontal load to be allowed for wind on each heavy-duty steel shoring tower having a vertical load carrying capacity exceeding 30 kips per leg shall be the sum of the products of the wind impact area, shape factor, and the applicable wind pressure value for each height zone. The wind impact area is the total projected area of all the elements in the tower face normal to the applied wind. The shape factor for heavy-duty steel shoring towers shall be taken as 2.2. Wind pressure values shall be determined from the following table: 2020 Standard Specifications M 41-10 Page 6-55 Concrete Structures 6-02 Wind Pressure on Heavy-Duty Steel Shoring Towers Height Zone (Feet Above Ground) Wind Pressure Value Adjacent to Traffic At Other Locations 0 to 30 20 psf 15 psf 30 to 50 25 psf 20 psf 50 to 100 30 psf 25 psf Over 100 35 psf 30 psf The minimum horizontal load to be allowed for wind on all other types of falsework, including falsework girders and forms supported on heavy-duty steel shoring towers, shall be the sum of the products of the wind impact area and the applicable wind pressure value for each height zone. The wind impact area is the gross projected area of the falsework support system, falsework girders, forms and any unrestrained portion of the permanent Structure, excluding the areas between falsework posts or towers where diagonal bracing is not used. Wind pressure values shall be determined from the following table: Wind Pressure on All Other Types of Falsework Height Zone (Feet Above Ground) Wind Pressure Value For Members Over and Bents Adjacent to Traffic Openings At Other Locations 0 to 30 2.0 Q psf 1.5 Q psf 30 to 50 2.5 Q psf 2.0 Q psf 50 to 100 3.0 Q psf 2.5 Q psf Over 100 3.5 Q psf 3.0 Q psf The value of Q in the above tabulation shall be determined as follows: Q = 1 + 0.2W; but Q shall not be more than 10. Where: W = is the width of the falsework system, in feet, measured normal to the direction of the wind force being considered. The falsework system shall also be designed so that it will be sufficiently stable to resist overturning prior to the placement of the concrete. The minimum factor of safety against falsework overturning in all directions from the assumed horizontal load for all stages of construction shall be 1.25. If the required resisting moment is less than 1.25 times the overturning moment, the difference shall be resisted by bracing, cable guys, or other means of external support. Design of falsework shall include the vertical component (whether positive or negative) of bracing loads imposed by the design horizontal load. Design of falsework shall investigate the effects of any horizontal displacement due to stretch of the bracing. This is particularly important when using cable or rod bracing systems. If the concrete is to be post-tensioned, the falsework shall be designed to support any increased or redistributed loads caused by the prestressing forces. Page 6-56 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(17)B Allowable Design Stresses and Deflections The maximum allowable stresses listed in this section are based on the use of identifiable, undamaged, high-quality materials. Stresses shall be appropriately reduced if lesser quality materials are to be used. These maximum allowable stresses include all adjustment factors, such as the short-term load duration factor. The maximum allowable stresses and deflections used in the design of the falsework and formwork shall be as follows: 6-02.3(17)B1 Deflection Deflection resulting from dead load and concrete pressure for exposed visible surfaces shall not exceed 1/360 of the span. Deflection resulting from dead load and concrete pressure for unexposed non-visible surfaces, including the bottom of the deck slab between girders shall not exceed 1/270 of the span. In the foregoing, the span length shall be the center line to center line distance between supports for simple and continuous spans, and from the center line of support to the end of the member for cantilever spans. For plywood supported on members wider than 1½ inches, the span length shall be taken as the clear span plus 1½ inches. Also, dead load shall include the weight of all successive placements of concrete, reinforcing steel, forms and falsework self weight. Only the self weight of falsework girders may be excluded from the calculation of the above deflections provided that the falsework girder deflection is compensated for by the installation of camber strips. Where successive placements of concrete are to act compositely in the completed Structure, deflection control becomes extremely critical. Maximum deflection of supporting members shall not exceed 1/500 of the span for members constructed in several successive placements (such as concrete box girder and concrete T-beam girder Structures). Falsework components shall be sized, positioned, and/or supported to minimize progressive increases in deflection of the Structure which would preload the concrete or reinforcing steel before it becomes fully composite. 2020 Standard Specifications M 41-10 Page 6-57 Concrete Structures 6-02 6-02.3(17)B2 Timber Each species and grade of timber/lumber used in constructing falsework and formwork shall be identified in the drawings. The allowable stresses and loads shall not exceed the lesser of stresses and loads given in the table below or factored stresses for designated species and grade in Table 7.3 of the Timber Construction Manual, latest edition, by the American Institute of Timber Construction. Compression perpendicular to the grain reduced to 300 psi for use when moisture content is 19 percent or more (areas exposed to rain, concrete curing water, green lumber). 450 psi Compression parallel to the grain but not to exceed 1,500 psi.480,000 psi (L/d)2 Flexural stress for members with a nominal depth greater than 8 inches.1,800 psi Flexural stress psi for members with a nominal depth of 8 inches or less.1,500 psi The maximum horizontal shear.140 psi AXIAL tension.1,200 psi The maximum modulus of elasticity (E) for timber.1,600,000 psi Where: L is the unsupported length; and d is the least dimension of a square or rectangular column, or the width of a square of equivalent cross-sectional area for round columns. The allowable stress for compression perpendicular to the grain, and for horizontal shear shall not be increased by any factors such as short duration loading. Additional requirements are found in other parts of Section 6-02.3(17). Criteria for the design of lumber and timber connections are found in Section 6-02.3(17)I. Plywood for formwork shall be designed in accordance with the methods and stresses allowed in the APA Design/Construction Guide for Concrete Forming as published by the American Plywood Association, Tacoma, Washington. As concrete forming is a special application for plywood, wet stresses shall be used and then adjusted for forming conditions such as duration of load, and experience factors. Concrete pour pressures shall be in accordance with Section 6-02.3(17)J. 6-02.3(17)B3 Steel For identified grades of steel, design stresses shall not exceed those specified in the Steel Construction Manual, latest edition, by the American Institute of Steel Construction, except as follows: Compression, flexural but not to exceed 0.6Fy 12,000,000 psi Ld/bt The modulus of elasticity (E) shall be 29,000,000 psi When the grade of steel cannot be positively identified as with salvaged steel and if rivets are present, design stresses shall not exceed the following: Page 6-58 2020 Standard Specifications M 41-10 6-02 Concrete Structures Yield point fy 30,000 psi Tension, axial, and flexural 16,000 psi Compression, axial except L/r shall not exceed 120 14,150 - 0.37(KL/r)2 psi Shear on gross section of the web of rolled shapes 9,500 psi Web crippling for rolled shapes 22,500 psi Compression, flexural but not to exceed 16,000 psi and L/b not greater than 39 16,000 - 5.2(L/b)2 psi The modulus of elasticity (E) shall be 29,000,000 psi Where: L is the unsupported length; d is the least dimension of rectangular columns, or the width of a square of equivalent cross-sectional area for round columns, or the depth of beams; b is the flange width; t is the thickness of the compression flange; r is the radius of gyration of the compression flange about the weak axis of the member; and Fy is the specified minimum yield stress, psi, for the grade of steel used. All dimensions are expressed in inches. 6-02.3(17)C Falsework and Formwork at Special Locations In addition to the minimum requirements specified in Sections 6-02.3(17)A and 6-02.3(17)B, falsework towers or posts supporting beams directly over Roadways or railroads which are open to traffic or the public shall be designed and constructed so that the falsework will be stable if subjected to impact by vehicles. The use of damaged materials, unidentifiable material, salvaged steel or steel with burned holes or questionable weldments shall not be used for falsework described in this section. For the purposes of this Specification the following public or private facilities shall also be considered as “Roadways”: pedestrian pathways and other Structures such as bridges, walls, and buildings. The dimensions of the clear openings to be provided through the falsework for Roadways, railroads, or pedestrian pathways shall be as specified in the Contract. Falsework posts or shoring tower systems which support members that cross over a Roadway or railroad shall be considered as adjacent to Roadways or railroads. Other falsework posts or shoring towers shall be considered as adjacent to Roadways or railroads only if the following conditions apply: 1. Located in the row of falsework posts or shoring towers nearest to the Roadway or railroad; and 2. Horizontal distance from the traffic side of the falsework to the edge of pavement is less than the total height of the falsework and forms; or 3. The total height of the falsework and forms is greater than the horizontal clear distance between the base of the falsework and a point 10 feet from the centerline of track. 2020 Standard Specifications M 41-10 Page 6-59 Concrete Structures 6-02 The Contractor shall provide any additional features for the Work needed to ensure that the falsework will be stable for impact by vehicles; providing adequate safeguards, safety devices, protective equipment, and any other needed actions to protect property and the life, health, and safety of the public; and shall comply with the provisions in Sections 1-07.23 and 6-02.3(17)M. The falsework design at special locations, shall incorporate the minimum requirements detailed in this section, even if protected by concrete median barrier. The vertical load used for the design of falsework posts and towers which support the portion of the falsework over openings, shall be the greater of the following: 1. 150 percent of the design load calculated in accordance with Section 6-02.3(17)B, but not including any increased or redistributed loads caused by the post-tensioning forces; or 2. 100 percent of the design load plus the increased or redistributed loads caused by the post-tensioning forces. Each falsework post or each shoring tower leg adjacent to Roadways or railroads shall consist of either steel with a minimum section modulus about each axis of 9.5 inches cubed or sound timbers with a minimum section modulus about each axis of 250 inches cubed. Each falsework post or shoring tower leg adjacent to Roadways or railroads shall be mechanically connected to its supporting footing at its base, or otherwise laterally restrained, to withstand a force of not less than 2,000 pounds applied at the base of the post or tower leg in any direction except toward the Roadway or railroad track. Posts or tower legs shall be connected to the falsework cap and stringer by mechanical connections capable of resisting a load in any horizontal direction of not less than 1,000 pounds. For falsework spans over Roadways and railroads, all falsework stringers shall be mechanically connected to the falsework cap or framing. The mechanical connections shall be capable of resisting a load in any direction, including uplift on the stringer, of not less than 500 pounds. All associated connections shall be installed before traffic is allowed to pass beneath the span. When timber members are used to brace falsework bents which are located adjacent to Roadways or railroads, all connections shall be bolted through the members using ⅝-inch diameter or larger bolts. Concrete traffic barrier shall be used to protect all falsework adjacent to traveled Roadways. The falsework shall be located so that falsework footings, mudsills, or piles are at least 2 feet clear of the traffic barrier and all other falsework members shall also be at least 2 feet clear of the traffic barrier. Traffic barrier used to protect falsework shall not be fastened, guyed, or blocked to any falsework but shall be fastened to the pavement according to details shown in the Plans. The installation of concrete traffic barrier shall be completed before falsework erection is begun. The traffic barrier at the falsework shall not be removed until allowed by the Engineer. Falsework openings which are provided for the Contractor’s own use (not for public use) shall also use concrete traffic barrier Page 6-60 2020 Standard Specifications M 41-10 6-02 Concrete Structures to protect the falsework, except the minimum clear distance between the barrier and falsework footings, mudsills, piles, or other falsework members shall be at least 3 inches. Falsework bents within 20 feet of the center line of a railroad track shall be braced to resist the required horizontal load or 2,000 pounds whichever is greater. Pedestrian openings through falsework shall be paved or surfaced with full width continuous wood walks which shall be wheel chair accessible and shall be kept clear. Pedestrians shall be protected from falling objects and water falling from construction above. Overhead protection for pedestrians shall extend at least 4 feet beyond the edge of the bridge deck. Plans and details of the overhead protection and pathway shall be submitted with the falsework Working Drawings. Pedestrian openings through falsework shall be illuminated by temporary lighting, constructed and maintained by the Contractor. The temporary lighting shall be constructed in accordance with local electrical code requirements. The temporary lighting shall be steady burning 60-watt, 120-volt lamps with molded waterproof lamp holders spaced at 25-foot centers maximum. All costs relating to pedestrian pathway paving, wood walks, overhead protection, maintenance, operating costs, and temporary pedestrian lighting shall be incidental to applicable adjacent items of Work. 6-02.3(17)D Falsework Support Systems: Foundations, Manufactured Shoring Towers, Caps, and Posts Foundations for falsework shall be designed for conditions stated in this Section using methods shown in the AASHTO Standard Specifications for Highway Bridges Seventeenth Edition – 2002 for allowable stress design, the AASHTO LRFD Bridge Design Specifications for load and resistance factor design or the AASHTO Guide Design Specifications for Bridge Temporary Works. Allowable stresses for materials shall not exceed stresses and conditions allowed by Section 6-02.3(17)B. 6-02.3(17)D1 Vacant 6-02.3(17)D2 Vacant 6-02.3(17)D3 Bents, Shoring Towers, Piling, Posts, and Caps Plans for falsework bents or shoring tower systems, including manufactured tower systems shall have plan, cross-section, and elevation view scale drawings showing all geometry. Show in the falsework plans the proximity of falsework to utilities or any nearby Structures including underground Structures. The ground elevation, cross-slopes, relation of stringers to one another, and dimensions to posts or piling shall be shown in the falsework plans. Column, pile, or tower heights shall be indicated. Member sizes, wall thickness and diameter of steel pipe columns or piles shall be shown in the falsework plans. Location of wedges, minimum bearing area and type of wedge material shall be identified in the falsework plans. Bracing size, location, material and all connections shall be described in the falsework plans. 2020 Standard Specifications M 41-10 Page 6-61 Concrete Structures 6-02 The relationship of the falsework bents or shoring tower systems to the permanent Structure’s pier and footing shall be shown. Load paths shall be as direct as possible. Loads shall be applied through the shear centers of all members to avoid torsion and buckling conditions. Where loads cause twisting, biaxial bending, or axial loading with bending, the affected members shall be designed for combined stresses and stability. Posts or columns shall be constructed plumb with tops and bottoms carefully cut to provide full end bearing. Caps shall be installed at all bents supported by posts or piling unless the falsework Working Drawings specifically permit otherwise. Caps shall be fastened to the piling or posts. The falsework shall be capable of supporting non uniform or localized loading without adverse effect. For example, the loading of cantilevered ends of stringers or caps shall not cause a condition of instability in the adjacent unloaded members. Timber posts and piling shall be fastened to the caps and mudsills by through-bolted connections, drift pins, or other accepted connections. The minimum diameter of round timber posts shall be shown in the falsework plans. Timber caps and timber mudsills shall be checked for crushing from columns or piling under maximum load. Steel posts and piling shall be welded or bolted to the caps, and shall be bolted or welded to the foundation. Steel members shall be checked for buckling, web yielding, and web crippling. Wedges shall be used to permit formwork to be taken up and released uniformly. Wedges shall be oak or close-grained Douglas fir. Cedar wedges or shims shall not be used anywhere in a falsework or forming system. Wedges shall be used at the top or bottom of shores, but not at both top and bottom. After the final adjustment of the shore elevation is complete, the wedges shall be fastened securely to the sill or cap beam. Only one set of wedges (with one optional block) shall be used at one location. Screw jacks (or other allowed devices) shall be used under arches to allow incremental release of the falsework. Sand jacks may be used to support falsework and are used for falsework lowering only. Sand jacks shall be constructed of steel with snug fitting steel or concrete pistons. Sand jacks shall be filled with dry sand and the jack protected from moisture throughout its use. They shall be designed and installed in such a way to prevent the unintentional migration or loss of sand. All sand jacks shall be tested in accordance with Section 6-02.3(17)G. When falsework is over or adjacent to Roadways or railroads, all details of the falsework system which contribute to the horizontal stability and resistance to impact shall be installed at the time each element of the falsework is erected and shall remain in place until the falsework is removed. For other requirements see Section 6-02.3(17)C. Transverse construction joints in the Superstructure shall be supported by falsework at the joint location. The falsework shall be constructed in such a manner that subsequent pours will not produce additional stresses in the concrete already in place. Page 6-62 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(17)D4 Manufactured Shoring Tower Systems and Devices Manufactured proprietary shoring tower systems shall be identified in the falsework plans by make and model and safe working load capacity per leg. The safe working load for shoring tower systems shall be based upon a minimum 2½ to 1 factor of safety. The safe working load capacity, anticipated deflection (or settlement), make and model shall be identified in the falsework plans for manufactured devices such as: single shores, overhang brackets, support bracket and jack assemblies, friction collars and clamps, hangers, saddles, and sand jacks. The safe working load for shop manufactured devices shall be based on a minimum ultimate strength safety factor of 2 to 1. The safe working load for field fabricated devices and all single shores shall be based on a minimum ultimate strength safety factor of 3 to 1. The safe working load of all devices shall not be exceeded. The design loads shall be as defined by Section 6-02.3(17)A. The maximum allowable free end deflection of deck overhang brackets under working loads applied shall not exceed 3/16 inch measured at the edge of the concrete slab regardless of the fact that the deflection may be compensated for by pre-cambering or of setting the elevations high. The Contractor shall comply with all manufacturer’s Specifications; including those relating to bolt torque, placing washers under nuts and bolt heads, cleaning and oiling of parts, and the reuse of material. Devices which are deteriorated, bent, warped, or have poorly fitted connections or welds, shall not be installed. Shoring tower or device capacity as shown in catalogs or brochures published by the manufacturer shall be considered as the maximum load which the shoring is able to safely support under ideal conditions. These maximum values shall be reduced for adverse loading conditions; such as horizontal loads, eccentricity due to unbalanced spans or placing sequence, and uneven foundation settlement. Copies of catalog data and/or other technical data shall be furnished with the falsework plans to verify the load-carrying capacity, deflection, and manufacturers installation requirements of any manufactured product or device proposed for use. Upon request by the Engineer, the Contractor shall furnish manufacturer certified test reports and results showing load capacity, deflection, test installation conditions, and identify associated components and hardware for shoring tower systems or other devices. In addition to manufacturer’s requirements, the criteria shown in the following sections for manufactured proprietary shoring tower systems and devices shall be complied with when preparing falsework plans, calculations, and installing these shoring tower systems and devices as falsework. Alternative criteria and/or systems shall be submitted as a Type 2 Working Drawing consisting of a written statement on the manufacturer’s letterhead, signed by the shoring or device manufacturer (not signed by a material supplier or the Contractor) addressing the following: 1. Identity of the specific Contract on which the alternative criteria and/or system will apply; 2020 Standard Specifications M 41-10 Page 6-63 Concrete Structures 6-02 2. Description of the alternative criteria and/or system; 3. Technical data and test reports; 4. The conditions under which the particular alternative criteria may be followed; and 5. That a design based on the alternative criteria will not overstress or over deflect any shoring component or device nor reduce the required safety factor. In any case where the falsework drawings detail a manufactured product and the manufacturer’s safe working load, load versus deflection curves, factor of safety, and installation requirements cannot be found in any catalog, the Engineer may require load testing in accordance with Section 6-02.3(17)G to verify the safe working load and deflection characteristics. Tower leg loads shall not exceed the limiting values under any loading condition or sequence. Frame extensions and any reduced capacity shall be shown in the falsework plans. Screw jacks shall fit tight in the leg assemblies without wobble. Screw jacks shall be plumb and straight. Shoring towers shall be installed plumb, and load distribution beams shall be arranged such that vertical loads are distributed to all legs for all successive concrete placements. There shall be no eccentric loads on shoring tower heads unless the heads have been designed for such loading. Shoring towers shall remain square or rectangular in plan view and shall not be skewed. There shall be no interchanging of parts from one manufactured shoring system to another. Bent or faulty components shall not be used. For manufactured shoring towers that allow ganging of frames, the number of ganged frames shall be limited to one frame per opposing side of a tower, and the total number of legs per ganged tower shall not exceed eight legs. Ganged frames shall be installed in accordance with the manufacturer’s published standards using the manufacturer’s components. Other gang arrangements shall not be used. For manufactured steel shoring tower systems, the Contractor shall have bracing designed and installed for horizontal loads and falsework overturning in accordance with Section 6-02.3(17)A. Minimum bracing criteria and allowable leg loads are described in the following paragraphs. All shoring tower systems and bracing shall be thoroughly inspected by the Contractor for plumb vertical support members, secure connections, and straight bracing members immediately prior to, at intervals during, and immediately after every concrete placement. For manufactured shoring tower systems, the maximum allowable deviation from the vertical is ⅛ inch in 3 feet. If this tolerance is exceeded, concrete shall not be placed until adjustments have brought the shoring towers within the acceptable tolerance. Page 6-64 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(17)E Stringers, Beams, Joists, Bridge Deck Support, and Deck Overhangs All stringers, beams, joists, and bridge deck support shall be designed for the design loads, deflections, and allowable stresses described in the preceding Section 6-02.3(17)A, B, and C and for the following conditions. At points of support, stringers, beams, joists, and trusses shall be restrained against rotation about their longitudinal axis. The effect of biaxial bending shall be investigated in all cases where falsework beams are not set plumb and the Structure cross-slope exceeds 3 percent. For box girder and T-beam bridges, the centerline of falsework beams or stringers shall be located within 2 feet of the bridge girder stems and preferably directly under the stems or webs. Stringers supporting formwork for concrete box girder and T-beam slab overhangs shall be stiff enough so that the differential deflection due to the placement of bridge deck concrete is no more than 3/16 inch between the outside edge of the bridge deck and the exterior web even if camber strips can compensate for the deflection. Friction shall not be relied upon for lateral stability of beams or stringers. If the compression flange of a beam is not laterally restrained, the allowable bending stress shall be reduced to prevent flange buckling. If flange restraint is provided and since it is impossible to predict the direction in which a compression flange will buckle, positive restraint shall be provided in both directions. Flange restraint shall be designed for a minimum load of 2 percent of the calculated compression force in the beam flange at the point under consideration. Camber strips shall be used to compensate for falsework take-up and deflection, vertical alignment, and the anticipated Structure dead load deflection shown in the camber diagram in the Contract Plans. Camber is the adjustment to the profile of a load- supporting beam or stringer so that the completed Structure will have the lines and grades shown in the Plans. The dead load camber diagram shown in the Contract Plans is the predicted Structure dead load deflection due to self mass. This dead load camber shall be increased by: 1. Amount of anticipated falsework take up, 2. Anticipated deflection of the falsework beam or stringer under the actual load imposed, and 3. Any vertical curve compensation. Camber strips shall be fastened by nailing to the top of wood members, or by clamping or banding in the case of steel members. Camber strips shall have sufficient contact bearing area to prevent crushing under total load. Camber strips are required when the total camber adjustment exceeds ¼ inch for exterior falsework stringers and ½ inch for interior stringers. 2020 Standard Specifications M 41-10 Page 6-65 Concrete Structures 6-02 On concrete box girder Structures, the forms supporting the bridge deck shall rest on ledgers or similar supports and shall not be supported from the bottom slab except as provided below. The form supports shall be fastened within 18 inches of the top of the web walls, producing a clear span between web walls. The bridge deck forms may be supported or posted from the bottom slab if the following conditions are met: 1. Permanent access, shown in the Contract Plans, is provided to the cells, and the centerline to centerline distance between web walls is greater than 10 feet; 2. Falsework stringers designed for total load, stresses and deflections in accordance with Section 6-02.3(17)A and B are located directly below each row of posts; 3. Posts have adequate lateral restraint; and 4. All forms (including the bridge deck forms), posts, and bracing are completely removed. The falsework and forms on concrete box girder Structures supporting a sloping web and deck overhang shall consist of a lateral support system which is designed to resist all rotational forces acting on the stem, including those caused by the placement of bridge deck concrete, bridge deck formwork mass, finishing machine, and other live loads. Stem reinforcing steel shall not be stressed by the construction of the bridge deck slab placement. Overhang brackets shall not be used for the support of bridge deck forms from sloping web concrete box girder bridges. Deck slab forms between girders or webs shall be constructed such that there is no differential settlement relative to the girders. The support systems for form panels supporting concrete deck slabs and overhangs on girder bridges (such as steel plate girders and prestressed girders) shall be designed as falsework. Falsework supporting deck slabs and overhangs on girder bridges shall be supported directly by the girders so that there will be no differential settlement between the girders and the deck forms during placement of deck concrete. 6-02.3(17)F Bracing All falsework bracing systems shall be designed to resist the horizontal design load in all directions with the falsework in either the loaded or unloaded condition. All bracing, connection details, specific locations of connections, and hardware used shall be shown in the falsework plans. Falsework diagonal bracing shall be thoroughly analyzed with particular attention given to the connections. The allowable stresses in the diagonal braces may be controlled by the joint strength or the compression stability of the diagonal. Timber bracing for timber falsework bents shall have connections designed in accordance with Section 6-02.3(17)I. Any damaged cross-bracing, such as split timber members shall be replaced. Steel strapping shall avoid making sharp angles or right- angle bends. A means of preventing accidental loss of tension shall be provided for steel strapping. See Sections 6-02.3(17)A, B, and C for design loads and allowable stresses. Bracing shall not be attached to concrete traffic barrier, guardrail posts, or guardrail. Page 6-66 2020 Standard Specifications M 41-10 6-02 Concrete Structures To prevent falsework beam or stringer compression flange buckling, cross-bracing members and connections shall be designed to carry tension as well as compression. All components, connection details and specific locations shall be shown in the falsework plans. Bracing, blocking, struts, and ties required for positive lateral restraint of beam flanges shall be installed at right angles to the beam in plan view. If possible, bracing in adjacent bays shall be set in the same transverse plane. However, if because of skew or other considerations, it is necessary to offset the bracing in adjacent bays, the offset distance shall not exceed twice the depth of the beam. All falsework and bracing shall be inspected by the Contractor for plumbness of vertical support members, secure connections, tight cables, and straight bracing members immediately prior to, during, and immediately after every concrete placement. Bracing shall be provided to withstand all imposed loads during erection of the falsework and all phases of construction for falsework adjacent to any Roadway, sidewalk, or railroad track which is open to the public. All details of the falsework system which contribute to horizontal stability and resistance to impact, including the bolts in bracing, shall be installed at the time each element of the falsework is erected and shall remain in place until the falsework is removed. The falsework plans shall show provisions for any supplemental bracing or methods to be used to conform to this requirement during each phase of erection and removal. Wind loads shall be included in the design of such bracing or methods. Loads, connections, and materials for falsework adjacent to Roadways, shall also be in accordance with Section 6-02.3(17)C. 6-02.3(17)F1 Cable or Tension Bracing Systems When cables, wire rope, steel rod, or other types of tension bracing members are used as external bracing to resist horizontal forces, or as temporary bracing to support bents while falsework is being erected or removed adjacent to traffic, all elements of the bracing system shall be shown in the falsework plans. Bracing shall not be attached to concrete traffic barrier, guardrail posts, or guardrail. Any damaged bracing, such as frayed and kinked guying systems shall be replaced. Wire rope shall avoid making sharp angles or right-angle bends and a means of preventing accidental loss of tension shall be provided. The following information shall be submitted as a Type 2 Working Drawing: 1. Cable diameter, rod, or tension member size, and allowable working load. 2. Location and method of attaching the cable, rod, or tension member to the falsework. The connecting device shall be designed to transfer both horizontal and vertical forces to the cable without overstressing any falsework component. 3. The type of cable connectors or fastening devices (such as U-bolt clips, plate clamps, etc.) to be used and the efficiency factor for each type. If cables are to be spliced, the splicing method shall be shown. 4. Method of tightening cables, rods, or tension members after installation if tightening is necessary to ensure their effectiveness. Method of preventing accidental loosening. 2020 Standard Specifications M 41-10 Page 6-67 Concrete Structures 6-02 5. Anchorage details, including the size and mass of concrete anchor blocks, the assumed coefficient of friction for surface anchorages, and the assumed lateral soil bearing capacity for buried anchorages. 6. Method of pre-stretching or preloading cable or tension members. 7. Determination of the potential stretch or elongation of the tension member under the design load and if the resulting lateral deflection will cause excessive secondary stresses in the falsework. Copies of manufacturer’s catalog or brochure showing technical data pertaining to the type of cable to be used shall be furnished with the falsework plans. Technical data shall include the cable diameter, the number of strands and the number of wires per strand, ultimate breaking strength or recommended safe working strength, and any other information as may be needed to identify the cable. In the absence of sufficient technical data to identify the cable, or if it is old and obviously worn, the Contractor shall perform cable breaking tests to establish the safe working load for each reel of cable furnished. For static guy cable the minimum factor of safety shall be 3 to 1. The Contractor shall provide the Engineer an opportunity to witness these tests. When cable bracing is used to prevent the overturning of heavy-duty shoring, attention shall be given to the connections by which forces are transferred from the shoring to the cables. Cable restraint shall be designed to act through the cap system to prevent the inadvertent application of forces which the shoring is not designed to withstand. Cables shall not be attached to any tower component. Cable splices made by lapping and clipping with “Crosby” type clamps shall not be used. Other splicing methods may be used; however, at each location where the cable is spliced, cable strength shall be verified by a load test. When cables are used as external bracing to resist overturning of a falsework system, the horizontal load to be carried by the cables shall be calculated as follows: 1. When used with heavy-duty shoring systems, cables shall be designed to resist the difference between 1.25 times the total overturning moment and the resistance to overturning provided by the individual falsework towers. 2. When used with pipe-frame shoring systems where supplemental bracing is required, cables shall be designed to resist the difference between 1.25 times the total overturning moment and the resistance to overturning provided by the shoring system as a whole. 3. When used as external bracing to prevent overturning of all other types of falsework, including temporary support during erection and removal of falsework at traffic openings, cables shall be designed to resist 1.25 times the total overturning moment. Page 6-68 2020 Standard Specifications M 41-10 6-02 Concrete Structures The maximum allowable cable design load shall be determined using the following criteria: 1. If the cable is new, or is in uniformly good condition, and if it can be identified by reference to a manufacturer’s catalog or other technical publication, the allowable load shall be the ultimate strength of the cable as specified by the manufacturer, multiplied by the efficiency of the cable connector, and divided by a safety factor of 3 (i.e., safe working load = breaking strength × connector efficiency/safety factor). 2. If the cable is used but still in serviceable condition, or is new or nearly new but cannot be found in a manufacturer’s catalog, the Contractor shall perform load breaking tests. In this case, the cable design load shall not exceed the breaking strength, as determined by the load test, multiplied by the connector efficiency factor, and divided by a safety factor of 3. 3. If the cable is used and still in serviceable condition, or is a new or nearly new cable which cannot be identified, and if load breaking tests are not performed, the cable design load shall not exceed the safe working load shown in the wire rope capacities table multiplied by the cable connector efficiency. Cable connectors shall be designed in accordance with criteria shown in the following tables “Efficiency of Wire Rope Connections” and “Applying Wire Rope Clips”. Cable safe working loads are provided in table “Wire Rope Capacities”. Efficiency of Wire Rope Connections (As compared to Safe Loads on Wire Rope) Type of Connection Connector Efficiency Wire Rope 100% Sockets – Zink Type 100% Wedge Sockets 70% Clips – Crosby Type With Thimble 80% Knot and Clip (Contractors Knot)50% Plate Clamp – 3 Bolt Type With Thimble 80% Spliced Eye and Thimble: ¼″ and smaller 100% ⅜″ to ¾″95% ⅞″ to 1″88% 1⅛″ to 1½″82% 1⅝″ to 2″75% 2⅛″ and larger 70% 2020 Standard Specifications M 41-10 Page 6-69 Concrete Structures 6-02 Wire Rope Capacities Safe Load in Pounds for New Plow Steel Hoisting Rope 6 Strands of 19-Wires, Hemp Center (Safety Factor of 6) Diameter inches Weight Lbs./Ft.Safe Load Lbs. ¼0.10 1,050 5/16 0.16 1,500 ⅜0.23 2,250 7⁄16 0.31 3,070 ½0.40 4,030 9⁄16 0.51 4,840 ⅝0.63 6,330 ¾0.95 7,930 ⅞1.29 10,730 1 1.60 15,000 1⅛2.03 18,600 1¼2.50 23,000 1⅜3.03 25,900 1½3.60 30,700 1⅝4.23 35,700 1¾4.90 41,300 6-02.3(17)F2 Applying Wire Rope Clips The only correct method of attaching U-bolt wire rope clips to rope ends is to place the base (saddle) of the clip against the live end of the rope, while the “U” of the bolt presses against the dead end. The clips are usually spaced about six rope diameters apart to give adequate holding power. A wire-rope thimble shall be used in the loop eye to prevent kinking when wire rope clips are used. The correct number of clips for safe application, and spacing distances, are shown below: Number of Clips and Spacing for Safe Application Improved Plow Steel Rope Diameter inches Number of Clips Minimum Drop Forged Other Material Spacing (Inches) ⅜2 3 3 ½3 4 3½ ⅝3 4 4 ¾4 5 4½ ⅞4 5 5¼ 1 5 6 6 1⅛6 6 6¾ 1¼6 7 7½ 1⅜7 7 8¼ 1½7 8 9 Page 6-70 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(17)F3 Anchor Blocks Concrete anchor blocks and connections used to resist forces from external bracing shall be shown in the falsework plans. Concrete anchor blocks shall be proportioned to resist both sliding and overturning. When designing anchor block stability, the mass of the anchor block shall be reduced by the vertical component of the cable or brace tension to obtain the net or effective mass to be used in the anchorage computations. The coefficient of friction assumed in the design shall not exceed the following: Friction Coefficient Anchor block set on sand 0.40 Anchor block set on clay 0.50 Anchor block set on gravel 0.60 Anchor block set on pavement 0.60 Multiply the friction coefficient by 0.67 if it is likely the supporting material is wet or will become wet during the construction period. The method of connecting the cable or brace to the anchor block is part of the anchor block design. The connection shall be designed to resist both horizontal and vertical forces. 6-02.3(17)F4 Temporary Bracing for Bridge Girders During Erection Steel girders shall be braced in accordance with Section 6-03.3(7)A. Prestressed concrete girders shall be braced sequentially during girder erection. The bracing shall be designed and detailed by the Contractor and shall be shown in the falsework/formwork Working Drawings. The Contractor shall furnish, install, and remove the bracing at no additional cost to the Contracting Agency. At a minimum, the Contractor shall brace girders at each end and at midspan to prevent lateral movement or rotation. This bracing shall be placed prior to the release of each girder from the erection equipment. If the bridge is constructed with cast-in-place concrete diaphragms, the bracing may be removed once the concrete in the diaphragms has been placed and cured for a minimum of 24 hours. 2020 Standard Specifications M 41-10 Page 6-71 Concrete Structures 6-02 6-02.3(17)F5 Temporary Bracing for Bridge Girders During Diaphragm and Bridge Deck Concrete Placement Prestressed concrete girders shall be braced to resist forces that would cause rotation or torsion in the girders caused by the placing of precast concrete deck panels and concrete for the bridge deck. Bracing shall be designed and detailed by the Contractor and shall be shown in the falsework/formwork Working Drawings. These braces shall be furnished, installed, and removed by the Contractor at no additional cost to the Contracting Agency. The Contractor may consider the bracing effects of the diaphragms in developing the falsework/formwork plans. The Contractor shall account for the added load from concrete finishing machines and other construction loadings in the design of the bracing. Falsework support brackets and braces shall not be welded to structural steel bridge members or to steel reinforcing bars. 6-02.3(17)G Testing Falsework Devices The Contractor shall establish the load capacity and deflection (or settlement) of all friction collars and clamps, brackets, hangers, saddles, sand jacks, and similar devices utilizing a recognized independent testing Laboratory accepted by the Engineer. Laboratory tests shall use the same materials and design that will be used on the project. Test loads shall be applied to the device in the same manner that the device will experience loading on the project. Any bolts or threaded rods used with the device shall be identified as to diameter, length, type, grade, and torque. Any wedges, blocks, or shims used with the device on the project shall also be tested with the device. Any adjustable jack system used as a part of a device shall be tested with the device and shall have its maximum safe working extended height identified. Devices shall not be tested in contact with the permanent Structure. Independent members with the same properties as the permanent Structure shall be used to test device connections. At least 14 days prior to the test, the Contractor shall submit a Type 2 Working Drawing consisting of the test procedure and scale drawing showing how the device will be tested and how data will be collected. The Contractor shall provide the Engineer an opportunity to witness these tests. The independent testing Laboratory shall provide a certified test report which shall be signed and dated. The test report shall clearly identify the device tested including trademarks and model numbers; identify all parts and materials used, including grade of steel, or lumber, member section dimensions; location, size, and the maximum tested extended height of any adjustable jacks; indicate condition of materials used in the device; indicate the size, length and location of all welds; indicate how much torque was used with all bolts and threaded rods. The report shall describe how the device was tested, report the results of the test, provide a scale drawing of the device showing the location(s) of where deflections or settlements were measured, and show where load was applied. Deflections or settlements shall be measured at load increments and the results shall be clearly graphed and labeled. Prior to installation of falsework devices named Page 6-72 2020 Standard Specifications M 41-10 6-02 Concrete Structures in this section, the Contractor shall submit Type 2 Working Drawings consisting of the certified test reports. The safe working load for shop manufactured devices named in this section shall be derived by dividing the ultimate strength by a safety factor of 2.0. The safe working load for field fabricated or field modified devices (including the use of timber blocks or wedges with the device) shall be determined by dividing the ultimate strength by a safety factor of 3.0. Working load shall include masses of all successive concrete placements, falsework, forms, all load transfer that takes place during post-tensioning, and any live loads; such as workers, Roadway finishing machines, and concrete delivery systems. The maximum allowable free end deflection of deck overhang brackets with combined dead and live working loads applied shall be 3/16 inch even though deflection may be compensated for by pre-cambering or setting the elevations high. The Contractor shall comply with all manufacturer’s Specifications; including those relating to bolt torque, cleaning and oiling of parts, and the reuse of material. Devices which are deteriorated, bent, warped or have poorly fitted connections or welds, shall not be installed. 6-02.3(17)H Formwork Accessories Formwork accessories such as form ties, form anchors, form hangers, anchoring inserts, and similar hardware shall be specifically identified in the formwork plans including the name and size of the hardware, manufacturer, safe working load, and factor of safety. The grade of steel shall also be indicated for threaded rods, coil rods, and similar hardware. Wire form ties shall not be used. Welding or clamping formwork accessories to Contract Plan reinforcing steel will not be allowed. Driven types of anchorages for fastening forms or form supports to concrete, and Contractor fabricated “J” hooks shall not be used. Field drilling of holes in prestressed girders is not allowed. Taper ties may be used provided the following conditions are met: 1. The structure is not designed to resist water pressure (pontoons, floating dolphins, detention vaults, etc.). 2. After the taper tie is removed, plugs designed and intended for plugging taper tie holes shall be installed at each face of concrete. The plug shall be installed a minimum of 1½ inches clear from the face of concrete. 3. After the plug is installed, the hole shall be cleaned of all grease, contamination and foreign matter. 4. Holes on the exposed faces of concrete shall be patched and finished to match the surrounding concrete. The following table from ACI 347R-88 provides minimum safety factors for formwork accessories. The hardware proposed shall meet these minimum ultimate strength requirements or the manufacturer’s minimum requirements, whichever provides the greater factor of safety. The Contractor shall attach copies of the manufacturer’s catalog cuts and/or test data of hardware proposed, to the formwork plans and submit the falsework and formwork Working Drawings with supporting calculations in accordance 2020 Standard Specifications M 41-10 Page 6-73 Concrete Structures 6-02 with Section 6-02.3(16). In situations where catalog cuts and/or test data are not available, testing shall be performed in accordance with Section 6-02.3(17)G. Minimum Safety Factors of Formwork Accessories* Accessory Safety Factor Type of Construction Form Tie 2.0 All applications. Form Anchor 2.0 Formwork supporting form mass and concrete pressures only. Form Anchor 3.0 Formwork supporting masses of forms, concrete, construction live loads, and impact. Form Hangers 2.0 All applications. Anchoring Inserts 2.0 Placed in previous opposing concrete placement to act as an anchor for form tie. *Safety factors are based on ultimate strength of the formwork accessory. The bearing area of external holding devices shall be adequate to prevent excessive bearing stress on form lumber. Form ties and form hangers shall be arranged symmetrically on the supporting members to minimize twisting or rotation of the members. Form tie elongation shall not exceed the allowable deflection of the wale or member that it supports. Inserts, bolts, coil rods, and other fasteners shall be analyzed and designed for appropriately combined bending, shear, torsion, and tension stresses. The formwork shall not be attached to Contract Plan rebar or rebar cages. However, the Contractor may install additional reinforcing steel for formwork anchorage. Frictional resistance shall not be considered as contributing to the stability of any connection or connecting device, except those designed as friction connectors such as U-bolt friction-type connectors. Form anchors and anchoring inserts shall be designed considering concrete strength at time of loading, available embedment, location in the member, and any other factors affecting their working strength, and shall be installed in concrete in accordance with the manufacturer’s published requirements. Form anchors and anchoring inserts embedded in previous concrete placements shall not be loaded until the concrete has reached the required design strength. The required design strength of concrete for loading of an anchor shall be shown in the formwork drawing if it is assumed that the anchor will be loaded before the concrete has reached its 28-day strength. Installation of permanent concrete inserts, such as form ties hangers, or embedded anchor assemblies, shall permit removal of all metal to at least ½ inch below the concrete surface. Holes shall be patched in accordance with Section 6-02.3(14). During removal of the outer unit, the bond between the concrete and the inner unit or rod shall not be broken. Page 6-74 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(17)I Timber Connections Timber connections shall be designed in accordance with the methods, stresses, and loads allowed in the Timber Construction Manual, Third Edition by the American Institute of Timber Construction (AITC). Timber falsework and formwork connections shall be designed using wet condition stresses for all installations West of the Cascade Range crest line and by criteria provided in the following sections. Frictional resistance shall not be considered as contributing to the stability of any timber connection. 6-02.3(17)I1 Bolted Connections Tabulated values in the AITC Timber Construction Manual, Current Edition are based on square posts. For a round post or pile, the main member thickness shall be the side of a square post having the same cross-sectional area as the round post used. The AITC Table 6.20 for Douglas Fir-Larch bolt Group 3 and for Hem-Fir bolt Group 8 show design values for bolts to be used when the load is applied either parallel or perpendicular to the direction of the wood grain. When the load is applied at an angle to the grain, as is the case with falsework bracing, the design value for the main member shall be obtained from the Hankinson formula shown in the AITC manual. Design values in the AITC Table 6.20 apply only to three-member joints (bolt in double- shear) in which the side members are each ½ the thickness of the main member. This joint configuration is not typical of bridge falsework where side members are usually much smaller than main members. For two-member joints (single shear bolt condition), the AITC Table 6.20 values shall be adjusted by a single shear load factor as follows: 1. 0.75 for installations East of the Cascade Range crest line, except as shown in item 3 below; 2. 0.50 for installations West of the Cascade Range crest line; and 3. 0.50 for load acting at an angle to the bolt axis, as is the case with longitudinal bracing when falsework bents are skewed. Except for connections in falsework adjacent to or over railroads or Roadways, threaded rods and coil rods may be used in place of bolts of the same diameter with no reduction in the tabulated values. At openings for Roadways and railroads, all connections shall be bolted using ⅝-inch diameter or larger through bolts. Bolt holes shall be a minimum 1/32 inch to a maximum ⅛ inch larger than the bolt diameter. A washer not less than a standard cut washer shall be installed between the wood and the bolt head and between the wood and the nut to distribute the bearing stress under the bolt head and nut and to avoid crushing the fibers. In lieu of standard cut washers, metal plates or straps with dimensions at least equal to that of a standard cut washer may be substituted. 2020 Standard Specifications M 41-10 Page 6-75 Concrete Structures 6-02 When steel bars or shapes are used as diagonal bracing, the tabulated design values shown in AITC Table 6.20 for the main members loaded parallel to grain (P value) are increased 75 percent for joints made with bolts ½ inch or less in diameter, 25 percent for joints made with bolts 1½ inch in diameter, and proportionally for intermediate diameters. No increase in the tabulated values is allowed for perpendicular-to-grain loading (Q value). Clearance requirements for end, edge, and bolt spacing distance shall be as shown below. All distances are measured from the end or side of the wood member to the center of the bolt hole. For members which are subject to load reversals the larger controlling distances shall be used for design. For parallel-to-grain loading, the minimum distances for full design load: 1. In tension, minimum end distance shall be seven times the bolt diameter; 2. In compression, minimum end distance shall be four times the bolt diameter; and 3. In tension or compression, the minimum edge distance shall be one and one-half times the bolt diameter. For perpendicular-to-grain loading, the minimum distance for full design load: 1. Minimum end distance shall be four times the bolt diameter; 2. Edge distance toward which the load is acting shall be at least four times the bolt diameter; and 3. Distance on the opposite edge shall be at least 1½-bolt diameters. Minimum clearance (spacing) between adjacent bolts in a row shall be four times the bolt diameter, measured center-to-center of the bolt holes. When more than two bolts are used in a line parallel to the axis of the side member, additional requirements shall be followed as shown in the AITC manual. 6-02.3(17)I2 Lag Screw Connections Design values for lag screws subject to withdrawal loading are found in AITC Table 6.27. Values for wood having a specific gravity of 0.51 for Douglas Fir-Larch or 0.42 for Hem-Fir shall be assumed when using the table. The withdrawal values are in pounds per inch of penetration of the threaded part of the lag screw into the side grain of the member holding the point, with the axis of the screw perpendicular to that member. The maximum load on a given screw shall not exceed the allowable tensile strength of the screw at the root section. AITC recommends against subjecting lag screws to end-grain withdrawal loading. However, if this condition cannot be avoided, the design value shall be 75 percent of the corresponding value for withdrawal from the side grain. Values in the Group II wood species column shall be used for Douglas Fir-Larch and the Group III wood species column shall be used for Hem-Fir. When the load is applied at an angle to the grain, as is the case with falsework bracing, the design value shall be obtained from the Hankinson formula shown in the AITC manual. Page 6-76 2020 Standard Specifications M 41-10 6-02 Concrete Structures When lag screws are subjected to a combined lateral and withdrawal loading, as would be the case with longitudinal bracing when the falsework bents are skewed, the effect of the lateral and withdrawal forces shall be determined separately. The withdrawal component of the applied load shall not exceed the allowable value in withdrawal. The lateral component of the applied load shall not exceed the allowable lateral load value. Lag screws shall be inserted in lead holes as follows: 1. The clearance hole for the shank shall have the same diameter as the shank, and the same depth of penetration as the length of unthreaded shank; 2. The lead hole for the threaded portion shall have a diameter equal to 60 to 75 percent of the shank diameter and a length equal to at least the length of the threaded portion. The larger percentile figure in each range shall apply to screws of the greater diameters used in Group II wood species; 3. The threaded portion of the screw shall be inserted in its lead hole by turning with a wrench, not by driving with a hammer; and 4. To facilitate insertion, soap or other lubricant shall be used on the screws or in the lead hole. 6-02.3(17)I3 Drift Pin and Drift Bolt Connections When drift pins or drift bolts are used, the required length and penetration shall be determined using the following criteria. The lateral load-carrying capacity of drift pins and drift bolts driven into the side grain of a wood member shall be limited to 75 percent of the design values for a common bolt of the same diameter and length in the main member. For drift pin connections, the pin penetration into the connected members shall be increased to compensate for the absence of a bolt head and nut. For drift bolts or pins driven into the end grain of a member, the lateral load-carrying capacity shall be limited to 60 percent of the allowable side grain load (perpendicular to grain value) for an equal diameter bolt with nut. To develop this allowable load the drift bolt or pin shall penetrate at least 12 diameters into the end grain. To fully develop the allowable load of the drift bolts or pins, they shall be driven into predrilled holes, 1/16 inch less in diameter than the drift pin or bolt diameter. The criteria shown in the AITC Timber Construction Manual, Current Edition shall apply to drift bolt or pin connection allowable loads for the following conditions: 1. Withdrawal resistance; and 2. When there are more than two drift bolts or pins in a joint, allowable loads shall be further reduced by applying applicable modification factors shown in the AITC Table 6.3. 2020 Standard Specifications M 41-10 Page 6-77 Concrete Structures 6-02 6-02.3(17)I4 Nailed and Spiked Joints Joints using nails or spikes shall conform to the provisions of AITC. For side grain withdrawal, the values in AITC Table 6.35 for wood having a specific gravity of 0.51 for Douglas Fir-Larch and a specific gravity of 0.42 for Hem-Fir shall be used. End grain withdrawal shall not be used. For lateral loading, the values in AITC Table 6.36 for wood species Group II for Douglas Fir-Larch and wood species Group III for Hem-Fir shall be used. Diameters listed in the tables apply to fasteners before application of any protective coating. When more than one nail or spike is used in a joint, the total design value for the joint in withdrawal or lateral resistance shall be the sum of the design values for the individual nails or spikes. The tabulated design values for lateral loads are valid only when the nail penetrates into the main member at least 11 diameters for Douglas Fir-Larch and 13 diameters for Hem- Fir. Note that the values are maximum values for the type and size of fastener shown. The tabulated values shall not be increased even if the actual penetration is exceeded. When main member penetration is less than 11 diameters for Douglas Fir-Larch and 13 diameters for Hem-Fir, the design value shall be determined by straight-line interpolation between zero and the tabulated load, except that penetration shall not be less than ⅓ of that specified. Double-headed or duplex nails used in falsework and formwork construction are shorter than common wire nails or box nails of the same size designation. They have less penetration into the main member and therefore their load-carrying capacity shall be adjusted accordingly. Nail and spike minimum spacing in timber connections shall be as follows: 1. The average center-to-center distance between adjacent nails, measured in any direction, shall not be less than the required penetration into the main member for the size of nail being used; and 2. The minimum end distance in the side member, and the minimum edge distance in both the side member and the main member, shall not be less than ½ of the required penetration. Allowable values for withdrawal and lateral load resistance are reduced when toe nails are used in accordance with the following: 1. For withdrawal loading, the design load shall not exceed ⅔ of the value shown in the applicable design table; and 2. For lateral loading, the design load shall not exceed 5⁄6 of the value shown in the applicable design table. Toe nails are recommended to be driven at an approximate angle of 30 degrees with the piece and started approximately ⅓ of the length of the nail from the end or side of the piece. Page 6-78 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(17)I5 Timber Connection Adjustment for Duration of Load Tabulated values for timber fasteners are for normal duration of load and may be increased for short duration loading, except for connections used in falsework and formwork for post tensioned Structures and staged construction sequences. Duration of load adjustment for timber connections shall not be allowed for all post tensioned Structures and for staged construction sequences where delayed and/or staged loading occurs for any type of concrete Structure. The adjustment for duration of load as described in this section applies only to design values for timber connectors, such as nails, bolts, and lag screws. Allowable stresses for timber and structural steel components used in the connection, as described in Section 6-02.3(17)B, are maximums and thus shall not be increased. Tabulated values for nails, bolts, and lag screws may be adjusted by the following duration-of-load factors: 1. 1.25 for falsework design governed by the minimum design horizontal load or greater (3 percent or greater of the dead load), 2. 1.33 for falsework design governed by wind load, and 3. 2.00 for falsework design governed by impact loading. 6-02.3(17)J Face Lumber, Studs, Wales, and Metal Forms Elements of this section shall be designed for the loads, allowable stresses, deflections, and conditions which pertain from other Subsections of Section 6-02.3(17). Forms battered or inclined above the concrete will tend to lift up as concrete is placed and shall have positive anchorage or counterweights designed to resist uplift and shall be shown in the formwork plans. Where the concrete pouring sequence causes fresh concrete to be significantly higher along one side of tied forms than the opposite side, a positive form anchorage system shall be designed capable of resisting the imbalance of horizontal thrust, and prevent the dislocation and sliding of the entire form unit. Wooden forms shall be faced with smooth sanded, exterior plywood. This plywood shall meet the requirements of the National Bureau of Standards, U.S. Product Standard PS 1, and the Design Specification of the American Plywood Association (APA). Each full sheet shall bear the APA stamp. The Contractor shall list in the form plans the grade and class of plywood. If the Engineer accepts the manufacturer’s certification of structural properties, the Contractor may use plywood that does not carry the APA stamp. Plywood panels stamped “shop” or “shop cutting”, shall not be used. Plyform is an APA plywood specifically designed and manufactured for concrete forming. Plyform differs from conventional exterior plywood grades in strength and the exterior face panels are sanded smooth and factory oiled. Likewise, there is a significant difference between grades designated Class 1, Class 2, and Structural I Plyform. 2020 Standard Specifications M 41-10 Page 6-79 Concrete Structures 6-02 The grades of plywood for various form applications shall be as follows: 1. Traffic and Pedestrian Barriers (except those that will receive an architectural surface treatment) – Plywood used for these surfaces shall be APA grade High- Density Overlaid (HDO) Plyform Class I. But if the Contractor coats the form to prevent it from leaving joint and grain marks on the surface, plywood that meets or exceeds APA grades B-B Plyform Class I or B-C (Group I species) may be used. Under this option, the Contractor shall provide for the Engineer’s acceptance a 4-foot-square, test panel of concrete formed with the same plywood and coating as proposed in the form plans. This panel shall include one form joint along its centerline. The Contractor shall apply coating material, according to the manufacturer’s instructions, before applying chemical release agents. 2. Other Exposed Surfaces (all but those on traffic and pedestrian barriers) – Plywood used to form these surfaces shall meet or exceed the requirements of APA grades B-B Plyform Class I or B-C (Group I series). If one face is less than B quality, the B (or better) face shall contact the concrete. 3. Unexposed Surfaces (such as the underside of the bridge deck between girders, the interiors of box girders, etc., and traffic and pedestrian barriers where surfaces will receive an architectural treatment) – Plywood used to form these surfaces may be APA grade CDX, provided the Contractor complies with stress and deflection requirements stated elsewhere in these Specifications. Form joints on an exposed surface shall be in a horizontal or vertical plane. But in wingwalls and box girders, side form joints shall be placed at right angles and parallel to the Roadway grade. Joints parallel to studs or joists shall be backed by a stud or joist. Joints at right angles to studs and joists shall be backed by a stud or other backing the Engineer accepts. Perpendicular backing is not required if studs or joists are spaced: 1. Nine inches or less on center and covered with ½-inch plywood, or 2. Twelve inches or less on center and covered with ¾-inch plywood. The face grain of plywood shall run perpendicular to studs or joists unless shown otherwise on the Contractor’s formwork Working Drawings. Proposals to deviate from the perpendicular orientation shall be accompanied by supporting calculations of the stresses and deflections. Forming for all exposed curved surfaces shall follow the shape of the curve shown in the Contract Plans and shall not be chorded except as follows. On any retaining wall that follows a horizontal circular curve, the wall stems may be a series of short chords if: 1. The chords within the panel are the same length, unless otherwise allowed by the Engineer; 2. The chords do not vary from a true curve by more than ½ inch at any point; and 3. All panel points are on the true curve. Where architectural treatment is required, the angle point for chords in wall stems shall fall at vertical rustication joints. Page 6-80 2020 Standard Specifications M 41-10 6-02 Concrete Structures For exposed surfaces of abutments, wingwalls, piers, retaining walls, and columns, the Contractor shall build forms of plywood at least ¾ inch thick with studs no more than 12 inches on center. The Engineer may allow exceptions, but deflection of the plywood, studs, or wales shall never exceed 1⁄360 of the span (or 1⁄270 of the span for unexposed surfaces, including the bottom of the deck slab between girders). All form plywood shall be at least ½ inch thick except on sharply curved surfaces. There, the Contractor may use ¼-inch plywood if it is backed firmly with heavier material. Round columns or rounded pier shafts shall be formed with a self-supporting metal shell form or form tube that leaves a smooth, nonspiralling surface. Wood forms are not permitted. Metal forms shall not be used elsewhere unless the Engineer is satisfied with the surface and allows use in writing. The Engineer may withdraw allowing use of metal forms at any time. If permitted to use a combination of wood and metal in forms, the Contractor shall coat the forms so that the texture produced by the wood matches that of the metal. Aluminum shall not be used for metal forms. For design purposes, the Contractor shall assume that on vertical surfaces concrete exerts 150 pounds per square foot per foot of depth. However, when the depth is reached where the rate of placement controls the pressure, the following table applies: Rate of Placing Feet per Hour Pressure, Pounds per Square Foot for Temperature of Concrete as Shown 60°F 70°F and Above 2 470 375 3 640 565 4 725 625 5 815 690 6 900 750 7 990 815 8 1,075 875 9 1,165 935 10 1,250 1,000 15 1,670 1,300 The pressures in the above table have been increased to provide an allowance for the vibration and impact. All corners shall be beveled ¾ inch. However, footings, footing pedestals, and seals need not be beveled unless required in the Plans. All forms shall be as mortar-tight as possible with no water standing in them as the concrete is placed. 2020 Standard Specifications M 41-10 Page 6-81 Concrete Structures 6-02 The Contractor shall apply a parting compound on forms for exposed concrete surfaces. This compound shall be a chemical release agent that permits the forms to separate cleanly from the concrete. The compound shall not penetrate or stain the surface and shall not attract dirt or other foreign matter. After the forms are removed, the concrete surface shall be dust-free and have a uniform appearance. The Contractor shall apply the compound at the manufacturer’s recommended rate to produce a surface free of dusting action and yet provide easy removal of the forms. The Engineer may reject any forms that will not produce a satisfactory surface. 6-02.3(17)K Concrete Forms on Steel Spans Concrete forms on all steel Structures shall be removable and shall not remain in place. Where needed, the forms shall have openings for truss or girder members. Each opening shall be large enough to leave at least 1½ inches between the concrete and steel on all sides of the steel member after the forms have been removed. Unit Contract prices cover all costs related to these openings. The Contractor shall not weld any part of the form to any steel member. The compression member or bottom connection of cantilever formwork support brackets shall bear either within 6 inches maximum vertically of the bottom flange or within 6 inches maximum horizontally of a vertical web stiffener. The Contractor’s bridge deck form system shall be designed to prevent rotation of the steel girder. This can be achieved by temporary struts and ties or other methods the Contractor shows to be effective. Partial depth cantilever formwork support brackets that do not conform to the above requirements shall not be used unless the Contractor submits Type 2E Working Drawings consisting of details showing the additional formwork struts and ties used to brace the steel girder against web distortion caused by the partial depth bracket. If the Engineer permits bolt holes in the web to support form brackets, the holes shall be shop drilled unless otherwise allowed by the Engineer. The Contractor shall fill the holes with fully torqued ASTM F3125 Grade A325 bolts in accordance with Section 6-03.3(33). Each bolt head shall be placed on the exterior side of the web. There shall be no holes made in the flanges. 6-02.3(17)L Finishing Machine Support System Before using any finishing machine, the Contractor shall submit a Type 2 Working Drawing consisting of detailed drawings that show the system proposed to support it. The Contractor shall not attach this (or any other) equipment support system to the sides or suspend it from any girder unless the Engineer permits. The Engineer will not permit such a method if it will unduly alter stress patterns or create too much stress in the girder. 6-02.3(17)M Restricted Overhead Clearance Sign The Contractor shall notify the Engineer not less than 15 working days before the anticipated start of each falsework and girder erection operation whenever such falsework or girders will reduce clearances available to the public traffic. Falsework openings shall not be more restrictive to traffic than shown in the Contract Plans. Page 6-82 2020 Standard Specifications M 41-10 6-02 Concrete Structures Where the height of vehicular openings through falsework is less than 15 feet, a W 12-2 “Low Clearance Symbol Sign” shall be erected on the Shoulder in advance of the falsework and two or more W 12-301 and/or W 12-302 signs shall be attached to the falsework to provide accurate usable clearance information over the entire falsework opening. The posted low clearance shall include an allowance for anticipated falsework girder deflection (rounded-up to the next whole inch) due to design dead load, including all successive concrete pours. W 12-302 signs shall be used to designate prominent clearance restrictions and limits of usable clearance. In addition, where the clearance is less than the legal height limit (14 feet), a W 12-2 sign shall be erected in advance of the nearest intersecting road or wide point in the road at which a vehicle can detour or turn around. A W 13-501 sign indicating the distance to the low clearance shall be installed below the advance sign. The Engineer will furnish the above noted signs and the Contractor shall erect and maintain them, all in accordance with Section 1-10.3(3). When erecting falsework that restricts overhead clearance above a railroad track, the Contractor shall immediately (as soon as the restriction occurs) place restricted overhead clearance signs. Sign details are shown in the Standard Plans. Unit Contract prices cover all costs relating to these signs. 6-02.3(17)N Removal of Falsework and Forms If the Engineer does not specify otherwise, the Contractor may request to remove forms based on the criteria in the table below. Both compressive strength and minimum time criteria shall be met if both are listed in the applicable row. The minimum time shall be from the time of the last concrete placement in the forms. In no case shall the Contractor remove forms or falsework without the Engineer’s concurrence. Concrete Placed In Percent of Specified Minimum Compressive Strength1 Minimum Compressive Strength1 Minimum Time Side forms not supporting the concrete weight, including columns, walls, crossbeams, nonsloping box girder webs, abutments, and traffic and pedestrian barriers. 3 days or 1,400 psi 18 hours Side forms of footings, pile caps, and shaft caps.2 18 hours Crossbeams, sloping box girder webs, struts, inclined columns, inclined walls, and other forms that support the concrete weight. 80 5 days Bridge decks supported on stringers, beam, or girders.3 80 10 days Box girders, T-beam girders, and flat-slab Superstructure.3 80 14 days Arches3 80 21 days 1Strength shall be proved by test cylinders made from the last concrete placed into the form. The cylinders shall be cured according to FOP for AASHTO T 23. 2Curing compound shall be immediately applied to the sides when forms are removed. 3Where continuous spans or segments are involved, the time for all spans will be determined by the last concrete placed affecting any span. 2020 Standard Specifications M 41-10 Page 6-83 Concrete Structures 6-02 Before releasing supports from beneath beams and girders, the Contractor shall remove forms from columns to enable the Engineer to inspect the column concrete. Curing shall comply with the requirements of Section 6-02.3(11). The concrete surface shall not become dry during form removal if removed during the cure period. Before placing forms for traffic and pedestrian barriers, the Contractor shall completely release all falsework under spans. The Engineer may allow leaving in place forms for footings in cofferdams or cribs. This decision will be based on whether removing them would harm the cofferdam or crib and whether the forms will show in the finished Structure. All cells of a box girder Structure which have permanent access shall have all forms completely removed, including the bridge deck forms. All debris and all projections into the cells shall be removed. Unless otherwise shown in the Plans, the bridge deck interior forms in all other cells where no permanent access is available, may be left in place. Falsework and forms supporting sloping exterior webs shall not be released until the bridge deck and deck overhang concrete has obtained its removal strength and number of days criteria listed in the table above. Stem reshoring shall not be used. Open joints shown in the Plans shall have all forms completely removed, including Styrofoam products and form anchors, allowing the completed Structure to move freely. If the Contractor intends to support or suspend falsework and formwork from the bridge Structure while the falsework and formwork is being removed, the Contractor shall submit a Type 2 Working Drawing consisting of the falsework and formwork removal plan and calculations. The falsework and formwork removal plan shall include the following: 1. The location and size of any cast-in-place falsework lowering holes and how the holes are to be filled; 2. The location, capacity, and size of any attachments, beams, cables, and other hardware used to attach to the Structure or support the falsework and formwork; 3. The type, capacity and factor of safety, weight, and spacing of points of reaction of lowering equipment; and 4. The weight at each support point of the falsework and formwork being lowered. All other forms shall be removed whether above or below the level of the ground or water. Sections 6-02.3(7) and 6-02.3(8) govern form removal for concrete exposed to sea water or to alkaline water or soil. The forms inside of hollow piers, girders, abutments, etc., shall be removed through openings shown in the Plans or as allowed by the Engineer. 6-02.3(17)O Early Concrete Test Cylinder Breaks The fabrication, curing, and testing of the early cylinders shall be the responsibility of the Contractor. Early cylinders are defined as all cylinders tested in advance of the design age of 28 days whose purpose is to determine the in-place strength of concrete in a Structure prior to applying loads or stresses. The Contractor shall retain a testing Laboratory to Page 6-84 2020 Standard Specifications M 41-10 6-02 Concrete Structures perform this Work. Testing Laboratories’ equipment shall be calibrated within 1 year prior to testing and testers shall be either ACI certified or qualified in accordance with AASHTO R 18. The concrete cylinders shall be molded in accordance with FOP for AASHTO T 23 from concrete last placed in the forms and representative of the quality of concrete placed in that pour. The cylinders shall be cured in the field in accordance with FOP for AASHTO T 23 Section 10.2 Field Curing. The concrete cylinders shall be tested for compressive strength in accordance with AASHTO T 22. The number of early cylinder breaks shall be in accordance with the Contractor’s need and as allowed by the Engineer. The Contractor shall submit a Type 2 Working Drawing consisting of all test results, proof of equipment calibration, and tester’s certification. The Contractor shall not remove forms without the concurrence of the Engineer. All costs in connection with furnishing cylinder molds, fabrication, curing, and testing of early cylinders shall be included in the unit Contract prices for the various Bid items of Work involved. 6-02.3(18) Placing Anchor Bolts The Contractor shall comply with the following requirements in setting anchor bolts in piers, abutments, or pedestals: 1. If set in the wet concrete, the bolts shall be accurately placed before the concrete is placed. 2. If the bolts are set in drilled holes, hole diameter shall exceed bolt diameter by at least 1 inch. Grouting shall comply with Section 6-02.3(20). 3. If the bolts are set in pipe, grouting shall comply with Section 6-02.3(20). 4. If freezing weather occurs before bolts can be grouted into sleeves or holes, they shall be filled with an accepted antifreeze solution (non-evaporating). 6-02.3(19) Bridge Bearings 6-02.3(19)A Submittals of Acceptance Test Reports and Certificates The Contractor shall submit the following production samples and test reports and certificates for fabricated bridge bearing assemblies as applicable: 1. A Type 2 Working Drawing consisting of a six-inch square by 1/8-inch thick sample of PTFE taken from the lot of production material. 2. A Type 2 Working Drawing consisting of a six-inch square by 1-inch thick sample of pre-formed fabric pad taken from the lot of production material. 2020 Standard Specifications M 41-10 Page 6-85 Concrete Structures 6-02 3. Type 1 Working Drawings consisting of Manufacturers’ Certificates of Compliance for the PTFE, polyether urethane, pre-formed fabric pad duck, silicone grease, epoxy gel, and resin filler. 4. Type 1 Working Drawings consisting of certified mill test reports for all steel and stainless steel in the bearing assemblies. 5. Type 1 Working Drawings consisting of certified test reports confirming that the pre- formed fabric pads meet the specific requirements of proof load. 6-02.3(19)B Bridge Bearing Assemblies For all fixed, sliding, or rolling bearings, the Contractor shall: 1. Machine all sliding and rolling surfaces true, smooth, and parallel to the movement of the bearing; 2. Polish all sliding surfaces; 3. Anchor expansion bearings securely, setting them true to line and grade; 4. Avoid placing concrete in such a way that it might interfere with the free action of any sliding or rolling surface. Grout placement under steel bearings shall comply with Section 6-02.3(20). 6-02.3(20) Grout for Anchor Bolts and Bridge Bearings Grout shall conform to Section 9-20.3(2) for anchor bolts and for bearing assemblies with bearing plates. Grout shall conform to Section 9-20.3(3) for elastomeric bearing pads and fabric pad bearings without bearing plates. Grout shall be a workable mix with a viscosity that is suitable for the intended application. Grout shall not be placed outside of the manufacturer recommended range of thickness. The Contractor shall receive concurrence from the Engineer before using the grout. Field grout cubes and cylinders shall be fabricated and tested in accordance with Section 9-20.3 when requested by the Engineer, but not less than one per bridge pier or once per day. Before placing grout, the substrate on which it is to be placed shall be prepared as recommended by the manufacturer to ensure proper bonding. The grout shall be cured as recommended by the manufacturer. The grout may be loaded when a minimum of 4,000 psi compressive strength is attained. To grout bridge bearing masonry plates, the Contractor shall: 1. Build a form approximately 4 inches high with sides 4 inches outside the base of each masonry plate, 2. Fill each form to the top with grout, 3. Work grout under all parts of each masonry plate, 4. Remove each form after the grout has hardened, Page 6-86 2020 Standard Specifications M 41-10 6-02 Concrete Structures 5. Remove the grout outside each masonry plate to the base of the masonry plate, 6. Bevel off the grout neatly to the top of the masonry, and 7. Place no additional load on the masonry plate until the grout has set at least 72 hours. After all grout under the masonry plate and in the anchor bolt cavities has attained a minimum strength of 4,000 psi, the anchor bolt nuts shall be tightened to snug tight. “Snug tight” means either the tightness reached by (1) a few blows from an impact wrench, or (2) the full effort of a person using a spud wrench. Once the nut is snug tight, the anchor bolt threads shall be burred just enough to prevent loosening of the nut. 6-02.3(21) Drainage of Box Girder Cells To drain box girder cells, the Contractor shall provide and install, according to details in the Plans, short lengths of nonmetallic pipe in the bottom slab at the low point of each cell. The pipe shall have a minimum inside diameter of 4 inches. If the difference in Plan elevation is 2 inches or less, the Contractor shall install pipe in each end of the box girder cell. All drainage holes shall be screened in accordance with the Plan details. 6-02.3(22) Drainage of Substructure The Contractor shall use weep holes and gravel backfill that complies with Section 9-03.12(2) to drain fill material behind retaining walls, abutments, tunnels, and wingwalls. To maintain thorough drainage, weep holes shall be placed as low as possible. Weep holes shall be covered with geotextile meeting the requirements of Section 9-33.2, Table 2 Class C before backfilling. Geotextile screening shall be bonded to the concrete with an accepted adhesive. Gravel backfill shall be placed and compacted as required in Section 2-09.3(1)E. In addition, if the Plans require, tiling, French or rock drains, or other drainage devices shall be installed. If underdrains are not installed behind the wall or abutment, all backfill within 18 inches of weep holes shall comply with Section 9-03.12(4). Unless the Plans require otherwise, all other backfill behind the wall or abutment shall be gravel backfill for walls. 6-02.3(23) Opening to Traffic Bridges with a bridge deck made of concrete shall remain closed to all traffic, including construction equipment, until the concrete has reached the 28-day specified compressive strength. This strength shall be determined with cylinders made of the same concrete as the bridge deck and cured under the same conditions. A concrete deck bridge shall never be opened to traffic earlier than 10 days after the deck concrete was placed and never before the Engineer allows. For load restrictions on bridges under construction, refer to Section 6-01.6. After curing bridge approach slabs in accordance with Section 6-02.3(11), the bridge approach slabs may be opened to traffic when a minimum compressive strength of 2,500 psi is achieved. 2020 Standard Specifications M 41-10 Page 6-87 Concrete Structures 6-02 6-02.3(24) Reinforcement Although a bar list is normally included in the Plans, the Contracting Agency does not guarantee its accuracy and it shall be used at the Contractor’s risk. Reinforcement fabrication details shall be determined from the information provided in the Plans. Before delivery of the reinforcing bars, the Contractor shall submit Type 1 Working Drawings consisting of two informational copies of the supplemental bending diagrams. 6-02.3(24)A Field Bending Field bending of AASHTO M31 Grade 60 and ASTM A706 Grade 60 reinforcement shall be done in accordance with the requirements of this section. Field bending of all other reinforcement shall require a Type 2 Working Drawing showing the bend radii, bending and heating procedures, and any inspection or testing requirements. Field bending shall not be done on reinforcement within the top or bottom third of column lengths or within plastic hinge regions identified in the Plans. Field bending shall not be done on bar sizes No. 14 or No. 18. In field-bending steel reinforcing bars, the Contractor shall: 1. Make the bend gradually using a bending tool equipped with a bending diameter as listed in Table 1. Bending shall not be done by means of hammer blows and pipe sleeves. When bending to straighten a previously bent bar, move a hickey bar progressively around the bend. 2. Apply heat as described below for bending bar sizes No. 6 through No. 11 and for bending bar sizes No. 5 and smaller when the bars have been previously bent. Previously unbent bars of sizes No. 5 and smaller may be bent without heating when the bar temperature is 40°F or higher. When previously unbent bars of sizes No. 5 and smaller have a bar temperature lower than 40°F, they shall be heated to within the range of 100°F to 150°F prior to bending. In applying heat for field-bending steel reinforcing bars, the Contractor shall: a. Avoid damage to the concrete by insulating any concrete within 6 inches of the heated bar area; b. Apply two heat tips simultaneously at opposite sides of bar sizes No. 7 or larger; c. Heat the bar to within the required temperature range shown in Table 2 as verified by using temperature-indicating crayons or other suitable means; d. Heat a minimum bar length as shown in Table 3. Locate the heated section of the bar to include the entire bending length; e. Bend immediately after the required temperature range has been achieved. Maintain the bar within the required temperature range during the entire bending process; f. Do not cool bars artificially with water, forced air, or other means. 3. Limit any bend or straightening to these maximum angles: 135 degrees for bar sizes No. 8 or smaller, and 90 degrees for bar sizes No. 9 through No. 11. Page 6-88 2020 Standard Specifications M 41-10 6-02 Concrete Structures 4. Repair epoxy coating on epoxy coated bars in accordance with Section 6-02.3(24)H. Table 1 Bending Diameters for Field-Bending Reinforcing Bars Bar Size Bend Diameter/Bar Diameter Ratio Heat Not Applied Heat Applied No. 4, No. 5 8 8 No. 6 through No. 9 Not Permitted 8 No. 10, No. 11 Not Permitted 10 The minimum bending diameters for stirrups and ties for No. 4 and No. 5 bars when heat is not applied shall be specified in Section 9-07. Table 2 Preheating Temperatures for Field-Bending Reinforcing Bars Bar Size Temperature (F) Minimum Maximum No. 4 1,200 1,250 No. 5, No. 6 1,350 1,400 No. 7 through No. 9 1,400 1,450 No. 10, No. 11 1,450 1,500 Table 3 Minimum Bar Length to be Heated (d = nominal diameter of bar) Bar Size Bend Angle 45°90°135° No. 4 through No. 8 8d 12d 15d No. 9 8d 12d Not Permitted No. 10, No. 11 9d 14d Not Permitted 6-02.3(24)B Protection of Materials The Contractor shall protect reinforcing steel from all damage. When placed into the Structure, the steel shall be free from dirt, loose rust or mill scale, paint, oil, and other foreign matter. When transporting, storing, or constructing in close proximity to bodies of salt water, plain and epoxy-coated steel reinforcing bar shall be kept in enclosures that provide protection from the elements. If plain or epoxy-coated steel reinforcing bar is exposed to mist, spray, or fog that may contain salt, it shall be flushed with fresh water prior to concrete placement. When the Engineer requires protection for reinforcing steel that will remain exposed for a length of time, the Contractor shall protect the reinforcing steel: 1. By cleaning and applying a coat of paint conforming to Section 9-08.1(2)B over all exposed surfaces of steel, or 2020 Standard Specifications M 41-10 Page 6-89 Concrete Structures 6-02 2. By cleaning and painting paint conforming to Section 9-08.1(2)B on the first 6 inches of the steel bars protruding from the concrete and covering the bars with polyethylene sleeves. The paint shall have a minimum dry film thickness of 1 mil. Epoxy-coated steel reinforcing bars shall not be exposed to environmental conditions for a cumulative duration exceeding 60 days on site prior to full embedment in concrete. Any provisions made to protect the reinforcing bars shall provide suitable protection from ultraviolet radiation including light and allow adequate ventilation to minimize condensation. 6-02.3(24)C Placing and Fastening The Contractor shall position reinforcing steel as the Plans require and shall ensure that the steel is set within specified tolerances. Adjustments to reinforcing details outside of specified tolerances to avoid interferences and for other purposes are acceptable when approved by the Engineer. When spacing between bars is 1 foot or more, they shall be tied at all intersections. When spacing is less than 1 foot, every other intersection shall be tied. If the Plans require bundled bars, they shall be tied together with wires at least every 6 feet. All epoxy-coated bars in the top mat of the bridge deck shall be tied at all intersections, however they may be tied at alternate intersections when spacing is less than 1 foot in each direction and they are supported by continuous supports meeting all other requirements of supports for epoxy-coated bars. Other epoxy-coated bars shall also be tied at all intersections, but shall be tied at alternate intersections when spacing is less than 1 foot in each direction. Wire used for tying epoxy-coated reinforcing steel shall be plastic coated. Tack welding is not permitted on reinforcing steel. Abrupt bends in the steel are permitted only when one steel member bends around another. Vertical stirrups shall pass around main reinforcement or be firmly attached to it. For slip-formed concrete, the reinforcing steel bars shall be tied at all intersections and cross braced to keep the cage from moving during concrete placement. Cross bracing shall be with additional reinforcing steel. Cross bracing shall be placed both longitudinally and transversely. After reinforcing steel bars are placed in a traffic or pedestrian barrier and prior to slip-form concrete placement, the Contractor shall check clearances and reinforcing steel bar placement. This check shall be accomplished by using a template or by operating the slip-form machine over the entire length of the traffic or pedestrian barrier. All clearance and reinforcing steel bar placement deficiencies shall be corrected by the Contractor before slip-form concrete placement. Page 6-90 2020 Standard Specifications M 41-10 6-02 Concrete Structures Precast concrete supports (or other accepted devices) shall be used to maintain the concrete coverage required by the Plans. The precast concrete supports shall: 1. Have a bearing surface measuring not greater than 2 inches in either dimension, and 2. Have a compressive strength equal to or greater than that of the concrete in which they are embedded. In slabs, each precast concrete support shall have either: (1) a grooved top that will hold the reinforcing bar in place, or (2) an embedded wire that protrudes and is tied to the reinforcing steel. If this wire is used around epoxy-coated bars, it shall be coated with plastic. Precast concrete supports may be accepted based on a Manufacturer’s Certificate of Compliance. In lieu of precast concrete supports, the Contractor may use metal or all-plastic supports to hold uncoated bars. Any surface of a metal chair support that will not be covered by at least ½ inch of concrete shall be one of the following: 1. Hot-dip galvanized after fabrication in keeping with AASHTO M232 Class D; 2. Coated with plastic firmly bonded to the metal. This plastic shall be at least 3/32 inch thick where it touches the form and shall not react chemically with the concrete when tested in the State Materials Laboratory. The plastic shall not shatter or crack at or above -5°F and shall not deform enough to expose the metal at or below 200°F; or 3. Stainless steel that meet the requirements of ASTM A493, Type 302. Stainless steel chair supports are not required to be galvanized or plastic coated. In lieu of precast concrete supports, epoxy-coated reinforcing bars may be supported by one of the following: 1. Metal supports coated entirely with a dielectric material such as epoxy or plastic, 2. Other epoxy-coated reinforcing bars, or 3. All-plastic supports. Damaged coatings on metal bar supports shall be repaired prior to placing concrete. All-plastic supports shall be lightweight, non-porous, and chemically inert in concrete. All-plastic supports shall have rounded seatings, shall not deform under load during normal temperatures, and shall not shatter or crack under impact loading in cold weather. All-plastic supports shall be placed at spacings greater than 1 foot along the bar and shall have at least 25 percent of their gross place area perforated to compensate for the difference in the coefficient of thermal expansion between plastic and concrete. The shape and configuration of all-plastic supports shall permit complete concrete consolidation in and around the support. 2020 Standard Specifications M 41-10 Page 6-91 Concrete Structures 6-02 A “mat” is two adjacent and perpendicular layers of reinforcing steel. In bridge decks, top and bottom mats shall be supported adequately enough to hold both in their proper positions. If bar supports directly support, or are directly supported on No. 4 bars, they shall be spaced at not more than 3-foot intervals (or not more than 4-foot intervals for bars No. 5 and larger). Wire ties to girder stirrups shall not be considered as supports. To provide a rigid mat, the Contractor shall add other supports and tie wires to the top mat as needed. Unless noted otherwise, the minimum concrete cover for main reinforcing bars shall be: 3 inches to a concrete surface deposited against earth without intervening forms. 2½ inches to the top surface of a concrete bridge deck or bridge approach slab. 2 inches to a concrete surface when not specified otherwise in this section or in the Contract documents. 1½ inches to a concrete barrier or curb surface. Except for top cover in bridge decks and bridge approach slabs, minimum concrete cover to ties and stirrups may be reduced by ½ inch but shall not be less than 1 inch. Minimum concrete cover shall also be provided to the outermost part of mechanical splices and headed steel reinforcing bars. Reinforcing steel bar location, concrete cover, and clearance shall not vary more than the following tolerances from what is specified in the Contract documents: Reinforcing bar location for members 12 inches or less in thickness: ±0.25 inch Reinforcing bar location for members greater than 12 inches in thickness: ±0.375 inch Reinforcing bar location for bars placed at equal spacing within a plane: the greater of either ±1 inch or ±1 bar diameter within the plane. The total number of bars shall not be fewer than that specified. The clearance between reinforcement shall not be less than the greater of the bar diameter or 1 inch for unbundled bars. For bundled bars, the clearance between bundles shall not be less than the greater of 1 inch or a bar diameter derived from the equivalent total area of all bars in the bundle. Longitudinal location of bends and ends of bars: ±1 inch Embedded length of bars and length of bar lap splices: No 3 through No. 11 -1 in. No. 14 through No. 18 -2 in. Concrete cover measured perpendicular to concrete surface (except for the top surface of bridge decks, bridge approach slabs and other roadway surfaces): ±0.25 inch Concrete cover measured perpendicular to concrete surface for the top surface of bridge decks, bridge approach slabs and other roadway surfaces: +0.25 inch, -0 inch Page 6-92 2020 Standard Specifications M 41-10 6-02 Concrete Structures Before placing any concrete, the Contractor shall: 1. Clean all mortar from reinforcement, and 2. Obtain the Engineer’s permission to place concrete after the Engineer has inspected the placement of the reinforcing steel. (Any concrete placed without the Engineer’s permission shall be rejected and removed.) 6-02.3(24)D Splicing The Contractor shall supply steel reinforcing bars in the full lengths the Plans require. Unless the Engineer concurs in writing, the Contractor shall not change the number, type, or location of splices. The Engineer may permit the Contractor to use thermal or mechanical splices in place of the method shown in the Plans if they are of an accepted design. Use of a new design may be granted if: 1. The Contractor provides technical data and proof from the manufacturer that the design will perform satisfactorily, and 2. Sample splices and materials from the manufacturer pass the Engineer’s tests. The Contractor shall: 1. Not lap-splice reinforcing bars Nos. 14 or 18. 2. Not permit any welded or mechanical splice to deviate in alignment more than ¼ inch per 3½ feet of bar. 3. Distribute splices evenly, grouping them together only at points of low tensile stress. 4. Ensure at least 2 inches clearance between any splice and the nearest bar or the surface of the concrete (or 1½ inch for the length of the sleeve on mechanical splices). 5. Rigidly clamp or wire all splices in a way accepted by the Engineer. 6. Place lap-spliced bars in contact for the length of the splice and tie them together near each end. 7. Securely fasten the ends and edges of welded-wire-fabric reinforcement, overlapping them enough to maintain even strength. 6-02.3(24)E Welding Reinforcing Steel Welding of steel reinforcing bars shall conform to the requirements of ANSI/AWS D1.4 Structural Welding Code – Reinforcing Steel, latest edition, except where superseded by the Special Provisions, Plans, and these Specifications. Before any welding begins, the Contractor shall submit a Type 2 Working Drawing consisting of the welding procedure for each type of welded splice to be used, including the weld procedure Specifications and joint details. The weld procedure Specifications shall be written on a form taken from AWS D1.4 Annex A, or equivalent. Test results of 2020 Standard Specifications M 41-10 Page 6-93 Concrete Structures 6-02 tensile strength, macroetch, and visual examination shall be included. The form shall be signed and dated. Welders shall be qualified in accordance with AWS D1.4. The Contractor shall be responsible for the testing and qualification of welders, and shall submit Type 2 Working Drawings consisting of welder qualification and retention records. The weld joint and welding position a welder is qualified in shall be in accordance with AWS D1.4. The welder qualifications shall remain in effect indefinitely unless, (1) the welder is not engaged in a given process of welding for which the welder is qualified for a period exceeding 6 months, or (2) there is some specific reason to question a welder’s ability. Filler metals used for welding reinforcing bars shall be in accordance with AWS D1.4 Table 5.1. All filler metals shall be low-hydrogen and handled in compliance with low-hydrogen practices specified in the AWS code. Short circuiting transfer with gas metal arc welding will not be allowed. Slugging of welds will not be allowed. For the purpose of compatibility with AWS D1.4, welded lap splices for spiral or hoop reinforcing shall be considered Flare-V groove welds, indirect butt joints. The Contractor is responsible for using a welding sequence that will limit the alignment distortion of the bars due to the effects of welding. The maximum out-of-line permitted will be ¼ inch from a 3.5-foot straightedge centered on the weld and in line with the bar. The ground wire from the welding machine shall be clamped to the bar being welded. Where epoxy-coated steel reinforcing bars are specified to be spliced by welding, the epoxy coating shall be left off or removed from the surfaces to be heated, but in no cases less than six inches of each bar being welded. After the welding is complete, the Contractor shall apply epoxy patching material to the uncoated portions of the bar in accordance with Section 6-02.3(24)H. 6-02.3(24)F Mechanical Splices The Contractor shall form mechanical splices with an Engineer-accepted system using sleeve filler metal, threaded coupling, or another method that complies with this section. If necessary to maintain required clearances after the splices are in place, the Contractor shall adjust, relocate, or add stirrups, ties, and bars. Before splicing, the Contractor shall provide the Engineer with the following information for each shipment of splice material: 1. The type or series identification (and heat treatment lot number for threaded-sleeve splices), 2. The grade and size of bars to be spliced, 3. A manufacturer’s catalog with complete data on material and procedures, 4. A written statement from the manufacturer that the material is identical to that used earlier by the Engineer in testing and accepting the system design, and Page 6-94 2020 Standard Specifications M 41-10 6-02 Concrete Structures 5. A written statement from the Contractor that the system and materials will be used according to the manufacturer’s instructions and all requirements of this section. All splices shall meet these criteria: 1. Mechanical splices shall develop at least 125 percent of the specified yield strength of the unspliced bar. The ultimate tensile strength of the mechanical splice shall exceed that of the unspliced bar. 2. The total slip of the bar within the spliced sleeve of the connector after loading in tension to 30.0 ksi and relaxing to 3.0 ksi shall not exceed the following measured displacements between gage points clear of the splice sleeve: a. 0.01 inches for bar sizes up to No. 14. b. 0.03 inches for No. 18 bars. 3. The maximum allowable bar size for mechanical laps splices shall be No. 6. The Engineer will visually inspect the splices and accept all that appear to conform with the test samples. For sleeve-filler splices, the Engineer will allow voids within the limits on file in the Working Drawing design submittal. If the Engineer considers any splice defective, it shall be removed and replaced at the Contractor’s expense. In preparing sleeve-filler metal splices, the Contractor shall: 1. Clean the bar surfaces by: (a) oxyacetylene torch followed by power wire brushing, or (b) abrasive blasting; 2. Remove all slag, mill scale, rust, and other foreign matter from all surfaces within and 2 inches beyond the sleeve; 3. Grind down any projection on the bar that would prevent placing the sleeve; 4. Prepare the ends of the bars as the splice manufacturer recommends and as the accepted procedure requires; and 5. Preheat, just before adding the filler, the entire sleeve and bar ends to 300°F, plus or minus 50°F. (If a gas torch is used, the flame shall not be directed into the sleeve.) When a metallic, sleeve-filler splice is used (or any other system requiring special equipment), both the system and the operator shall qualify in the following way under the supervision of the State Materials and Fabrication Inspector. The operator shall prepare six test splices (three vertical, three horizontal) using bars having the same AASHTO Designation and size (maximum) as those to be used in the Work. Each test sample shall be 42 inches long, made up of two 21-inch bars joined end-to-end by the splice. The bar alignment shall not deviate more than ⅛ inch from a straight line over the whole length of the sample. All six samples must meet the tensile strength and slip criteria specified in this section. The Contractor shall provide labor, materials, and equipment for making these test samples at no expense to the Contracting Agency. The Contracting Agency will test the samples at no cost to the Contractor. 2020 Standard Specifications M 41-10 Page 6-95 Concrete Structures 6-02 6-02.3(24)G Job Control Tests As the Work progresses, the Engineer may require the Contractor to provide a sample splice (thermal or mechanical) to be used in a job control test. The operator shall create this sample on the job site with the Engineer present using bars of the same size as those being spliced in the Work. The sample shall comply with all requirements of these Specifications, and is in addition to all other sample splices required for qualification. The Engineer will require no more than two samples on any project with fewer than 200 splices and no more than one sample per 100 splices on any project with more than 200 splices. 6-02.3(24)H Epoxy-Coated Steel Reinforcing Bar This Work is furnishing, fabricating, coating, and placing epoxy-coated steel reinforcing bars as the Plans, these Specifications, and the Special Provisions require. Coating material shall be applied electrostatically, by spraying, or by the fluidized-bed method. All epoxy-coated bars shall comply with the requirements of Section 9-07. Fabrication may occur before or after coating. The Contractor shall protect epoxy-coated bars from damage using padded or nonmetallic slings and straps free from dirt or grit. To prevent abrasion from bending or sagging, the Contractor shall lift bundled bars with a strong-back, multiple supports, or a platform bridge. Bundled bars shall not be dropped or dragged. During shop or field storage, bars shall rest on wooden or padded cribbing. The Contractor may substitute other methods for protecting the bars if the Engineer concurs. If the Engineer believes the coated bars have been badly damaged, they will be rejected. Metal chairs and supports shall be coated with epoxy (or another inert coating accepted by the Engineer). The Contractor may use other support devices with the Engineer’s concurrence. Plastic coated tie wires (accepted by the Engineer) shall be used to protect the coated bars from being damaged during placement. The bars shall be placed as the Plans require and held firmly in place during placing and setting of the concrete. All bars shall be placed and fastened as specified in Section 6-02.3(24)C. In the interval between installing coated bars and concreting the deck, the Contractor shall protect the coating from damage that might result from other construction Work. The Engineer will inspect the coated bars after they are placed and before the deck concrete is placed. The Contractor shall patch any areas that show significant damage (as defined below). Significant damage means any opening in the coating that exposes the steel in an area that exceeds: 1. 0.05 square inch (approximately ¼ inch square or ¼ inch in diameter or the equivalent). Page 6-96 2020 Standard Specifications M 41-10 6-02 Concrete Structures 2. 0.012 square inches (approximately ⅛ inch square or ⅛ inch in diameter) when the opening is within ¼ inch of another opening of equal or larger size. 3. 6 inches long, any width. 4. 0.50 square inch aggregate area in any 1 foot length of bar. The Contractor shall patch significantly damaged areas with a patching material obtained from the epoxy resin manufacturer and accepted by the Engineer. This material shall be compatible with the coating and inert in concrete. Areas to be patched shall be clean and free of surface contaminants. Patching shall be done before oxidation occurs and according to the resin manufacturer’s instructions. 6-02.3(25) Prestressed Concrete Girders The Contractor shall perform quality control inspection. The manufacturing plant of prestressed concrete girders shall be certified by the Precast/Prestressed Concrete Institute’s Plant Certification Program for the type of prestressed member to be produced and shall be approved by WSDOT as a Certified Prestress Concrete Fabricator prior to the start of production. WSDOT certification will be granted at, and renewed during, the annual prestressed plant review and approval process in accordance with WSDOT Materials Manual M 46-01.04 Standard Practice QC 6. Prior to the start of production of girders, the Contractor shall advise the Engineer of the production schedule. The Contractor shall give the Inspector safe and free access to the Work. If the Inspector observes any nonspecification Work or unacceptable quality control practices, the Inspector will advise the plant manager. If the corrective action is not acceptable to the Engineer, the girder(s) will be subject to rejection by the Engineer. The Contracting Agency intends to perform Quality Assurance Inspection. By its inspection, the Contracting Agency intends only to facilitate the Work and verify the quality of that Work. This inspection shall not relieve the Contractor of any responsibility for identifying and replacing defective material and workmanship. The various types of prestressed concrete girders are: Prestressed Concrete I Girder – Refers to a prestressed concrete girder with a flanged I shaped cross section, requiring a cast-in-place concrete deck to support traffic loads. WSDOT standard girders in this category include Series W42G, W50G, W58G, and W74G. Prestressed Concrete Wide Flange I Girder – Refers to a prestressed concrete girder with an I shaped cross section with wide top and bottom flanges, requiring a cast-in-place concrete deck to support traffic loads. WSDOT standard girders in this category include Series WF36G, WF42G, WF50G, WF58G, WF66G, WF74G, WF83G, WF95G, and WF100G. Prestressed Concrete Wide Flange Deck Girder – Refers to a prestressed concrete wide flange I girder with extended top flange widths designed to support traffic loads, and designed to be mechanically connected at the flange edges to adjacent girders at the 2020 Standard Specifications M 41-10 Page 6-97 Concrete Structures 6-02 job site. WSDOT standard girders in this category include Series WF39DG, WF45DG, WF53DG, WF61DG, WF69DG, WF77DG, WF86DG, WF98DG, and WF103DG. Prestressed Concrete Wide Flange Thin Deck Girder – Refers to a prestressed concrete wide flange I girder with extended top flange widths requiring a cast-in-place concrete deck to support traffic loads. Flange edges extend to flange edges of adjacent girders at the job site. WSDOT standard girders in this category include Series WF36TDG, WF42TDG, WF50TDG, WF58TDG, WF66TDG, WF74TDG, WF83TDG, WF95TDG, and WF100TDG. Prestressed Concrete Deck Bulb Tee Girder – Refers to a prestressed concrete girder with a top flange designed to support traffic loads, and designed to be mechanically connected at the flange edges to adjacent girders at the job site. WSDOT standard girders in this category include Series W35DG, W41DG, W53DG, and W65DG. Prestressed Concrete Slab Girder – Refers to a prestressed concrete slab girder, with or without voids. Prestressed concrete ribbed section girders and prestressed concrete double tee girders shall conform to the requirements specified for prestressed concrete slab girders. Prestressed Concrete Tub Girder – Refers to prestressed concrete tub girders with a U shaped cross section, requiring a cast-in-place concrete deck to support traffic loads. WSDOT standard girders in this category include Series U**G* or Series UF**G*, where U specifies webs without top flanges, UF specifies webs with top flanges, ** specifies the girder height in inches, and * specifies the bottom flange width in feet. Spliced Prestressed Concrete Girder – Refers to prestressed concrete girders initially fabricated in segments which are longitudinally spliced together with cast-in-place concrete closures and post tensioning. Post tensioning materials and construction shall conform to Section 6-02.3(26), except that ducts for prestressed concrete wide flange I girders may be 24-gage, semi-rigid, galvanized, corrugated, ferrous metal. WSDOT prestressed concrete wide flange I girders in this category include Series WF74PTG, WF83PTG, WF95PTG, and WF100PTG. WSDOT prestressed concrete tub girders in this category include Series U**PTG* and UF**PTG* where U, UF, **, and * are as defined for prestressed concrete tub girders. 6-02.3(25)A Shop Drawings Shop drawings for prestressed concrete girders shall be submitted as Type 2 Working Drawings. The only deviations to the Plans that will be permitted are those approved by the annual plant approval process and those listed below: 1. Addition of inserts for construction purposes including falsework. 2. Small penetrations no larger than 1-inch diameter for construction purposes including overhang bracket supports, deck formwork hangers and temporary girder bracing. Penetrations in top flanges shall be offset from the edge of the flange the minimum distance shown in the Plans. 3. Small penetrations no larger than 2-inch in diameter for girder shipping tie-downs. Page 6-98 2020 Standard Specifications M 41-10 6-02 Concrete Structures 4. Small adjustments in girder length to account for elastic shortening, creep and shrinkage 5. Strand adjustments, as long as the center of gravity of the strands remains at the location shown in the plans and concrete cover is not reduced. 6. Diaphragm web hole vertical adjustments to avoid harped strands. 7. Substitution of welded wire reinforcement for conventional reinforcing steel. Shop drawings shall show the size and location of all inserts and penetrations. Penetrations for deck formwork and falsework shall match the deck formwork Working Drawings. Field-drilled holes in prestressed concrete girders are not allowed. Deformed welded wire reinforcement conforming to Sections 9-07.7 and 9-07.8 may be substituted for the mild steel reinforcement shown in the plans. The substitution shall be submitted as a Type 2E Working Drawing. The AASHTO LRFD Bridge Design Specification requirements (latest edition including interims) shall be satisfied, including at a minimum the following Articles: 5.8.2.6 Types of Transverse Reinforcement 5.8.2.8 Design and Detailing Requirements 5.10.3 Spacing of Reinforcement 5.10.6.3 Ties 5.10.7 Transverse Reinforcement for Flexural Members 5.10.8 Shrinkage and Temperature Reinforcement 5.10.10 Pretensioned Anchorage Zones 5.11.2.5 Welded Wire Fabric 5.11.2.6.3 Anchorage of Wire Fabric Reinforcement 5.11.6 Splices of Welded Wire Fabric Yield strengths in excess of 75.0 ksi shall not be used for welded wire reinforcement. The spacing of vertical welded wire reinforcement within slabs and girder webs shall not exceed 18 inches or the height of the member minus 3 inches, whichever is less. Longitudinal wires and welds are permitted in girder flanges but shall be excluded from girder webs. For vertical welded wire reinforcement in prestressed concrete slab girders, no welded joints other than those required for anchorage shall be permitted. Epoxy- coated wire and welded wire reinforcement shall conform to Section 9-07.3 with the exception that ASTM A884 Class A Type I shall be used instead of ASTM A775. Shop drawings for spliced prestressed concrete girders shall also conform to Section 6-02.3(26)A. The Working Drawings for spliced prestressed concrete girders shall include all details related to the post-tensioning operations in the field, including details of hardware required, tendon geometry, blockout details, and details of additional or modified steel reinforcing bars required in cast-in-place closures. 2020 Standard Specifications M 41-10 Page 6-99 Concrete Structures 6-02 6-02.3(25)B Prestressing Each stressing system shall have a pressure gauge or load cell that will measure jacking force. The gauge shall display pressure accurately and readably with a dial at least 6 inches in diameter or with a digital display. Each jack and its gauge shall be calibrated as a unit and shall be accompanied by a certified calibration chart. The Contractor shall submit a Type 1 Working Drawing consisting of one copy of this chart. The cylinder extension during calibration shall be in approximately the position it will occupy at final jacking force. Jacks and gauges shall be recalibrated and recertified: 1. Annually, 2. After any repair or adjustment, and 3. Anytime there are indications that the jack calibration is in error. The Engineer may use load cells to check jacks, gauges, and calibration charts before and during tensioning. All load cells shall be calibrated and shall have an indicator that shows prestressing force in the strand. The range of this cell shall be broad enough that the lowest 10 percent of the manufacturer’s rated capacity will not be used to measure jacking force. From manufacture to encasement in concrete, prestressing strand shall be protected against dirt, oil, grease, damage, and all corrosives. Strand shall be stored in a dry, covered area and shall be kept in the manufacturer’s original packaging until placement in the forms. If prestressing strand has been damaged or pitted, it will be rejected. Prestressing strand with rust shall be spot-cleaned with a nonmetallic pad to inspect for any sign of pitting or section loss. Once the prestressing steel has been installed, no welds or grounds for welders shall be made on the forms or the steel in the girder, except as specified. Post-tensioning of spliced prestressed concrete girders shall conform to Section 6-02.3(26) and the following requirements: 1. Before tensioning, the Contractor shall remove all side forms from the cast-in-place concrete closures. From this point until 48 hours after grouting the tendons, the Contractor shall keep all construction and other live loads off the Superstructure and shall keep the falsework supporting the superstructure in place. 2. The Contractor shall not tension the post-tensioning reinforcement until the concrete in the cast-in-place closures reaches the minimum compressive strength specified in the Plans. This strength shall be measured with concrete cylinders made of the same concrete and cured under the same conditions as the cast-in-place closures. 3. All post-tensioning shall be completed before placing the sidewalks and barriers on the Superstructure. Page 6-100 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(25)C Casting Side forms shall be steel except that cast-in-place concrete closure forms for spliced prestressed concrete girders, interior forms of prestressed concrete tub girders, and end bulkhead forms of prestressed concrete girders may be wood. Interior voids for prestressed concrete slab girders with voids shall be formed by either wax soaked cardboard or expanded polystyrene forms. The interior void forms shall be secured in the position as shown in the Working Drawings, and shall remain in place. All concrete mixes to be used shall be preapproved in the WSDOT plant certification process. The temperature of the concrete when placed shall be between 50°F and 90°F. Slump shall not exceed 4 inches for normal concrete nor 7 inches with the use of a high range water-reducing admixture, nor 9 inches when both a high range water-reducing admixture is used and the water/cement ratio is less than or equal to 0.35. For self- consolidating concrete (SCC), the slump requirements specified above do not apply, and are instead replaced by the target slump flow and slump flow range specified as part of the SCC mix design. Air-entrainment is not required in the concrete placed into prestressed concrete girders, including cast-in-place concrete closures for spliced prestressed concrete girders. 6-02.3(25)C1 Acceptance Testing of Concrete for Prestressed Concrete Girders Compressive strength cylinders and concrete acceptance testing shall be performed once per prestressed concrete girder or once per fabrication line of prestressed concrete girders. Concrete shall not be placed until fresh concrete testing indicates concrete is within acceptable limits. Acceptance testing shall be performed by the Contractor and test results shall be submitted to the Engineer. Unless otherwise noted below, the test methods described in Section 6-02.3(5)D shall be followed. Concrete compressive strength shall be in accordance with Section 6-02.3(25)E. Concrete that is not self-consolidating concrete will be accepted as follows: 1. Temperature within the allowable temperature band. 2. Slump below the maximum allowed. Concrete that is self-consolidating concrete will be accepted as follows: 1. Temperature within the allowable temperature band. 2. Slump flow within the target slump flow range 3. VSI less than or equal to 1 in accordance with ASTM C1611, Appendix X1, using Filling Procedure B. 2020 Standard Specifications M 41-10 Page 6-101 Concrete Structures 6-02 4. J ring passing ability less than or equal to 1.5-inches. 5. Rapid assessment of static segregation resistance of self-consolidating concrete using penetration test in accordance with ASTM C1712 shall be less than or equal to 15 mm. 6-02.3(25)D Curing During curing, the Contractor shall keep the girder in a saturated curing atmosphere until the girder concrete has reached the required release strength. If the Engineer concurs, the Contractor may shorten curing time by heating the outside of impervious forms. Heat may be radiant, convection, conducted steam, or hot air. With steam, the arrangement shall envelop the entire surface with saturated steam. Hot air curing will not be allowed, unless the Contractor submits Type 2 Working Drawings consisting of the proposed method to envelop and maintain the girder in a saturated atmosphere. Saturated atmosphere means a relative humidity of at least 90 percent. The Contractor shall never allow dry heat to touch the girder surface at any point. Under heat curing methods, the Contractor shall: 1. Keep all unformed girder surfaces in a saturated atmosphere throughout the curing time; 2. Embed a thermocouple (linked with a thermometer accurate to plus or minus 5°F) 6 to 8 inches from the top or bottom of the girder on its centerline and near its midpoint; 3. Monitor with a recording sensor (accurate to plus or minus 5°F) arranged and calibrated to continuously record, date, and identify concrete temperature throughout the heating cycle; 4. Make this temperature record available for the Engineer to inspect; 5. Heat concrete to no more than 100°F during the first 2 hours after placing the concrete, and then increase no more than 25°F per hour to a maximum of 175°F; 6. Cool concrete, after curing is complete, no more than 25°F per hour, to 100°F; and 7. Keep the temperature of the concrete above 60°F until the girder reaches release strength. The Contractor may strip side forms from prestressed concrete girders once the concrete has reached a minimum compressive strength of 3,000 psi. All damage from stripping is the Contractor’s responsibility. Curing of cast-in-place concrete closures for spliced prestressed concrete girders shall conform to Section 6-02.3(11). Page 6-102 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(25)E Contractors Control Strength Concrete strength shall be measured on test cylinders cast from the same concrete as that in the girder. These cylinders shall be cured under time-temperature relationships and conditions that simulate those of the girder. If the forms are heated by steam or hot air, test cylinders will remain in the coolest zone throughout curing. If forms are heated another way, the Contractor shall provide a record of the curing time-temperature relationship for the cylinders for each girder to the Engineer. When two or more girders are cast in a continuous line and in a continuous pour, a single set of test cylinders may represent all girders provided the Contractor demonstrates uniformity of casting and curing to the satisfaction of the Engineer. The Contractor shall mold, cure, and test enough of these cylinders to satisfy Specification requirements for measuring concrete strength. The Contractor may use 4- by 8-inch or 6- by 12-inch cylinders. Test cylinders may be cured in a moist room or water tank in accordance with FOP for AASHTO T 23 after the girder concrete has obtained the required release strength. If, however, the Contractor intends to ship the girder prior to the standard 28-day strength test, the design strength for shipping shall be determined from cylinders placed with the girder and cured under the same conditions as the girder. These cylinders may be placed in a noninsulated, moisture-proof envelope. To measure concrete strength in the girder, the Contractor shall randomly select two test cylinders. The average compressive strength of the two cylinders shall be equal or greater than the specified strength and neither cylinder shall have a compressive strength that is more than 5 percent below the specified strength. If too few cylinders were molded to carry out all required tests on the girder, the Contractor shall remove and test cores from the girder under the surveillance of the Engineer. If the Contractor casts cylinders to represent more than one girder, all girders in that line shall be cored and tested. Cores shall avoid all prestressing strands, steel reinforcing bars and interior voids. For prestressed concrete slab girders, a test shall consist of four cores measuring 3 inches in diameter by 6 inches in length (for slabs) or by the thickness of the web (for ribbed and double tee sections). Two cores shall be taken from each side of the girder with one on each side of the girder span midpoint, at locations accepted by the Engineer. The core locations for prestressed concrete ribbed and double tee sections shall be immediately beneath the top flange. For prestressed concrete tub girders, a test shall consist of four cores measuring 3 inches in diameter by the thickness of the web. Two cores shall be taken from each web approximately 3 feet to the left and to the right of the center of the girder span. 2020 Standard Specifications M 41-10 Page 6-103 Concrete Structures 6-02 For all other prestressed concrete girders, a test shall consist of three cores measuring 3 inches in diameter by the thickness of the web and shall be removed from just below the top flange; one at the midpoint of the girder’s length and the other two approximately 3 feet to the left and approximately 3 feet to the right. The cores shall be taken in accordance with AASHTO T 24 and shall be tested in accordance with AASHTO T 22. The Engineer may accept the girder if the average compressive strength of the all test cores from the girder are at least 85 percent of the specified compressive strength with no one core less than 75 percent of specified compressive strength. If there are more than four cored holes in a girder, the prestressing reinforcement shall not be released until the holes are patched and the patch material has attained a minimum compressive strength equal to the required release compressive strength. All cored holes shall be patched and cured prior to shipment of the girder. The girder shall not be shipped until tests show the patch material has attained a minimum compressive strength of 4,000 psi. If the annual plant approval includes procedures for patching cored holes, the cored holes shall be patched in accordance with this procedure. Otherwise, the Contractor shall submit a core hole patching procedure as a Type 2 Working Drawing. 6-02.3(25)F Prestress Release Side and flange forms that restrain deflection shall be removed before release of the prestressing reinforcement. All strands shall be released in a way that will minimize eccentricity of the prestressing force about the centerline of the girder. This release shall not occur until tests show each girder has reached the minimum compressive strength required by the Plans. The Contractor may request permission to release the prestressing reinforcement at a minimum concrete compressive strength less than specified in the Plans. This request shall be submitted as a Type 2E Working Drawing analyzing changes in vertical deflection, girder lateral stability and concrete stresses in accordance with Section 6-02.3(25)L2. 6-02.3(25)G Protection of Exposed Reinforcement When a girder is removed from its casting bed, all prestressing reinforcement strands projecting from the girder shall be cleaned and painted with a minimum dry film thickness of 1 mil of paint conforming to Section 9-08.1(2)B, and all steel reinforcing bars, including welded wire fabric, projecting from the girder shall be protected in accordance with Section 6-02.3(24)B. During handling and shipping, projecting reinforcement shall be protected from bending or breaking. Just before placing concrete around the painted projecting bars or strands, the Contractor shall remove from them all spattered concrete remaining from girder casting, dirt, oil, and other foreign matter. Page 6-104 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(25)H Finishing The Contractor shall apply a Class 1 finish, as defined in Section 6-02.3(14), to: 1. The exterior surfaces of the outside girders; and 2. The bottoms, sides, and tops of the lower flanges on all girders, including the top of the bottom slab between the tub girder webs. All other girder surfaces shall receive a Class 2 finish. The interface on girders that contact a cast-in-place concrete deck shall have a finish of dense, screeded concrete without a smooth sheen or laitance on the surface. After vibrating and screeding, and just before the concrete reaches initial set, the Contractor shall texture the interface. This texture shall be applied with a steel brooming tool that etches the surface transversely leaving grooves ⅛ to ¼ inch wide, between ⅛ and ¼ inch deep, and spaced ¼ to ½ inch apart. On prestressed concrete wide flange deck girders, deck bulb tee girders, ribbed section girders and double tee girders, the Contractor shall test the top surface for flatness and make corrections in accordance with Section 6-02.3(10)D3 except that the straightedge need not exceed the width of the girder top flange when checking the transverse direction. The top surface shall be finished in accordance with Section 6-02.3(10)D6. The Contractor may repair defects in prestressed concrete girders in accordance with Section 6-01.16. 6-02.3(25)I Fabrication Tolerances The girders shall be fabricated as shown in the processed shop drawings, and shall meet the dimensional tolerances listed below. Construction tolerances of cast-in-place closures for spliced prestressed concrete girders shall conform to the tolerances specified for spliced prestressed concrete girders. Actual acceptance or rejection will depend on how the Engineer believes a defect outside these tolerances will affect the Structure’s strength or appearance: 1. Length: ± ¼ inch per 25 feet of beam length, up to a maximum of ± 1½ inches 2. Width: Flanges and webs: + ⅜ inch, - ¼ inch Slab girders: ± ¼ inch 3. Girder Depth (overall): ± ¼ inch 4. Flange Depth: ± ¼ inch 5. Strand Position: Individual strands: ± ¼ inch Bundled strands: ± ½ inch Harped strand group center of  gravity at the girder ends: ± 1 inch 2020 Standard Specifications M 41-10 Page 6-105 Concrete Structures 6-02 6. Longitudinal Location of Harp Points for Harped Strands from Design Locations: ± 20 inches 7. Position of an Interior Void, vertically  and horizontally: ± ½ inch 8. Bearing Recess (center of recess to girder end): ± ⅝ inch 9. Girder Ends (deviation from square or designated skew): Horizontal: ± ⅛ inch per foot of girder width, up to a maximum of ± ½ inch Vertical: ± 3/16 inch per foot of girder depth, up to a maximum of ± 1 inch 10. Bearing Area Deviation from Plane  (in length or width of bearing): ± ⅛ inch. 11. Stirrup Reinforcing Spacing: ± 1 inch. 12. Stirrup Projection from Top of Girder: Wide flange thin deck and slab girders: ± 1/2 inch All other girders: ± ¾ inch 13. Mild Steel Concrete Cover: - ⅛ inch, + ⅜ inch. 14. Local smoothness of any surface: ± ¼ inch. in 10 feet 15. Differential Camber between Girders in a Span (measured in place at the job site): For wide flange deck and deck bulb tee girders with a cast-in-place reinforced concrete deck: Cambers shall be equalized when the differences in cambers between adjacent girders exceeds ± ¾ inch For wide flange deck, deck bulb tee and slab girders without a cast-in-place reinforced deck: Cambers shall be equalized when the differences in cambers between adjacent girders exceeds ± ¼ inch 16. Position of Inserts for Structural Connections: ± 1 inch. 17. Position of Lifting Embedments: ± 3 inches longitudinal, ± ¼ inch transverse. 18. Weld Ties: ± ½ inch longitudinal, ± ⅛ inch vertical. 19. Position of post tensioning ducts in  spliced prestressed concrete girders: ± ¼ inch. 20. Deviation from a smooth curve for post-tensioning ducts at closures based on the sum total of duct placement and alignment tolerances: ± ⅜ inch. Page 6-106 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(25)J Horizontal Alignment The Contractor shall check and record the horizontal alignment (sweep) of each girder at the following times: 1. Initial – Upon removal of the girder from the casting bed 2. Shipment – Within 14 days prior to shipment; and 3. Erection – After girder erection and cutting temporary top strands but prior to any equalization, welding ties or placement of diaphragms. Horizontal alignment of the top and bottom flanges shall be checked and recorded. Alternatively, the Contractor may check and record the horizontal alignment of the web near mid-height of the girder. Each check shall be made by measuring the maximum offset at mid-span relative to a chord that starts and stops at the girder ends. The Contractor shall check and record the alignment at a time when the girder is not influenced by temporary differences in surface temperature. Records for the initial check (item 1 above) shall be included in the Contractor’s prestressed concrete certificate of compliance. Records for all other checks shall be submitted as a Type 1 Working Drawing. For each check (items 1 to 3 above), the alignment shall not be offset more than ⅛ inch for each 10 feet of girder length. Girders not meeting this tolerance for the shipment check (item 2 above) shall require an analysis of girder lateral stability and stresses in accordance with Section 6-02.3(25)L1. The Contractor shall perform this analysis and submit it as a Type 2E Working Drawing prior to shipment of the girder. Any girder that exceeds an offset of ⅛ inch for each 10 feet of girder length for the erection check (item 3 above) shall be corrected at the job site to the ⅛ inch maximum offset per 10 feet of girder length before concrete is placed into the diaphragms. The Contractor shall submit a Type 2 Working Drawing for any required corrective action. The maximum distance between the side of a prestressed concrete slab girder, or the edge of the top flange of a wide flange deck, wide flange thin deck or deck bulb tee girder, and a chord that extends the full length of the girder shall be ± ½ inch after erection (item 3 above). 6-02.3(25)K Vertical Deflection The Contractor shall check and record the vertical deflection (camber) of each girder at the following times: 1. Initial – Upon removal of the girder from the casting bed; 2. Shipment – Within 14 days prior to shipment; 3. Erection – After girder erection and cutting temporary top strands but prior to any equalization, welding ties or placement of diaphragms. At a minimum, survey data shall be taken at each girder end and at midspan. The Contractor shall perform and record each check at a time when the alignment of the girder is not influenced by temporary differences in surface temperature. Records for the initial check (Item 1 above) shall be included in the Contractor’s Prestressed Concrete 2020 Standard Specifications M 41-10 Page 6-107 Concrete Structures 6-02 Certificate of Compliance. Records for all other checks shall be submitted as a Type 1 Working Drawing. Girders with vertical deflections not meeting the limit shown in the Plans for the shipment check (item 2 above) shall require an analysis of girder lateral stability and stresses in accordance with Section 6-02.3(25)L1. The Contractor shall perform this analysis and submit it as a Type 2E Working Drawing prior to shipment. The “D” dimensions shown in the Plans are computed upper and lower bounds of girder vertical deflections at midspan based on a time lapse of 40 and 120 days after release of the prestressing strands. Any temporary top strands are assumed to be cut 30 days prior to these elapsed times (10 and 90 days after release of the prestressing strands). Any diaphragms are assumed to be placed. The “D” dimensions are intended to advise the Contractor of the expected range of girder vertical deflection at the time of deck placement. A positive (+) “D” dimension indicates upward deflection. If the girder vertical deflection measured for the erection check (item 3 above) is not between the lower “D” dimension bound shown in the Plans and the upper “D” dimension bound shown in the Plans plus ¾ inches, the Engineer may require corrective action. The Contractor shall submit a Type 2 Working Drawing for any required corrective action. 6-02.3(25)L Handling and Storage During handling and storage, each prestressed concrete girder shall always be kept plumb and upright. It shall be lifted only by the lifting embedments (strand lift loops or high- strength threaded steel bars) at either end. For strand lift loops, only ½-inch diameter or 0.6-inch diameter strand conforming to Section 9-07.10 shall be used, and a minimum 2-inch diameter straight pin of a shackle shall be used through the loops. Multiple loops shall be held level in the girder during casting in a manner that allows each loop to carry its share of the load during lifting. The minimum distance from the end of the girder to the centroid of the strand lift loops shall be 3 feet. The loops for all prestressed concrete girders, with the exception of prestressed concrete slab girders, shall project a minimum of 1′-6″ from the top of the girder. The loops for prestressed concrete slab girders shall project a minimum of 4 inches. Loops shall extend to within 3 inches clear of the bottom of the girder, terminating with a 9-inch long 90-degree hook. Loads on individual loops shall be limited to 12 kips, and all girders shall be picked up at a minimum angle of 60 degrees from the top of the girder. For high-strength threaded steel bars, a minimum of two 1⅜-inch diameter bars conforming to Section 9-07.11 shall be used at each end of the girder. The lifting hardware that connects to the bars shall be designed, detailed, and furnished by the Contractor. The minimum distance from the end of the girder to the centroid of the lifting bars shall be 3 feet. Lifting bars shall extend to within 3 inches clear of the bottom of the girder and shall be anchored in the bottom flange with steel plates and nuts. The minimum size of embedded plates for lifting bars shall be ½ inch thick by 3 inches square. Lifting forces on the lifting bars shall not exceed 58 kips on an individual bar, and shall be within 10 degrees of perpendicular to the top of the girder. Page 6-108 2020 Standard Specifications M 41-10 6-02 Concrete Structures For some girders, straight temporary top flange strands may be specified in the Plans. The lifting locations and concrete release strengths shown in the girder schedule in the Plans assume that these temporary strands are pretensioned. Alternatively, these temporary strands may be post-tensioned provided the strands are stressed on the same day that the permanent prestress is released into the girder and the strands are tensioned prior to lifting the girder. These temporary strands shall be of the same diameter and shall be tensioned to the same force as the permanent strands. The inside diameter of the debonding sleeves shall be large enough such that the temporary strands fully retract upon cutting. When temporary top strands are specified for spliced prestressed concrete girders, the temporary top strands shall be post-tensioned prior to lifting the assembled girder. When the post-tensioned alternative is used, the Contractor shall be responsible for properly sizing the anchorage plates, and configuring the reinforcement adjacent to the anchorage plates, to prevent bursting or splitting of the concrete in the top flange. Temporary strands shall be cut or released in accordance with Section 6-02.3(25)N. If girders are to be stored, the Contractor shall place them on a stable foundation that will keep them in a vertical position. Stored girders shall be supported at the bearing recesses or, if there are no recesses, approximately 2 to 3 feet from the girder ends. After post- tensioning, spliced prestressed concrete girders shall be supported at points between 2 and 5 feet from the girder ends, unless otherwise shown in the Plans. For long-term storage of girders with initial horizontal curvature, the Contractor may wedge one side of the bottom flange, tilting the girders to control curvature. If the Contractor elects to set girders out of plumb during storage, the Contractor shall have the proposed method analyzed by the Contractor’s engineer to ensure against damaging the girder. 6-02.3(25)L1 Girder Lateral Stability and Stresses The Contractor shall be responsible for safely lifting, storing, shipping and erecting prestressed concrete girders. The Contract documents may provide shipping and handling details for girders including lifting embedment locations (L), shipping support locations (L1 and L2), minimum shipping support rotational spring constants (Kθ), minimum shipping support center- to-center wheel spacings (Wcc), vertical deflections and number of temporary top strands. These shipping and handling details have been determined in accordance with Section 6-02.3(25)L2. The Contractor shall submit a Type 2E Working Drawing analyzing girder lateral stability and concrete stresses during lifting, storage, shipping and erection in accordance with Section 6-02.3(25)L2 in the following cases: 1. Any of the analysis assumptions listed in Section 6-02.3(25)L2 are invalid. Determination of validity shall be made by the Contractor, except that analysis assumptions shall be considered invalid if the actual values are outside of the provided tolerances. 2. The Contractor intends to alter the shipping and handling details provided in the Contract documents. 3. The Contract documents do not provide shipping and handling details. 2020 Standard Specifications M 41-10 Page 6-109 Concrete Structures 6-02 6-02.3(25)L2 Lateral Stability and Stress Analysis Analysis for girder lateral stability and concrete stresses during lifting, storage, shipping and erection shall be in accordance with the PCI Recommended Practice for Lateral Stability of Precast, Prestressed Concrete Bridge Girders, First Edition, Publication CB-02-16-E and the AASHTO LRFD Bridge Design Specifications edition identified in the Contract documents. The following design criteria shall be met: 1. Factor of Safety against cracking shall be at least 1.0 2. Factor of Safety against failure shall be at least 1.5 3. Factor of Safety against rollover shall be at least 1.5 4. Allowable concrete stresses shall be as specified in Section 6-02.3(25)L3 The analysis shall address any effects on girder vertical deflection (camber), “A” dimensions at centerline of bearings and deck screed cambers (C). Shipping and handling details provided in the Contract documents have been determined using the following analysis assumptions: 1. Girder dimensions, strand locations and lifting embedment locations are within the tolerances specified in Section 6-02.3(25)I 2. Girder horizontal alignment (sweep) is within the tolerance specified in Section 6-02.3(25)J 3. Girder vertical deflection (camber) at midspan is less than or equal to the value shown in the Plans for shipping 4. Minimum concrete compressive strength at release (f’ci) has been reached before initial lifting from casting bed. Minimum concrete compressive strength at 28 days (f’c) has been reached before shipping. 5. Height of girder bottom above roadway at shipping supports is less than or equal to 72 inches 6. Height of shipping support roll center above roadway is 24 inches, ± 2 inches 7. Shipping support longitudinal placement (L1 and L2) tolerance is ± 6 inches 8. Shipping support lateral placement tolerance is ±1 inches 9. Shipping supports provide the minimum shipping support rotational spring constant (Kθ) and minimum shipping support center-to-center wheel spacings (Wcc) shown in the Plans 10. For shipping at highway speeds a ±20 percent dynamic load allowance (impact) is included with a typical roadway superelevation of 2 percent 11. For turning at slow speeds, no dynamic load allowance (impact) is included with a maximum roadway superelevation of 6 percent 12. Wind, centrifugal and seismic forces are not considered Page 6-110 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Compressive All locations 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Compressive All locations 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Final Stresses at Service Load Tensile Precompressed tensile zone 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Compressive Effective prestress and permanent loads 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Effective prestress, permanent loads and transient (live) loads 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 6-02.3(25)L3 Allowable Stresses Prestressed concrete girder stresses shall be limited to the following values at all stages of construction and in service: Condition Stress Location Allowable Stress (ksi) Temporary Stress at Transfer and Lifting from Casting Bed Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐′ Temporary Stress at Shipping and Erection Tensile In areas without bonded reinforcement sufficient to resist the tensile force in the concrete 0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′≤0.2 In areas with bonded reinforcement sufficient to resist the tensile force in the concrete 0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ In areas with bonded reinforcement sufficient to resist the tensile force in the concrete when shipping at 6% superelevation, without impact 0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Compressive All locations 0.65𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Service Load Tensile Precompressed tensile zone 0.0 Compressive Effective prestress and permanent loads 0.45𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Effective prestress, permanent loads and transient (live) loads 0.60𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Final Stresses at Fatigue Load Compressive Fatigue I Load Combination plus one-half effective prestress and permanent loads 0.40𝑓𝑓𝑓𝑓𝑐𝑐𝑐𝑐′ Variables are as defined in the AASHTO LRFD Bridge Design Specifications. Variables are as defined in the AASHTO LRFD Bridge Design Specifications. 6-02.3(25)M Shipping After the girder has reached its 28-day design strength, the girder and a completed Certification of Compliance, signed by a Precast/Prestressed Concrete Institute Certified Technician or a Professional Engineer, shall be submitted to the Engineer for inspection. If the Engineer finds the certification and the girder to be acceptable, the Engineer will stamp the girder “Approved for Shipment”. No prestressed concrete slab girder shall be shipped for at least 3 days after concrete placement. No prestressed concrete wide flange deck, deck bulb tee or tub girder shall be shipped for at least 7 days after concrete placement, except that they may be shipped 3 days after concrete placement when L/(bd) is less than or equal to 5.0, where L equals the shipping length of the girder, b equals the girder top flange width (for prestressed concrete wide flange deck and deck bulb tee girders) or the bottom flange width (for prestressed concrete tub girders), and d equals the girder depth, all in feet. No other girder shall be shipped for at least 10 days after concrete placement. 2020 Standard Specifications M 41-10 Page 6-111 Concrete Structures 6-02 Girder support locations during shipping shall be no closer than the girder depth to the ends of the girder at the girder centerline. Girder lateral stability and stresses during shipping shall be in accordance with Section 6-02.3(25)L1. If the Contractor elects to assemble spliced prestressed concrete girders into shipping configurations not shown in the Contract documents, the Contractor shall submit a Type 2E Working Drawing analyzing girder lateral stability and concrete stresses in accordance with Section 6-02.3(25)L2 before shipping. 6-02.3(25)N Prestressed Concrete Girder Erection Before erecting any prestressed concrete girders, the Contractor shall submit an erection plan as a Type 2E Working Drawing. The erection plan shall conform Section 6-02.3(25) L1. The erection plan shall provide complete details of the erection process including at a minimum: 1. Temporary falsework support, bracing, guys, deadmen, and attachments to other Structure components or objects; 2. Procedure and sequence of operation; 3. Girder stresses during progressive stages of erection; 4. Girder weights, lift points, lifting embedments and devices, spreaders, and angle of lifting cables in accordance with Section 6-02.3(25)L, etc.; 5. Crane(s) make and model, mass, geometry, lift capacity, outrigger size, and reactions; 6. Girder launcher or trolley details and capacity (if intended for use); and 7. Locations of cranes, barges, trucks delivering girders, and the location of cranes and outriggers relative to other Structures, including retaining walls and wing walls. The erection plan shall include drawings, notes, catalog cuts, and calculations clearly showing the above listed details, assumptions, and dimensions. Material properties and Specifications, structural analysis, and any other data used shall also be included. The concrete in piers and crossbeams shall reach at least 80 percent of design strength before girders are placed on them. The Contractor shall hoist girders only by the lifting embedments at the ends, always keeping the girders plumb and upright. When the girders are to receive a cast-in-place concrete deck, lifting embedments shall be removed after erection to provide a minimum 2½-inch clearance to the top of the deck. When the girders are not to receive a cast-in- place concrete deck, lifting embedments shall be removed 1-inch below the girder surface and grouted with an epoxy grout conforming to Section 9-26.3(1)A. Page 6-112 2020 Standard Specifications M 41-10 6-02 Concrete Structures The girders shall be braced in accordance with Sections 6-02.3(17)F4 and 6-02.3(17)F5. When temporary strands in the top flange are used, they shall be cut after the girders are braced and before girder deflections are equalized and the intermediate diaphragms are cast. Instead of the oak block wedges shown in the Plans, the Contractor may use Douglas fir blocks if the grain is vertical. The height of oak block wedges at the girder centerline shall not exceed the width. The Contractor shall fill all block-out holes with a mortar or grout acceptable to the Engineer. Stop plates and dowel bars for prestressed concrete girders shall be set with either epoxy grout conforming to Section 9-26.3 or type IV epoxy bonding agent conforming to Section 9-26.1. 6-02.3(25)O Girder to Girder Connections When differential camber between adjacent girders in a span exceeds the tolerance in Section 6-02.3(25)I, the Contractor shall submit a method of equalizing deflections as a Type 1 Working Drawing. Any temporary strands in the top flange shall be cut in accordance with Section 6-02.3(25)N prior to equalizing girder deflections. Prestressed concrete girders shall be constructed in the following sequence: 1. If required, deflections shall be equalized in accordance with the Contractor’s equalization plan. 2. Any intermediate diaphragms shall be placed and any weld ties shall be welded in accordance with Section 6-03.3(25). Welding ground shall be attached directly to the steel plates being welded when welding the weld-ties. 3. Any keyways between adjacent girders shown in the Plans to receive grout shall be filled flush with the surrounding surfaces using a grout conforming to Section 9-20.3(2). 4. Equalization equipment shall not be removed and other construction equipment shall not be placed on the structure until intermediate diaphragms and keyway grout have attained a minimum compressive strength of 2,500 psi. 6-02.3(26) Cast-In-Place Prestressed Concrete Unless otherwise shown in the Plans, concrete for cast-in-place prestressed bridge members shall be Class 4000D in the bridge deck, and Class 4000 at all other locations. Air entrainment shall conform to Sections 6-02.3(2)A and 6-02.3(3). The Contractor shall construct supporting falsework in a way that leaves the Superstructure free to contract and lift off the falsework during post-tensioning. Forms that will remain inside box girders to support the bridge deck shall, by design, resist girder contraction as little as possible. 2020 Standard Specifications M 41-10 Page 6-113 Concrete Structures 6-02 Before tensioning, the Contractor shall remove all side forms from girders. From this point until 48 hours after grouting the tendons, the Contractor shall keep all construction and other live loads off the Superstructure and shall keep the falsework supporting the Superstructure in place. Once the prestressing steel is installed, no welds or welding grounds shall be attached to metal forms, structural steel, or reinforcing bars of the structural member. The Contractor shall not stress the strands until all concrete has reached a compressive strength of at least 4,000 psi (or the strength shown in the Plans). This strength shall be measured on concrete test cylinders made of the same concrete cured under the same conditions as the cast-in-place unit. All post-tensioning shall be completed before sidewalks and barriers are placed. 6-02.3(26)A Shop Drawings Before casting the structural elements, the Contractor shall submit Type 2E Working Drawings of the prestressing system shop drawings. These shop drawings shall show complete details of the methods, materials, and equipment the Contractor proposes to use in prestressing Work. The shop drawings shall follow the design conditions shown in the Plans unless the Engineer permits equally effective variations. In addition, the shop drawings shall show: 1. The method and sequence of stressing. 2. Technical data on tendons and steel reinforcement, anchorage devices, anchorage device efficiency and acceptance test results and records, anchoring stresses, types of tendon conduit, and all other data on prestressing operations. 3. Stress and elongation calculations. Separate stress and elongation calculations shall be submitted for each tendon if the difference in tendon elongations exceeds 2 percent. 4. That tendons in the bridge will be arranged to locate their center of gravity as the Plans require. 5. Details of additional or modified reinforcing steel required by the stressing system. 6. Procedures and lift-off forces at both ends of the tendon for performing a force verification lift-off in the event of discrepancies between measured and calculated elongations. Couplings or splices will not be permitted in prestressing strands. Couplings or splices in bar tendons are subject to the Engineer’s acceptance. Page 6-114 2020 Standard Specifications M 41-10 6-02 Concrete Structures Friction losses used to calculate forces of the post-tensioning steel shall be based on the assumed values used for the design. The assumed anchor set, friction coefficient “μ”, and friction wobble coefficient “k” values for design are shown in the Plans. The post- tensioning supplier may revise the assumed anchor set value provided all the stress and force limits listed in Section 6-02.3(26)G are met. The Contractor shall determine all points of interference between the mild steel reinforcement and the paths of the post-tensioning tendons. Details to resolve interferences shall be submitted with the shop drawings for approval. Where reinforcing bar placement conflicts with post-tensioning tendon placement, the tendon profile shown in the Plans shall be maintained. The Contractor may deviate from the processed shop drawings only after submitting a new Type 2E Working Drawing that describes the proposed changes. Before physical completion of the project, the Contractor shall provide the Engineer with reproducible originals of the shop drawings (and any processed changes). These shall be clear, suitable for microfilming, and on permanent sheets that measure no smaller than 11 by 17 inches. Alternatively, the shop drawings may be provided in an electronic format with the concurrence of the Bridge and Structures Engineer. 6-02.3(26)B General Requirements for Anchorages Post-tensioning reinforcement shall be secured at each end by means of an accepted anchorage device, which shall not kink, neck down, or otherwise damage the post- tensioning reinforcement. The anchorage assembly shall be grouted to the Engineer’s satisfaction. The structure shall be reinforced with steel reinforcing bars in the anchorage zone in the vicinity of the anchorage device. This reinforcement shall be categorized into two zones. The first or local zone shall be the concrete surrounding and immediately ahead of the anchorage device. The second or general zone shall be the overall anchorage zone, including the local zone. The steel reinforcing bars required for concrete confinement in the local zone shall be determined by the post-tensioning system supplier and shall be shown in the shop drawings. The calculations shall be submitted with the shop drawings. The local zone steel reinforcing bars shall be furnished and installed by the Contractor, at no additional cost to the Contracting Agency, in addition to the structural reinforcement required by the Plans. The steel reinforcing bars required in the general zone shall be as shown in the Plans and are included in the appropriate Bid items. The Contractor shall submit Type 2E Working Drawings consisting of details, certified test reports, and/or supporting calculations, as specified below, which verify the structural adequacy of the anchorage devices. This requirement does not apply where the anchorage devices have been previously accepted by the Contracting Agency for the same Structure configuration. The Contractor shall also submit any necessary changes to the Contract Plans. The test report shall specify all pertinent test data. 2020 Standard Specifications M 41-10 Page 6-115 Concrete Structures 6-02 Dead ended anchorages will not be permitted. Dead ended anchorages are defined as anchorages that cannot be accessed during the stressing operations. Materials and workmanship shall conform to the applicable requirements of Sections 6-03 and 9-06. Before installing the anchorage device, the Contractor shall submit a Manufacturer’s Certificate of Compliance. Anchorage devices shall meet the requirements listed in either Sections 6-02.3(26)C or 6-02.3(26)D. All anchorages shall develop at least 96 percent of the actual ultimate strength of the prestressing steel, when tested in an unbonded state, without exceeding anticipated set. This anchor efficiency test shall be performed, or inspected and certified, by an independent testing agency accepted by the Engineer. 6-02.3(26)C Normal Anchorage Devices Normal anchorage devices, defined as post-tensioning anchorage assemblies conforming to the factored bearing resistance requirements specified in this section, shall provide a factored bearing resistance greater than or equal to 1.2 times the maximum jacking force. The Contractor shall submit Type 2E Working Drawings consisting of calculations showing that the factored bearing resistances of the anchorage devices are not exceeded. The factored bearing resistance of the anchorages shall be taken as: Pr = φfnAb For which fn is the lesser of:()()() c'f QUPfcc'f2 − ()()() cf QUPcoresfcf ' '85.56.3 − cm'f cin g cin f2.25f and,A Af0.7f ′= ′= Where: φ = Resistance factor of 0.70 A = Maximum area of the portion of the supporting surface that is similar to the loaded area and concentric with it and does not overlap similar areas for adjacent anchorage devices (square inches) Ab = Effective net area of the bearing plate calculated as the area Ag, minus the area of openings in the bearing plate (square inches) Ag = Gross bearing area of the bearing plate calculated in accordance with the requirements specified below (square inches) f’ci = Nominal compressive strength of concrete at the time of application of the tendon force (ksi) Page 6-116 2020 Standard Specifications M 41-10 6-02 Concrete Structures The full bearing plate area may be used for Ag and the calculation of Ab if the plate material does not yield at the factored tendon force and the slenderness of the bearing plate, n/t, conforms to: (n/t) ≤ 0.08(Eb/fb)0.33 Where: Eb = Modulus of elasticity of the bearing plate material (ksi) fb = Stress in the anchor plate at a section taken at the edge of the wedge hole or holes (ksi) = Projection of the base plate beyond the wedge hole or wedge plate, as appropriate (inches) t = average thickness of the bearing plate (inches) For anchorages with separate wedge plates, n may be taken as the largest distance from the outer edge of the wedge plate to the outer edge of the bearing plate. For rectangular bearing plates, this distance shall be measured parallel to the edges of the bearing plate. If the anchorage has no separate wedge plate, n may be taken as the projection beyond the outer perimeter of the group of holes in the direction under consideration. For bearing plates that do not meet the slenderness requirement specified above, the effective gross bearing area, Ag, shall be taken as: 1. For anchorages with separate wedge plates, the area geometrically similar to the wedge plate, with dimensions increased by twice the bearing plate thickness. 2. For anchorages without separate wedge plates, the area geometrically similar to the outer perimeter of the wedge holes, with dimensions increased by twice the bearing plate thickness. 6-02.3(26)D Special Anchorage Devices Special anchorage devices, defined as post-tensioning anchorage assemblies that do not conform to the factored bearing pressure requirements specified in Section 6-02.3(26)C, shall conform to the acceptance test requirements specified below. Acceptance testing shall be performed, or inspected and certified, by an independent testing agency accepted by the Engineer. Results of the special anchorage device acceptance testing shall be recorded and submitted as a Type 1 Working Drawing. 6-02.3(26)D1 Test Block Requirements The test block shall be a rectangular prism of sufficient size to contain all the special anchorage device components that will also be embedded in the concrete of the Structure being post-tensioned. The arrangement of the special anchorage device components shall conform to practical application to the project and the special anchorage device manufacturer’s recommendations. The test block shall contain an empty duct of a size appropriate for the maximum tendon size that can be accommodated by the special anchorage device. 2020 Standard Specifications M 41-10 Page 6-117 Concrete Structures 6-02 6-02.3(26)D2 Test Block Dimensions The dimensions of the test block perpendicular to the tendon in each direction shall be the smaller of twice the minimum edge distance or the minimum spacing specified by the special anchorage device manufacturer, with the stipulation that the concrete cover over any confining reinforcing steel or supplementary skin reinforcement shall be appropriate for the project-specific application and circumstances. The length of the block along the axis of the tendon shall be at least two times the larger of the cross-section dimensions. 6-02.3(26)D3 Local Zone Reinforcement for Confinement The confining reinforcing steel in the local zone of the test block shall be the same as that recommended by the special anchorage device manufacturer. 6-02.3(26)D4 Supplementary Skin Reinforcement In addition to the special anchorage device and the associated local zone reinforcement for confinement, supplementary skin reinforcement may be provided throughout the test block. Such supplementary skin reinforcement shall be as specified by the special anchorage device manufacturer, but shall not exceed a volumetric ratio of 0.01. The Contractor shall furnish and install supplementary skin reinforcement in the anchorage zone of the Structure similar in configuration and equivalent in volumetric ratio to the supplementary skin reinforcement used in the test block at no additional cost to the Contracting Agency. The steel reinforcing bars shown in the Plans in corresponding portions of the general zone may be counted toward this reinforcement requirement. 6-02.3(26)D5 Test Block Concrete Strength The compressive strength of the test block at the time of acceptance testing shall not exceed the compressive strength of the Structure being post-tensioned at the time of post-tensioning. 6-02.3(26)D6 Special Anchorage Device Acceptance Testing Special anchorage device acceptance testing shall be conducted in accordance with one of the following test methods: 1. Cyclic load test. 2. Sustained load test. 3. Monotonic load test. The loads specified for the tests are specified in fractions of the ultimate load Fpu of the largest tendon that the special anchorage device is designed to accommodate. The specimen shall be loaded in accordance with conventional usage of the device in post- tensioning applications, except that the load may be applied directly to the wedge plate or equivalent area. Page 6-118 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(26)D7 Cyclic Loading Test A load of 0.8Fpu shall be applied. The load shall then be cycled between 0.1Fpu and 0.8Fpu until crack widths stabilize, but for not less than ten cycles. Crack widths are considered stabilized if they do not change by more than 0.001 inches over the last three readings. Upon completion of the cyclic loading portion of the test, the specimen shall be loaded to failure, or, if limited by the capacity of the loading equipment, to at least 1.1Fpu. Crack widths and crack patterns shall be recorded at the initial load of 0.8Fpu, at least at the last three consecutive peak loadings before termination of the cyclic loading portion of the test, and at 0.9Fpu. The maximum load shall also be reported. 6-02.3(26)D8 Sustained Loading Test A load of 0.8Fpu shall be applied and held constant until crack widths stabilize, but not less than 48 hours. Crack widths are considered stabilized if they do not change by more than 0.001 inches over the last three readings. Upon completion of the sustained loading portion of the test, the specimen shall be loaded to failure, or, if limited by the capacity of the loading equipment, to at least 1.1Fpu. Crack widths and crack patterns shall be recorded at the initial load of 0.8Fpu, at least three times at intervals of not less than 4 hours during the last 12 hours of the sustained loading time period, and at 0.9Fpu. The maximum load shall also be reported. 6-02.3(26)D9 Monotonic Loading Test A load of 0.9Fpu shall be applied and held constant for 1 hour. Upon completion of the 1-hour load hold period, the specimen shall be loaded to failure, or, if limited by the capacity of the loading equipment, to at least 1.2Fpu. Crack widths and crack patterns shall be recorded at 0.9Fpu, at the conclusion of the 1-hour load hold period, and at 1.0Fpu. The maximum load shall also be reported. 6-02.3(26)D10 Special Anchorage Device Test Performance Requirements The test block shall conform to the following load requirements under test load: 1. The maximum test load for cyclic loading and sustained loading tests shall be 1.1Fpu minimum. 2. The maximum test load for monotonic loading tests shall be 1.2Fpu minimum. The test block shall conform to the following crack width requirements under test load: 1. Cracks shall not exceed 0.010 inches in width at 0.8Fpu at completion of the cyclic loading test or sustained loading test, or at 0.9Fpu after the 1-hour load hold period of the monotonic loading test. 2. Cracks shall not exceed 0.016 inches at 0.9Fpu for the cyclic loading test or the sustained loading test, or at 1.0Fpu for the monotonic loading test. 2020 Standard Specifications M 41-10 Page 6-119 Concrete Structures 6-02 6-02.3(26)D11 Test Series Requirements A test series shall consist of three test specimens. Each one of the tested specimens shall conform to the acceptance criteria specified above. If one of the three specimens fails to pass the test, a supplementary test series of three additional specimens shall be conducted. The three additional test specimens shall conform to the specified acceptance criteria. 6-02.3(26)D12 Special Anchorage Device Acceptance Testing Results Report The special anchorage device acceptance testing results report shall be a Type 1 Working Drawing consisting of the following: 1. Dimensions of the test specimen. 2. Working drawings with details and dimensions of the special anchorage device, including all confining reinforcing steel. 3. Amount and arrangement of supplementary skin reinforcement. 4. Type and yield strength of reinforcing steel. 5. Type and compressive strength of the concrete at the time of testing. 6. Type of testing procedure and all measurements specified for each specimen under the test. The special anchorage device manufacturer shall specify auxiliary and confining reinforcement, minimum edge distance, minimum anchor spacing, and minimum concrete strength at the time of stressing required for proper performance of the local zone. 6-02.3(26)E Ducts Ducts shall be round, except that ducts for transverse post-tensioning of bridge deck slabs may be rectangular. Ducts shall conform to the following requirements for internal embedded installation and external exposed installation. Elliptical shaped duct may be used if allowed by the Engineer. 6-02.3(26)E1 Ducts for Internal Embedded Installation Ducts, including their splices, shall be semi-rigid, air and mortar tight, corrugated plastic ducts of virgin polyethylene or polypropylene materials, free of water-soluble chlorides or other chemicals reactive with concrete or post-tensioning reinforcement. Ducts, including their splices, shall either have a white coating on the outside or shall be of a white material with ultraviolet stabilizers added. Ducts, including their splices, shall be capable of withstanding concrete pressures without deforming or permitting the intrusion of cement paste during placement of concrete. All fasteners shall be appropriate for use with plastic ducts, and all clamps shall be of an accepted plastic material. Page 6-120 2020 Standard Specifications M 41-10 6-02 Concrete Structures Polyethylene ducts shall conform to ASTM D3350 with a cell classification of 345464A. Polypropylene ducts shall conform to ASTM D4101 with a cell classification range of PP0340B14541 to PP0340B67884. Resins used for duct fabrication shall have a minimum oxidation induction time of 20 minutes, in accordance with ASTM D3895, based on tests performed by the duct fabricator on samples taken from the lot of finished product. The duct thickness shall be as specified in Section 10.8.3 of the AASHTO LRFD Bridge Construction Specifications, latest edition and current interims. All duct splices, joints, couplings, and connections to anchorages shall be made with devices or methods (mechanical couplers, plastic sleeves, shrink sleeves) that are accepted by the duct manufacturer and produce a smooth interior alignment with no lips or kinks. All connections and fittings shall be air and mortar tight. Taping is not acceptable for connections and fittings. Each duct shall maintain the required profile within a placement tolerance of plus or minus ¼ inch for longitudinal tendons and plus or minus ⅛ inch for transverse slab tendons during all phases of the work. The minimum acceptable radius of curvature shall be as recommended by the duct manufacturer and as supported by documented industry standard testing. The ducts shall be completely sealed to keep out all mortar. Each duct shall be located to place the tendon at the center of gravity alignment shown in the Plans. To keep friction losses to a minimum, the Contractor shall install ducts to the exact lines and grades shown in the Plans. Once in place, the ducts shall be tied firmly in position before they are covered with concrete. During concrete placement, the Contractor shall not displace or damage the ducts. The ends of the ducts shall: 1. Permit free movement of anchorage devices, and 2. Remain covered after installation in the forms to keep out all water or debris. Immediately after any concrete placement, the Contractor shall force blasts of oil-free, compressed air through the ducts to break up and remove any mortar inside before it hardens. Before deck concrete is placed, the Contractor shall satisfy the Engineer that ducts are unobstructed and contain nothing that could interfere with tendon installation, tensioning, or grouting. If the tendons are in place, the Contractor shall show that they are free in the duct. Ducts shall be capped and sealed at all times until the completion of grouting to prevent the intrusion of water. Strand tendon duct shall have an inside cross-sectional area large enough to accomplish strand installation and grouting. The area of the duct shall be at least 2.5 times the net area of prestressing steel in the duct. The maximum duct diameter shall be 4½ inches. 2020 Standard Specifications M 41-10 Page 6-121 Concrete Structures 6-02 The inside diameter of bar tendon duct shall at least be ¼ inch larger than the bar diameter. At coupler locations the duct diameter shall at least be ¼ inch larger than the coupler diameter. Ducts installed and cast into concrete prior to prestressing steel installation, shall be capable of withstanding at least 10 feet of concrete fluid pressure. Ducts shall have adequate longitudinal bending stiffness for smooth, wobble free placement. A minimum of three successful duct qualification tests are required for each diameter and type of duct, as follows: 1. Ducts with diameters 2 inches and smaller shall not deflect more than 3 inches under its own weight, when a 10-foot duct segment is supported at its ends. 2. Ducts larger than 2 inches in diameter shall not deflect more than 3 inches under its own weight, when a 20-foot duct segment is supported at its ends. 3. Duct shall not dent more than ⅛ inch under a concentrated load of 100 pounds applied between corrugations by a #4 steel reinforcing bar. When the duct must be curved in a tight radius, more flexible duct may be used, subject to the Engineer’s concurrence. 6-02.3(26)E2 Ducts for External Exposed Installation Duct shall be high-density polyethylene (HDPE) conforming to ASTM D3035. The cell classification for each property listed in the table below: Property Cell Classification 1 3 or 4 2 2, 3, or 4 3 4 or 5 4 4 or 5 5 2 or 3 6 2, 3, or 4 The color code shall be C. Duct for external tendons, including their splices, shall be water tight, seamless or welded, and be capable of resisting at least 150 psi grout pressure. Transition couplers between ducts shall conform to either the standard pressure ratings of ASTM D3035 or the hydrostatic design stresses of ASTM F714 at 73°F. The inside diameter through the coupled length shall not be less than that produced by the dimensional tolerances specified in ASTM D3035. Workers performing HDPE pipe welding shall have satisfactorily completed a certified HDPE pipe welding course and shall have a minimum of 5 years experience in welding HDPE pipe. Page 6-122 2020 Standard Specifications M 41-10 6-02 Concrete Structures The Contractor shall submit a Type 2 Working Drawing consisting of the name and HDPE pipe welding work experience of each HDPE pipe welder proposed to perform this Work in the project. The experience submittal for each HDPE pipe welder shall include: 1. The name of the pipe welder. 2. The name, date, and location of the certified HDPE pipe welding course, with the course completion certificate. 3. A list of at least three projects in the last 5 years where the pipe welder performed HDPE pipe welding, including: a. The project name and location, and date of construction. b. The Governmental Agency/Owner. c. The name, address, and phone number of the Governmental Agency/Owner’s representative. The Engineer may require the HDPE pipe welder to demonstrate test HDPE pipe welding before receiving final acceptance. 6-02.3(26)E3 Transitions Transitions between ducts and wedge plates shall have adequate length to reduce the angle change effect on the performance of strand-wedge connection, friction loss at the anchorage, and fatigue strength of the post-tensioning reinforcement. 6-02.3(26)E4 Vents, Grout Injection Ports, Drains, and Caps The Contractor shall install vents at high points and drains at low points of the tendon profile (and at other places if the Plans require). Vents at high points shall consist of a set of three vents: one to be installed at the high point of the duct, and flanking vents to be installed on either side of the high-point vent at locations where the duct profile is 8 to 12 inches below the elevation of the high-point vent. Vents shall include grout injection ports. Vents and drains shall have a minimum inside diameter of ¾ inches, and shall be of either stainless steel, nylon, or polyolefin materials, free of water-soluble chlorides or other chemicals reactive with concrete or post-tensioning reinforcement. Stainless steel vents and drains shall conform to ASTM A240 Type 316. Nylon vents and drains shall conform to cell classification S-PA0141 (weather-resistant). Polyolefin vents and drains shall contain an antioxidant with a minimum oxidation induction time of 20 minutes in accordance with ASTM D3895. Polyolefin vents and drains shall also have a stress crack resistance of 3 hours minimum when tested at an applied stress of 350 psi in accordance with ASTM F2136. All fasteners shall be appropriate for use with plastic ducts, and all clamps shall be of an accepted plastic material. Taping of connections is not allowed. Valves shall be positive mechanical shut-off valves. Valves, and associated caps, shall have a minimum pressure rating of 100 psi. 2020 Standard Specifications M 41-10 Page 6-123 Concrete Structures 6-02 Vents shall point upward and remain closed until grouting begins. Drains shall point downward and remain open until grouting begins. Ends of stainless steel vents and drains shall be removed 1 inch inside the concrete surface after grouting has been completed. Ends of nylon or polyolefin vents and drains may be left flush to the surface unless otherwise specified by the Engineer. Vents, except for grout injection, are not required for transverse post-tensioning ducts in the bridge deck unless specified in the Plans. Caps shall be made of either stainless steel or fiber reinforced polymer (FRP). Stainless steel caps shall conform to ASTM A240 Type 316L. The resin for FRP caps shall be either nylon, polyester, or acrylonitrite butadiene styrene (ABS). Nylon shall conform to cell classification S-PA0141 (weather-resistant). Caps shall be sealed with “O” ring seals or precision-fitted flat gaskets placed against the bearing plate. Caps shall be fastened to the anchorage with stainless steel bolts conforming to ASTM A240 Type 316L. 6-02.3(26)E5 Leak Tightness Testing The Contractor shall test each completed duct assembly for leak tightness after placing concrete but prior to placing post-tensioning reinforcement. The Contractor shall submit a Type 2 Working Drawing consisting of the equipment used to conduct the leak tightness testing and to monitor and record the pressure maintained in and lost from the closed assembly, and the process to be followed in conducting the leak-tightness testing along with the post-tensioning system shop drawings in accordance with Section 6-02.3(26)A. Prior to testing, all grout caps shall be installed and all vents, grout injection ports, and drains shall either be capped or have their shut-off valves closed. The Contractor shall pressurize the completed duct assembly to an initial air pressure of 50 psi. This pressure shall be held for five minutes to allow for internal adjustments within the assembly. After five minutes, the air supply valve shall be closed. The Contractor shall monitor and measure the pressure maintained within the closed assembly, and any subsequent loss of pressure, over a period of one minute following the closure of the air supply valve. The maximum pressure loss for duct assemblies equal to or less than 150 feet in length shall be 25 psig. The maximum pressure loss for duct assemblies greater than 150 feet in length shall be 15 psig. If the pressure loss exceeds the allowable, locations of leakage shall be identified, repaired or reconstructed using methods accepted by the Engineer. The repaired system shall then be retested. The cycle of testing, repair and retesting of each completed duct assembly shall continue until the completed duct assembly completes a test with pressure loss within the specified amount. 6-02.3(26)F Prestressing Reinforcement All prestressing reinforcement strand shall comply with Section 9-07.10. They shall not be coupled or spliced. Tendon locations shown in the Plans indicate final positions after stressing (unless the Plans say otherwise). No tendon made of 7-wire strands shall contain more than 37 strands of ½-inch diameter, or more than 27 strands of 0.6-inch diameter. All prestressing reinforcement bar shall conform to Section 9-07.11. They shall not be coupled or spliced except as otherwise specified in the Plans or Special Provisions. Page 6-124 2020 Standard Specifications M 41-10 6-02 Concrete Structures Prestressing reinforcement not conforming to either Section 9-07.10 or 9-07.11 will not be allowed except as otherwise noted. Such reinforcement may be used provided it is specifically allowed by the Plans or Special Provisions, it satisfies all material and performance criteria specified in the Plans or Special Provisions, and receives the Engineer’s acceptance. From manufacture to encasement in concrete or grout, prestressing strand shall be protected against dirt, oil, grease, damage, and all corrosives. Strand shall be stored in a dry, covered area and shall be kept in the manufacturer’s original packaging. If prestressing strand has been damaged or pitted, it will be rejected. Prestressing strand with rust shall be spot-cleaned with a nonmetallic pad to inspect for any sign of pitting or section loss. If the prestressing reinforcement will not be stressed and grouted for more than 7 calendar days after it is placed in the ducts, the Contractor shall place an accepted corrosion inhibitor conforming to Federal Specification MIL-I-22110C in the ducts. The feeding ends of the strand tendons shall be equipped with a bullet nosing or similar apparatus to facilitate strand tendon installation. Strand tendons may be installed by pulling or pushing. Any equipment capable to performing the task may be used, provided it does not damage the strands and conforms to the following: 1. Pulling lines shall have a capacity of at least 2.5 times the dead weight of the tendons when used for essentially horizontal tendon installation. 2. Metal pushing wheels shall not be used. 3. Bullets for checking duct clearance prior to concreting shall be rigid and be ⅛ inch smaller than the inside diameter of the duct. Bullets for checking duct after concreting shall be less than ¼ inch smaller than the inside diameter of the duct. 6-02.3(26)G Tensioning Equipment for tensioning post-tensioning reinforcement shall meet the following requirements: 1. Stressing equipment shall be capable of producing a jacking force of at least 81 percent of the specified tensile strength of the post-tensioning reinforcement. 2. Jacking force test capacity shall be at least 95 percent of the specified tensile strength of the post-tensioning reinforcement. 3. Wedge seating methods shall assure uniform seating of wedge segments and uniform wedge seating losses on all strand tendons. 4. Accumulation of differential seating losses during tensioning cycling shall be prevented by proper devices. 5. Jacks used for stressing tendons less than 20 feet long shall have wedge power seating capability. 2020 Standard Specifications M 41-10 Page 6-125 Concrete Structures 6-02 The Contractor shall not begin to tension the tendons until: 1. All concrete has reached a compressive strength of at least 4,000 psi or the strength specified in the Plans. When tensioning takes place prior to 28-day compressive strength testing on concrete sampled in accordance with Section 6-02.3(25)H, compressive strength shall be verified on field cured cylinders in accordance with the FOP for AASHTO T23. 2. The Engineer is satisfied that all strands are free in the ducts. Tendons shall be tensioned to the values shown in the Plans (or processed shop drawings) with hydraulic jacks. When stressing from both ends of a tendon is specified, it need not be simultaneous unless otherwise specified in the Plans. The jacking sequence shall follow the processed shop drawings. Each jack shall have a pressure gauge that will determine the load applied to the tendon. The gauge shall display pressure accurately and readably with a dial at least 6 inches in diameter or with a digital display. Each jack and its gauge shall be calibrated as a unit and shall be accompanied by a certified calibration chart. The Contractor shall provide one copy of this chart to the Engineer for use in monitoring. The cylinder extension during calibration shall be in approximately the position it will occupy at final jacking force. All jacks and gauges must be recalibrated and recertified: (1) at least every 180 days, and (2) after any repair or adjustment. The Engineer may use pressure cells to check jacks, gauges, and calibration charts before and during tensioning. These stress limits apply to all tendons (unless the Plans set other limits): 1. During jacking prior to seating: 90 percent of the yield strength of the steel. 2. At anchorages after seating: 70 percent of the specified tensile strength of the steel. 3. At service limit state after losses: 80 percent of the yield strength of the steel. Tendons shall be anchored at initial stresses that will ultimately maintain service loads at least as great as the Plans require. As stated in Section 6-02.3(26)A, the assumed design friction coefficient “μ” and wobble coefficient “k” shown in the Plans shall be used to calculate the stressing elongation. These coefficients may be revised by the post-tensioning supplier by the following method provided it is accepted by the Engineer: Early in the project, the post-tensioning supplier shall test, in place, two representative tendons of each size and type shown in the Plans, for the purpose of accurately determining the friction loss in a strand and/or bar tendon. The test procedure shall consist of stressing the tendon at an anchor assembly with load cells at the dead end and jacking end. The test specimen shall be tensioned to 80 percent of the specified tensile strength in 10 increments. For each increment, the gauge pressure, elongation, and load cell force shall be recorded and the data furnished to the Engineer. The theoretical elongations and post-tensioning forces shown on the post-tensioning shop drawings shall be re-evaluated by the post-tensioning supplier using the results of the tests and corrected as necessary. Page 6-126 2020 Standard Specifications M 41-10 6-02 Concrete Structures Revisions to the theoretical elongations shall be submitted as a Type 2E Working Drawing. The apparatus and methods used to perform the tests shall be proposed by the post-tensioning supplier and be subject to the Engineer’s acceptance. All costs associated with testing and evaluating test data shall be included in the unit Contract prices for the applicable items of Work involved. As tensioning proceeds, the Engineer will be recording the applied load, tendon elongation, and anchorage seating values. Elongation measurements shall be made at each stressing location to verify that the tendon force has been properly achieved. If proper anchor set has been achieved and the measured elongation of each strand tendon is within plus or minus 7 percent of the accepted calculated elongation, the stressed tendon represented by the elongation measurements is acceptable to the Contracting Agency. In the event discrepancies greater than 7 percent exist between the measured and calculated elongations, the jack calibration shall be checked and stressing records reviewed for any evidence of wire or strand breakage. If the jack if properly calibrated and there is no evidence of wire or strand breakage, a force verification lift off shall be performed to verify the force in the tendon. The post-tensioning supplier force verification lift off procedure shall provide access for visual verification of anchor plate lift off. The jacking equipment shall be capable of bridging and lifting off the anchor plate. The tendon is acceptable if the verification lift off force is not less than 99 percent of the accepted calculated force nor more than 70 percent of the specified tensile strength of the prestressing steel or as accepted by the Engineer. Elongation measurements shall be recorded for bar tendons to verify proper tensioning only. Acceptance will be by force verification lift off. The bar tendon is acceptable if the verification lift off force is not less than 95 percent nor more than 105 percent of the accepted calculated force or as accepted by the Engineer. When removing the jacks, the Contractor shall relieve stresses gradually before cutting the prestressing reinforcement. The prestressing strands shall be cut a minimum of 1 inch from the face of the anchorage device. 6-02.3(26)H Grouting Grout for post-tensioning reinforcement shall conform to Section 9-20.3(1). Prepackaged components of the grout mix shall be used within 6 months or less from date of manufacture to date of usage. Grout for post-tensioning reinforcement will be accepted based on manufacturer’s certificate of compliance in accordance with Section 1-06.3, except that the water-cementitious material ratio of 0.45 maximum shall be field verified. All grout produced for any single structure shall be furnished by one supplier. All grouting operations shall be conducted by ASBI-certified grout technicians. 2020 Standard Specifications M 41-10 Page 6-127 Concrete Structures 6-02 The Contractor shall submit a Type 2 Working Drawing consisting of the grouting operation Plan. The grouting operation Plan shall include, but not be limited to, the following: 1. Names of the grout technicians, accompanied by documentation of their ASBI certification. 2. Type, quantity, and brand of materials used in the grouting operations, including all manufacturer’s certificates of compliance. 3. Type of equipment to be used, including meters and measuring devices used to positively measure the quantity of materials used to mix the post-tensioning grout, the equipment capacity in relation to demand and working conditions, and all back- up equipment and spare parts. 4. General grouting procedure. 5. Duct leak tightness testing and repair procedures as specified in Section 6-02.3(26)E. 6. Methods used to control the rate of grout flow within the ducts. 7. Theoretical grout volume calculations, and target flow rates recommended by the grout manufacturer as a function of the mixer equipment and the expected range of ambient temperatures. 8. Grout mixing and pumping procedures. 9. Direction of grouting. 10. Sequence of use of the grout injection ports, vents, and drains. 11. Procedures for handling blockages. 12. Procedures for postgrouting repairs. Post-tensioning grout shall be mixed in accordance with the prepackaged grout manufacturer’s recommendations using high-shear colloidal mixers. Mechanical paddle mixers will not be allowed. The grout produced for filling post-tensioning ducts shall be free of lumps and undispersed cement. All equipment used to mix each batch of post- tensioning grout shall be equipped with appropriate meters and measuring devices to positively measure all quantities of all materials used to produce the mixed grout. The field test for water-cementitious materials ratio shall be performed prior to beginning the grout injection process. Grouting shall not begin until the material properties of each batch of grout have been confirmed as acceptable. After tensioning the tendons, the Contractor shall again blow oil-free, compressed air through each duct. All drains shall then be closed and the vents opened. Grout caps shall be installed at tendon ends prior to grouting. After completely filling the duct with grout, the Contractor shall pump the grout from the low end at a pressure of not more than 250 psig, except for transverse tendons in deck slabs the grout pressure shall not exceed 100 psig. Grout shall be continuously wasted through each vent until no more air or water pockets show. At this point, all vents shall be closed and grouting pressure at the injector held between 100 and 200 psig for at least 10 seconds, except for transverse tendons in deck slabs the grouting pressure shall be held between 50 and 75 psig for at least Page 6-128 2020 Standard Specifications M 41-10 6-02 Concrete Structures 10 seconds. The Contractor shall leave all plugs, caps, and valves in place and closed for at least 24 hours after grouting. Grouting equipment shall: 1. Include a pressure gauge with an upper end readout of between 275 and 325 psig; 2. Screen the grout before it enters the pump with an easily reached screen that has clear openings of no more than 0.125 inches; 3. Be gravity fed from an attached, overhead hopper kept partly full during pumping; and 4. Be able to complete the largest tendon on the project in no more than 20 minutes of continuous grouting. In addition, the Contractor shall have standby equipment (with a separate power source) available for flushing the grout when the regular equipment cannot maintain a one-way flow of grout. This standby equipment shall be able to pump at 250 psig. The grout mix shall be injected within 30 minutes after the water is added to the cement. Temperature of the surrounding concrete shall be at least 35°F from the time the grout injecting begins until 2-inch cubes of the grout have a compressive strength of 800 psi. Cubes shall be made in accordance with WSDOT T 813 and stored in accordance with FOP for AASHTO T 23. If ambient conditions are such that the surrounding concrete temperature may fall below 35°F, the Contractor shall provide a heat source and protective covering for the Structure to keep the temperature of the surrounding concrete above 35°F. Grout temperature shall not exceed 90°F during mixing and pumping. If conditions are such that the temperature of the grout mix may exceed 90°F, the Contractor will make necessary provisions, such as cooling the mix water and/or dry ingredients, to ensure that the temperature of the grout mix does not exceed 90°F. 6-02.3(27) Concrete for Precast Units Precast units shall not be removed from forms until the concrete has attained a minimum compressive strength of 70 percent of the specified design strength as verified by rebound number determined in accordance with FOP for ASTM C805. Type III portland cement or blended hydraulic cement is permitted to be used in precast concrete units. Precast units shall not be shipped until the concrete has reached the specified design strength as determined by testing cylinders made from the same concrete as the precast units. The cylinders shall be made, handled, and stored in accordance with FOP for AASHTO T 23 and compression tested in accordance with AASHTO T 22 and AASHTO T 231. 2020 Standard Specifications M 41-10 Page 6-129 Concrete Structures 6-02 6-02.3(27)A Use of Self-Consolidating Concrete for Precast Units Self-consolidating concrete (SCC) may be used for the following precast concrete structure elements: 1. Precast roof, wall, and floor panels and retaining wall panels in accordance with Section 6-02.3(28). 2. Precast reinforced concrete three-sided structures, box culverts and split box culverts in accordance with Section 7-02.3(6). 3. Precast concrete barrier in accordance with Section 6-10.3(1). 4. Precast concrete wall stem panels in accordance with Section 6-11.3(3). 5. Precast concrete noise barrier wall panels in accordance with Section 6-12.3(6). 6. Structural earth wall precast concrete facing panels in accordance with Section 6-13.3(4). 7. Precast drainage structure elements in accordance with Section 9-05.50. 8. Precast junction boxes, cable vaults, and pull boxes in accordance with Section 9-29.2. 6-02.3(27)B Submittals for Self-Consolidating Concrete for Precast Units With the exception of items 3, 7, and 8 in Section 6-02.3(27)A, the Contractor shall submit the mix design for SCC to the Engineer for annual plant approval in accordance with Section 6-02.3(28)B. The mix design submittal shall include items specified in Sections 6-02.3(2)A and 6-02.3(2)C1. Items 3, 7, and 8 in Section 6-02.3(27)A require the precast plant to cast one representative structure acceptable to the Engineer and have the structure sawn in half for examination by the Contracting Agency to determine that segregation has not occurred. The Contracting Agency’s acceptance of the sawn structure will constitute acceptance of the precast plant’s use of SCC, and a concrete mix design submittal is not required. 6-02.3(27)C Acceptance Testing of Concrete for Precast Units Acceptance testing shall be performed by the Contractor and test results shall be submitted to the Engineer. Concrete shall conform to the requirements specified in Section 6-02.3(2)A. Unless otherwise noted below, the test methods described in Section 6-02.3(5)D shall be followed. Concrete compressive strength shall be in accordance with Section 6-02.3(27). Compressive strength testing shall be performed a minimum of once per day and once for every 20 cubic yards of concrete that is placed. Page 6-130 2020 Standard Specifications M 41-10 6-02 Concrete Structures Concrete for items 1, 2, 4, 5, and 6 in Section 6-02.3(27)A that is not self-consolidating concrete will be accepted as follows: 1. Temperature within the allowable temperature band. 2. Slump below the maximum allowed. 3. Air content within the required range. SCC for items 1, 2, 4, 5, and 6 in Section 6-02.3(27)A will be accepted as follows: 1. Temperature within the allowable temperature band. 2. Slump flow within the target slump flow range. 3. VSI less than or equal to 1 in accordance with ASTM C1611, Appendix X1, using Filling Procedure B. 4. J ring passing ability less than or equal to 1.5-inches. 5. Air content within the required range. SCC for concrete barrier will be accepted in accordance with temperature, air, and compressive strength testing listed above. SCC for precast junction boxes, cable vaults, and pull boxes will be accepted in accordance with the temperature and compressive strength testing listed above. SCC for precast drainage structure elements will be accepted in accordance with the requirements of AASHTO M199. 6-02.3(28) Precast Concrete Panels The Contractor shall perform quality control inspection. The manufacturing plant for precast concrete panels shall be certified by the Precast/Prestressed Concrete Institute’s Plant Certification Program for the type of precast member to be produced, or the National Precast Concrete Association’s Plant Certification Program or be an International Congress Building Officials or International Code Council Evaluation Services recognized fabricator of structural precast concrete products, and shall be approved by WSDOT as a Certified Precast Concrete Fabricator prior to the start of production. WSDOT Certification will be granted at, and renewed during, the annual precast plant review and approval process in accordance with WSDOT Materials Manual M 46-01 Standard Practice QC 7. Products that shall conform to this requirement include noise barrier panels, wall panels, floor and roof panels, marine pier deck panels, retaining walls, pier caps, and bridge deck panels. Precast concrete panels that are prestressed shall meet all the requirements of Section 6-02.3(25). Prior to the start of production of the precast concrete panels, the Contractor shall advise the Engineer of the production schedule. The Contractor shall give the Inspector safe and free access to the Work. If the Inspector observes any nonspecification Work or unacceptable quality control practices, the Inspector will advise the plant manager. If the corrective action is not acceptable to the Engineer, the panel(s) will be rejected. 2020 Standard Specifications M 41-10 Page 6-131 Concrete Structures 6-02 6-02.3(28)A Shop Drawings Before casting the structural elements, the Contractor shall submit Type 2E Working Drawings of the precast panel shop drawings. These shop drawings shall show complete details of the methods, materials, and equipment the Contractor proposes to use in prestressing/precasting Work. The shop drawings shall follow the design conditions shown in the Plans unless the Engineer concurs with equally effective variations. The shop drawings shall contain as a minimum: 1. Panel shapes (elevations and sections) and dimensions. 2. Finishes and method of constructing the finish (i.e., forming, rolling). 3. Reinforcing, joint, and connection details. 4. Lifting, bracing, and erection inserts. 5. Locations and details of hardware attached to the Structure. 6. Relationship to adjacent material. The Contractor may deviate from the processed shop drawings only after submitting a Type 2E Working Drawing that describes the proposed changes. Before completion of the Contract, the Contractor shall provide the Engineer with reproducible originals of the shop drawings (and any processed changes). These shall be clear, suitable for microfilming, and on permanent sheets that conform with the size requirements of Section 6-01.9. 6-02.3(28)B Casting Before casting precast concrete panels, the Contractor and Fabrication Inspector shall have possession of a processed set of shop drawings. Concrete shall meet the requirements of Section 6-02.3(25)C for annual preapproval of the concrete mix design and slump. If SCC is used, the concrete shall conform to Sections 6-02.3(27)B and 6-02.3(27)C. Precast panels shall not be removed from forms until the concrete has attained a minimum compressive strength of 70 percent of the specified design strength. A minimum compressive strength at other than 70 percent may be used for specific precast panels if the fabricator requests and receives acceptance as part of the WSDOT plant certification process. Forms may be steel or plywood faced, providing they impart the required finish to the concrete. Page 6-132 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(28)C Curing Concrete in the precast panels shall be cured by either moist or accelerated curing methods. The methods to be used shall be preapproved in the WSDOT plant certification process. 1. For moist curing, the surface of the concrete shall be kept covered or moist until such time as the compressive strength of the concrete reaches the strength specified for stripping. Exposed surfaces shall be kept continually moist by fogging, spraying, or covering with moist burlap or cotton mats. Moist curing shall commence as soon as possible following completion of surface finishing. 2. For accelerated curing, heat shall be applied at a controlled rate following the initial set of concrete in combination with an effective method of supplying or retaining moisture. Moisture may be applied by a cover of moist burlap, cotton matting, or other effective means. Moisture may be retained by covering the panel with an impermeable sheet. Heat may be radiant, convection, conducted steam or hot air. Heat the concrete to no more than 100°F during the first 2 hours after placing the concrete, and then increase no more than 25°F per hour to a maximum of 175°F. After curing is complete, cool the concrete no more than 25°F per hour to 100°F. Maintain the concrete temperature above 60°F until the panel reaches stripping strength. Concrete temperature shall be monitored by means of a thermocouple embedded in the concrete (linked with a thermometer accurate to plus or minus 5°F). The recording sensor (accurate to plus or minus 5°F) shall be arranged and calibrated to continuously record, date, and identify concrete temperature throughout the heating cycle. This temperature record shall be made available to the Engineer for inspection and become a part of the documentation required. The Contractor shall never allow dry heat to directly touch exposed panel surfaces at any point. 6-02.3(28)D Contractors Control Strength The concrete strength at stripping and the verification of design strength shall be determined by testing cylinders made from the same concrete as the precast panels. The cylinders shall be made, handled, and stored in accordance with FOP for AASHTO T 23 and compression tested in accordance with AASHTO T 22 and AASHTO T 231. For accelerated cured panels, concrete strength shall be measured on test cylinders cast from the same concrete as that in the panel. These cylinders shall be cured under time- temperature relationships and conditions that simulate those of the panel. If the forms are heated by steam or hot air, test cylinders will remain in the coolest zone throughout curing. If forms are heated another way, the Contractor shall provide a record of the curing time-temperature relationship for the cylinders for each panel to the Engineer. When two or more panels are cast in a continuous line and in a continuous operation, a single set of test cylinders may represent all panels provided the Contractor demonstrates uniformity of casting and curing to the satisfaction of the Engineer. 2020 Standard Specifications M 41-10 Page 6-133 Concrete Structures 6-02 The Contractor shall mold, cure, and test enough of these cylinders to satisfy Specification requirements for measuring concrete strength. The Contractor may use 4- by 8-inch or 6- by 12-inch cylinders. The Contractor shall let cylinders cool for at least ½ hour before testing for release strength. Test cylinders may be cured in a moist room or water tank in accordance with FOP for AASHTO T 23 after the panel concrete has obtained the required release strength. If, however, the Contractor intends to ship the panel prior to standard 28-day strength test, the design strength for shipping shall be determined from cylinders placed with the panel and cured under the same conditions as the panel. These cylinders may be placed in a noninsulated, moisture-proof envelope. To measure concrete strength in the precast panel, the Contractor shall randomly select two test cylinders and average their compressive strengths. The compressive strength in either cylinder shall not fall more than 5 percent below the specified strength. If these two cylinders do not pass the test, two other cylinders shall be selected and tested. 6-02.3(28)E Finishing The Contractor shall provide a finish on all relevant concrete surfaces as defined in Section 6-02.3(14), unless the Plans or Special Provisions require otherwise. The Contractor may repair defects in precast panels in accordance with Section 6-01.16. 6-02.3(28)F Tolerances The panels shall be fabricated as shown in the Plans, and shall meet the dimensional tolerances listed in the latest edition of PCI-MNL-116, unless otherwise required by the Plans or Special Provisions. 6-02.3(28)G Handling and Storage The Contractor shall lift all panels only by adequate devices at locations designated on the shop drawings. When these devices and locations are not shown in the Plans, Section 6-02.3(25)L shall apply. Precast panels shall be stored off the ground on foundations suitable to prevent differential settlement or twisting of the panels. Stacked panels shall be separated and supported by dunnage of uniform thickness capable of supporting the panels. Dunnage shall be arranged in vertical planes. The upper panels of a stacked tier shall not be used as storage areas for shorter panels unless substantiated by engineering analysis and accepted by the Engineer. Page 6-134 2020 Standard Specifications M 41-10 6-02 Concrete Structures 6-02.3(28)H Shipping Precast panels shall not be shipped until the concrete has reached the specified design strength, and the Engineer has reviewed the fabrication documentation for Contract compliance and stamped the precast concrete panels “Approved for Shipment”. The panels shall be supported in such a manner that they will not be damaged by anticipated impact on their dead load. Sufficient padding material shall be provided between tie chains and cables to prevent chipping or spalling of the concrete. 6-02.3(28)I Erection When the precast panels arrive on the project, the Engineer will confirm that they are stamped “Approved for Shipment”. The Engineer will evaluate the present panels for damage before accepting them. The Contractor shall lift all panels by suitable devices at locations designated on the shop drawings. Temporary shoring or bracing shall be provided, if necessary. Panels shall be properly aligned and leveled as required by the Plans. Variations between adjacent panels shall be leveled out by a method accepted by the Engineer. 6-02.4 Measurement Except as noted below, all classes of concrete shall be measured in place by the cubic yard to the neat lines of the Structure as shown in the Plans. Exception: concrete in cofferdam seals. Payment for Class 4000W concrete used in these seals will be based on the volume calculated using the neatline dimensions for the seal as shown in the Contract Plans. For calculated purposes, the horizontal dimension will be increased by 1 foot outside the seal neatline perimeter. The vertical dimension is the distance between the top and bottom neatline elevations. No payment will be made for any concrete that lies outside of these limits to accommodate the Contractor’s cofferdam configuration. If the Engineer eliminates the seal in its entirety a Contract change order will be issued. Exception: concrete in a separate lump-sum, Superstructure Bid item. Any concrete quantities noted under this item in the Special Provisions will not be measured. Although the Special Provisions list approximate quantities for the Contractor’s convenience, the Contracting Agency does not guarantee the accuracy of these estimates. Before submitting a Bid, the Contractor shall have verified the quantities. Even though actual quantities used may vary from those listed in the Special Provisions, the Contracting Agency will not adjust the lump sum Contract price for Superstructure (except for processed changes). The Contracting Agency will pay for no concrete placed below the established elevation of the bottom of any footing or seal. 2020 Standard Specifications M 41-10 Page 6-135 Concrete Structures 6-02 Lean concrete will be measured by the cubic yard for the quantity of material placed in accordance with the producer’s invoice, except that lean concrete included in other Contract items will not be measured. No deduction will be made for pile heads, reinforcing steel, structural steel, bolts, weep holes, rustications, chamfers, edgers, joint filler, junction boxes, miscellaneous hardware, ducts or less than 6-inch diameter drain pipes when computing concrete quantities for payment. All reinforcing steel will be measured by the computed weight of all steel required by the Plans. The weight of mechanical splices will be based on the weight specified in the manufacturer’s existing catalog cut for the specific item. Splices noted as optional in the plans but installed by the Contractor will be included in the measurement. Epoxy- coated bars will be measured before coating. The Contractor shall furnish (without extra allowance): 1. Bracing, spreaders, form blocks, wire clips, and other fasteners. 2. Extra steel in splices not shown in the Plans or specified in the Plans as optional. 3. Extra shear steel at construction joints not shown in the Plans when the Engineer permits such joints for the Contractor’s convenience. The following table shall be used to compute weight of reinforcing steel: Steel Reinforcing Bar Deformed Bar Designation Number Nominal Diameter inches Unit Weight Pounds per Foot 3 0.375 0.376 4 0.500 0.668 5 0.625 1.043 6 0.750 1.502 7 0.875 2.044 8 1.000 2.670 9 1.128 3.400 10 1.270 4.303 11 1.410 5.313 14 1.690 7.650 18 2.260 13.600 Gravel backfill will be measured as specified in Section 2-09.4. Expansion joint system___seal - superstr. will be measured by the linear foot along its completed line and slope. Expansion joint modification will be measured by the linear foot of expansion joint modified along its completed line and slope. Page 6-136 2020 Standard Specifications M 41-10 6-02 Concrete Structures Prestressed concrete girder will be measured by the linear foot of girder specified in the Proposal. Bridge approach slab will be measured by the square yard. Permeon treatment will be measured by the square yard of concrete surface area receiving the treatment. 6-02.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Conc. Class ____”, per cubic yard. “Commercial Concrete”, per cubic yard. All concrete, except in Superstructure when this is covered by a separate Bid item, will be paid for at the unit Contract price per cubic yard in place for the various classes of concrete. All costs in connection with concrete curing, producing concrete surface finish, and furnishing and applying sealer to concrete surfaces as specified, shall be included in the unit contract price per cubic yard for “Conc. Class ____”. If the concrete is to be paid for other than by class of concrete, then the costs shall be included in the associated item of work. “Superstructure (name bridge)”, lump sum. All costs in connection with constructing, finishing and removing the bridge deck test slab as specified in Section 6-02.3(10)D1 shall be included in the lump sum Contract price for “Superstructure___” or “Bridge Deck___” for one bridge in each project, as applicable. All costs in connection with providing holes for vents, for furnishing and installing cell drainage pipes for box girder Structures, and furnishing and placing grout and shims under steel shoes shall be included in the unit Contract prices for the various Bid items involved. All costs in connection with the construction of weep holes, including the gravel backfill for drains surrounding the weep holes except as provided in Section 2-09.4, shall be included by the Contractor in the unit Contract price per cubic yard for “Conc. Class ____”. “Lean Concrete”, per cubic yard. Lean concrete, except when included in another Bid item, will be paid for at the unit Contract price per cubic yard. “St. Reinf. Bar ____”, per pound. 2020 Standard Specifications M 41-10 Page 6-137 Concrete Structures 6-02 “Epoxy-Coated St. Reinf. Bar ____”, per pound. Payment for reinforcing steel shall include the cost of drilling holes in concrete for, and setting, steel reinforcing bar dowels with epoxy bonding agent, and furnishing, fabricating, placing, and splicing the reinforcement. In Structures of reinforced concrete where there are no structural steel Bid items, such minor metal parts as expansion joints, bearing assemblies, and bolts will be paid for at the unit Contract price for “St. Reinf. Bar ____” unless otherwise specified. “Gravel Backfill for Foundation Class A”, per cubic yard. “Gravel Backfill for Foundation Class B”, per cubic yard. “Gravel Backfill for Wall”, per cubic yard. “Deficient Strength Conc. Price Adjustment”, by calculation. “Deficient Strength Conc. Price Adjustment” shall be calculated and paid for as described in Section 6-02.3(5)L. For the purpose of providing a common Proposal for all Bidders, the Contracting Agency has entered an amount for the item “Deficient Strength Conc. Price Adjustment” in the Bid Proposal to become a part of the total Bid by the Contractor. The item “Deficient Strength Conc. Price Adjustment” covers all applicable classes of concrete. “Expansion Joint System _____ - Superstr.”, per linear foot. “Expansion Joint Modification - ___”, per linear foot. “Prestressed Conc. Girder ___”, per linear foot. “Bridge Approach Slab”, per square yard. The unit Contract price per square yard for “Bridge Approach Slab” shall be full pay for providing, placing, and compacting the crushed surfacing base course, furnishing and placing Class 4000A concrete, and furnishing and installing compression seal, anchors, and reinforcing steel. “Permeon Treatment”, per square yard. The unit contract price per square yard for “Permeon Treatment” shall be full pay for performing the work as specified. Page 6-138 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03 Steel Structures 6-03.1 Description This Work consists of furnishing, fabricating, erecting, cleaning, and painting steel Structures and the structural steel parts of nonsteel Structures 6-03.2 Materials Materials shall meet the requirements of the following sections: Structural Steel and Related Materials 9-06 Paints and Related Materials 9-08 Grout 9-20.3 Structural steel shall be classified as: 1. Structural carbon steel (to be used whenever the Plans do not specify another classification), 2. Structural low alloy steel, and 3. Structural high-strength steel. Unless the Plans or Special Provisions state otherwise, the following shall be classified as structural carbon steel: shims; ladders; stairways; anchor bolts and sleeves; pipe, fittings, and fastenings used in handrails; and other metal parts, even if made of other materials, for which payment is not specified. All AASHTO M270 material used in what the Plans show as main load-carrying tension members or as tension components of flexural members shall meet the Charpy V-notch requirements of AASHTO M270 temperature zone 2. All AASHTO M270 material used in what the Plans show as fracture critical members shall meet the Charpy V-notch requirements of AASHTO M270, Fracture Critical Impact Test Requirements, temperature zone 2. Charpy V-notch requirements for other steel materials shall be as specified in the Plans and Special Provisions. The Contractor shall submit Type 1 Working Drawings describing the methods for visibly marking the material so that it can be traced. These marks shall remain visible at least through the fit-up of the main load-carrying tension members. The marking method shall permit the Engineer to verify: (1) material Specification designation, (2) heat number, and (3) material test reports to meet any special requirements. For steel in main load-carrying tension members and in tension components of flexural members, the Contractor shall include the heat numbers on the reproducible copies of the as-built shop plans. 2020 Standard Specifications M 41-10 Page 6-139 Steel Structures 6-03 6-03.3 Construction Requirements Structural steel fabricators of plate and box girders, floorbeams, truss members, stringers, cross frames, diaphragms, and laterals shall be certified under the AISC Certification Program for Steel Bridge Fabricators, Advanced Bridges Category. When fracture critical members are specified in the Contract, structural steel fabricators shall also meet the supplemental requirements F, Fracture Critical, under the AISC Quality Certification Program for Steel Bridge Fabricators. 6-03.3(1) Vacant 6-03.3(2) Facilities for Inspection The Contractor shall provide all facilities the Inspector requires to inspect material and workmanship. Inspectors shall be given safe and free access to all areas in the mill and shop. 6-03.3(3) Inspector’s Authority The Inspector may reject materials or workmanship that does not comply with these Specifications. In any dispute, the Contractor may appeal to the Engineer whose decision shall be final. By its inspection at the mill and shop, the Contracting Agency intends only to facilitate the Work and prevent errors. This inspection shall not relieve the Contractor of any responsibility for identifying and replacing defective material or workmanship. 6-03.3(4) Rejections Even if the Inspector accepts materials or finished members, the Contracting Agency may later reject them if defective. The Contractor shall promptly replace or make good any rejected materials or workmanship. 6-03.3(5) Mill Orders and Shipping Statements The Contractor shall furnish as many copies of mill orders and shipping statements as the Engineer requires. 6-03.3(6) Weighing Structural steel need not be weighed unless the Plans or Special Provisions require it. When a weight is required, it may either be calculated or obtained by scales. The Contractor shall furnish as many copies of the calculations or weight slips as the Engineer requires. If scale weights are used, the Contractor shall record separately the weights of all tools, erection material, and dunnage. Page 6-140 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(7) Shop Plans The Contractor shall submit all shop detail plans for fabricating the steel as Type 2 Working Drawings. If these plans will be submitted directly from the fabricator, the Contractor shall so notify the Engineer in writing. No material shall be fabricated until: (1) the Working Drawing review is complete, and (2) the Engineer has accepted the materials source. Before physical completion of the project, the Contractor shall furnish the Engineer one set of reproducible copies of the as built shop plans. The reproducible copies shall be clear, suitable for microfilming, and on permanent sheets that measure no smaller than 11 by 17 inches. Alternatively, the shop drawings may be provided in an electronic format with the approval of the Engineer. 6-03.3(7)A Erection Methods Before beginning to erect any steel Structure, the Contractor shall submit Type 2E Working Drawings consisting of the erection plan and procedure describing the methods the Contractor intends to use. The erection plan and procedure shall provide complete details of the erection process including, at a minimum, the following: 1. Temporary falsework support, bracing, guys, deadmen, and attachments to other Structure components or objects; 2. Procedure and sequence of operation; 3. Girder stresses during progressive stages of erection; 4. Girder masses, lift points, and lifting devices, spreaders, glommers, etc.; 5. Crane(s) make and model, mass, geometry, lift capacity, outrigger size and reactions; 6. Girder launcher or trolley details and capacity (if intended for use); and 7. Locations of cranes, barges, trucks delivering girders, and the location of cranes and outriggers relative to other Structures, including retaining walls and wing walls. As part of the erection plan Working Drawings, the Contractor may submit details of an engineered and fabricated lifting bracket bolted to the girder top flanges providing the following requirements are satisfied: 1. The lifting bracket shall be engineered and supporting calculations shall be submitted with the erection plan; 2. The calculations shall include critical stresses in the girder including local stresses in the flanges at lifting bracket locations; 3. The calculations shall include computation of the lifting bracket and associated bolt hole locations and the expected orientation of the girder during picking operation; 2020 Standard Specifications M 41-10 Page 6-141 Steel Structures 6-03 4. The lifting bracket shall be load tested and certified for a load at least 2 times the working load and at all angles it will be used (angle of load or rigging). Certification documentation from a previous project may be submitted; 5. Bolt holes in girders added for the lifting bracket connections shall be shown in the shop plans and shall be drilled in the shop. Field drilling of bolt holes for lifting brackets will not be permitted; 6. Bolt holes in girder top flanges shall be filled with high strength bolts after erection in accordance with Section 6-02.3(17)K. The erection plan shall include drawings, notes, catalog cuts, and calculations clearly showing the above listed details, assumptions, and dimensions. Material properties, Specifications, structural analysis, and any other data used shall also be included. 6-03.3(8) Substitutions The Contractor shall not substitute sections that differ from Plan dimensions unless the Engineer approves in writing. If the Contractor requests and receives approval to substitute heavier members, the Contracting Agency shall not pay any added cost. 6-03.3(9) Handling, Storing, and Shipping of Materials Markings applied at the mill shall distinguish structural low alloy steel from structural carbon steel. The fabricator shall keep the two classes of steel carefully separated. Before fabrication, all material stored at the fabricating plant shall be protected from rust, dirt, oil, and other foreign matter. The Contracting Agency will accept no rust-pitted material. After fabrication, all material awaiting shipment shall be subject to the same storage requirements as unfabricated material. All structural steel shall arrive at the job in good condition. As the Engineer requires, steel damaged by salt water shipment shall be thoroughly cleaned by high pressure water flushing, chemical cleaning, or sandblasting, and repainted with the specified shop coat. All material shall be stored so as to prevent rust and loss of small parts. Piled material shall not rest on the ground or in water but on skids or platforms. The loading, transporting, unloading, and piling of the structural steel material shall be so conducted that the metal will be kept clean and free from injury from rough handling. In field assembly of structural parts, the Contractor shall use methods and equipment not likely to twist, bend, deform, or otherwise injure the metal. Any member slightly bent or twisted shall be corrected before it is placed. The Contracting Agency will reject any member with serious handling damage. Girder sections shall be handled so as to prevent damage to the girders. If necessary, the Contractor shall provide temporary stiffeners to prevent buckling during erection. Page 6-142 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(10) Straightening Bent Material If the Engineer permits in writing, plates, angles, other shapes, and built-up members may be straightened. Straightening methods shall not fracture or injure the metal. Distorted members shall be straightened mechanically. A limited amount of localized heat may be applied only if carefully planned and supervised, and only in accordance with the heat-straightening procedure Working Drawing submittal. Parts to be heat-straightened shall be nearly free from all stress and external forces except those that result from the mechanical pressure used with the heat. After straightening, the Contractor shall inspect the member for fractures using a method proposed by the Contractor and accepted by the Contracting Agency. The Contracting Agency will reject metal showing sharp kinks and bends. The procedure for heat straightening of universal mill (UM) plates by the mill or the fabricator shall be submitted as a Type 2 Working Drawing. 6-03.3(11) Workmanship and Finish Workmanship and finish shall be first-class, equaling the best practice in modern bridge fabrication shops. Welding, shearing, burning, chipping, and grinding shall be done neatly and accurately. All parts of the Work exposed to view shall be neatly finished. Wherever the Plans show a surface finish symbol, the surface shall be machined. 6-03.3(12) Falsework All falsework shall meet the requirements of Section 6-02. 6-03.3(13) Fabricating Tension Members Plates for main load-carrying tension members or tension components of flexural members shall be: 1. Blast cleaned entirely or blast cleaned on all areas within 2 inches of welds to SSPC-SP6, Commercial Blast Cleaning; and 2. Fabricated from plate stock with the primary rolling direction of the stock parallel to the length of the member, or as shown in the Plans. 6-03.3(14) Edge Finishing All rolled, sheared, and thermal cut edges shall be true to line and free of rough corners and projections. Corners along exposed sheared or cut edges shall be broken by light grinding or another method acceptable to the Engineer to achieve an approximate 1/16-inch chamfer or rounding. Sheared edges on plates more than ⅝ inch thick shall be planed, milled, ground, or thermal cut to a depth of at least ⅛ inch. 2020 Standard Specifications M 41-10 Page 6-143 Steel Structures 6-03 Re-entrant corners or cuts shall be filleted to a minimum radius of 1 inch. Exposed edges of main load-carrying tension members or tension components of flexural members shall have a surface roughness no greater than 250-micro inches as defined by the American National Standards Institute, ANSI B46.1, Surface Texture. Exposed edges of other members shall have surface roughness no greater than 1,000-micro inches. The Rockwell hardness of thermal-cut edges of structural low alloy or high-strength steel flanges, as specified in Sections 9-06.2 and 9-06.3, for main load-carrying tension members or tension components of flexural members shall not exceed RHC 30. The fabricator shall prevent excessive hardening of flange edges through preheating, post heating, or control of the burning process as recommended by the steel manufacturer. Hardness testing shall consist of testing thermal-cut edges with a portable hardness tester. The hardness tester, and its operating test procedures, shall be submitted as a Type 1 Working Drawing. The hardness tester shall be convertible to Rockwell C scale values. At two locations, two tests shall be performed on each thermal-cut edge, one each within ¼ inch of the top and bottom surfaces. The tests shall be located ¼ the length of each thermal-cut edge from each end of the cut. If one or more readings are greater than RHC 30, the entire length of the edge shall be ground or machined to a depth sufficient to provide acceptable readings upon further retests. If thermal-cutting operations conform to procedures established by the steel manufacturer, and hardness testing results are consistently within acceptable limits, the Engineer may authorize a reduction in the testing frequency. 6-03.3(15) Planing of Bearing Surfaces Ends of columns that bear on base and cap plates shall be milled to true surfaces and accurate bevels. When assembled, caps and base plates of columns and the sole plates of girders and trusses shall have a fit tolerance within 1/32 inch for 75 percent of the contact area. If warped or deformed, the plates shall be heat straightened, planed, or corrected in some other way to produce accurate, even contact. If necessary for proper contact, bearing surfaces that will contact other metal surfaces shall be planed or milled. Surfaces of warped or deformed base and sole plates that will contact masonry shall be rough finished. On the surface of expansion bearings, the cut of the planer shall be in the direction of expansion. Where mill to bear is specified in the Plans, the bearing end of the stiffener shall be flush and square with the flange and shall have at least 75 percent of this area in contact with the flange. Page 6-144 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(16) Abutting Joints Abutting ends of compression members shall be faced accurately so that they bear evenly when in the Structure. On built-up members, the ends shall be faced or milled after fabrication. Ends of tension members at splices shall be rough finished to produce neat, close joints. A contact fit is not required. 6-03.3(17) End Connection Angles On floorbeams and stringers, end connection angles shall be flush with each other and set accurately in relationship to the position and length of the member. Unless the Plans require it, end connection angles shall not be finished. If, however, faulty assembly requires them to be milled, milling shall not reduce thickness by more than ¹/16 inch. 6-03.3(18) Built Members The various pieces forming one built member shall be straight and close fitting, true to detailed dimensions, and free from twists, bends, open joints, or other defects. When fabricating curved girders, localized heat or the use of mechanical force shall not be used to bend the girder flanges about an axis parallel to girder webs. 6-03.3(19) Hand Holes Hand holes, whether punched or cut with burning torches, shall be true to sizes and shapes shown in the Plans. Edges shall be true to line and ground smooth. 6-03.3(20) Lacing Bars Unless the Plans state otherwise, ends of lacing bars shall be neatly rounded. 6-03.3(21) Plate Girders 6-03.3(21)A Web Plates If web plates are spliced, gaps between plate ends shall be set at shop assembly to measure ¼ inch, and shall not exceed ⅜ inch. 6-03.3(21)B Vacant 6-03.3(21)C Web Splices and Fillers Web splice plates and fillers under stiffeners shall fit within ⅛ inch at each end. In lieu of the steel material specified in the Plans or Special Provisions, the Contractor may substitute ASTM A1008 or ASTM A1011 steel for all filler plates less than ¼ inch thickness, provided that the grade of filler plate steel meets or exceeds that of the splice plates. 2020 Standard Specifications M 41-10 Page 6-145 Steel Structures 6-03 6-03.3(22) Eyebars Eyebars shall be straight, true to size, and free from twists or folds in the neck or head and from any other defect that would reduce their strength. Heads shall be formed by upsetting, rolling, or forging. Dies in use by the manufacturer may determine the shape of bar heads if the Engineer approves. Head and neck thickness shall not overrun by more than ¹/16 inch. Welds shall not be made in the body or head of any bar. Each eyebar shall be properly annealed and carefully straightened before it is bored. Pinholes shall be located on the centerline of each bar and in the center of its head. Holes in bar ends shall be so precisely located that in a pile of bars for the same truss panel the pins may be inserted completely without driving. All eyebars made for the same locations in trusses shall be interchangeable. 6-03.3(23) Annealing All eyebars shall be annealed by being heated uniformly to the proper temperature, then cooled slowly and evenly in the furnace. At all stages, the temperature of the bars shall be under full control. Slight bends on secondary steel members may be made without heat. Crimped web stiffeners need no annealing. 6-03.3(24) Pins and Rollers Pins and rollers shall be made of the class of forged steel the Plans specify. They shall be turned accurately to detailed dimensions, smooth, straight, and flawless. The final surface shall be produced by a finishing cut. Pins and rollers 9 inches or less in diameter may either be forged and annealed or made of cold-finished carbon steel shafting. Pins more than 9 inches in diameter shall have holes at least 2 inches in diameter bored longitudinally through their centers. Pins with inner defects will be rejected. The Contractor shall provide pilot and driving nuts for each size of pin unless the Plans state otherwise. 6-03.3(24)A Boring Pin Holes Pin holes shall be bored true to detailed dimensions, smooth and straight, and at right angles to the axis of the member. Holes shall be parallel with each other unless the Plans state otherwise. A finishing cut shall always be made. The distance between holes shall not vary from detailed dimensions by more than 1/32 inch. In tension members, this distance shall be measured from outside to outside of holes; in compression members, inside to inside. Page 6-146 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(24)B Pin Clearances Each pin shall be 1/50 inch smaller in diameter than its hole. All pins shall be numbered after being fitted into their holes in the assembled member. 6-03.3(25) Welding and Repair Welding Welding and repair welding of all steel bridges shall comply with the AASHTO/AWS D1.5M/D1.5, latest edition, Bridge Welding Code. Welding and repair welding for all other steel fabrication shall comply with the AWS D1.1/D1.1M, latest edition, Structural Welding Code. The requirements described in the remainder of this section shall prevail whenever they differ from either of the above welding codes. The Contractor shall weld structural steel only to the extent shown in the Plans. No welding, including tack and temporary welds shall be done in the shop or field unless the location of the welds is shown on the approved shop drawings reviewed and accepted by the Engineer. Welding procedures shall accompany the shop drawing Working Drawing submittal. The procedures shall specify the type of equipment to be used, electrode selection, preheat requirements, base materials, and joint details. When the procedures are not prequalified by AWS or AASHTO, evidence of qualification tests shall be submitted. Welding shall not begin until completion of the shop plan Working Drawing review as required in Section 6-03.3(7). These plans shall include procedures for welding, assembly, and any heat-straightening or heat-curving. Any welded shear connector longer than 8 inches may be made of two shorter shear connectors joined with full-penetration welds. In shielded metal-arc welding, the Contractor shall use low-hydrogen electrodes. In submerged-arc welding, flux shall be oven-dried at 550ºF for at least 2 hours, then stored in ovens held at 250ºF or more. If not used within 4 hours after removal from a drying or storage oven, flux shall be redried before use. Preheat and interpass temperatures shall conform to the applicable welding code as specified in this section. When welding main members of steel bridges, the minimum preheat shall not be less than 100ºF. If groove welds (web-to-web or flange-to-flange) have been rejected, they may be repaired no more than twice. If a third failure occurs, the Contractor shall: 1. Trim the members, if the Engineer concurs, at least ½ inch on each side of the weld; or 2. Replace the members at no expense to the Contracting Agency. By using extension bars and runoff plates, the Contractor shall terminate groove welds in a way that ensures the soundness of each weld to its ends. The bars and plates shall be removed after the weld is finished and cooled. The weld ends shall then be ground smooth and flush with the edges of abutting parts. 2020 Standard Specifications M 41-10 Page 6-147 Steel Structures 6-03 The Contractor shall not: 1. Weld with electrogas or electroslag methods, 2. Weld nor flame cut when the ambient temperature is below 20ºF, or 3. Use coped holes in the web for welding butt splices in the flanges unless the Plans show them. 6-03.3(25)A Welding Inspection The Contractor’s inspection procedures, techniques, methods, acceptance criteria, and inspector qualifications for welding of steel bridges shall be in accordance with the AASHTO/AWS D1.5M/D1.5: 2010 Bridge Welding Code. The Contractor’s inspection procedures, techniques, methods, acceptance criteria, and inspector qualifications for welding of steel Structures other than steel bridges shall be in accordance with AWS D1.1/D1.1M, latest edition, Structural Welding Code. The requirements described in the remainder of this section shall prevail whenever they differ from either of the above welding codes. Nondestructive testing in addition to visual inspection shall be performed by the Contractor. Unless otherwise shown in the Plans or specified in the Special Provisions, the extent of inspection shall be as specified in this section. Testing and inspection shall apply to welding performed in the shop and in the field. After the Contractor’s welding inspection is complete, the Contractor shall allow the Engineer sufficient time to perform quality assurance ultrasonic welding inspection. 6-03.3(25)A1 Visual Inspection All welds shall be 100 percent visually inspected. Visual inspection shall be performed before, during, and after the completion of welding. 6-03.3(25)A2 Radiographic Inspection Complete penetration tension groove welds in Highway bridges shall be 100 percent radiographically inspected. These welds include those in the tension area of webs, where inspection shall cover the greater of these two distances: (a) 15 inches from the tension flange, or (b) ⅓ of the web depth. In addition, edge blocks conforming to the requirements of AASHTO/AWS D1.5M/D1.5: 2010 Bridge Welding Code Section 6.10.14 shall be used for radiographic inspection. The Contractor shall maintain the radiographs and the radiographic inspection report in the shop until the last joint to be radiographed in that member is accepted by the radiographer representing the Contractor. Within 2 working days following this acceptance, the Contractor shall mail the film and two copies of the radiographic inspection report to the Materials Engineer, Department of Transportation, PO Box 47365, Olympia, WA 98504-7365. Page 6-148 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(25)A3 Ultrasonic Inspection Complete penetration groove welds on plates 5/16 inch and thicker in the following welded assemblies or Structures shall be 100 percent ultrasonically inspected: 1. Welded connections and splices in Highway bridges and earth retaining Structures, excluding longitudinal butt joint welds in beam or girder webs. 2. Bridge bearings and modular expansion joints. 3. Sign bridges, cantilever sign Structures, and bridge mounted sign brackets excluding longitudinal butt joint welds in beams. 4. Light, signal, and strain pole standards, as defined in Section 9-29.6. A minimum of 30 percent of complete penetration vertical welds on steel column jackets thicker than 5/16-inch, within 1.50 column jacket diameter of the top and bottom of each column, shall be inspected. If any rejectable flaws are found, 100 percent of the weld within the specified limits shall be inspected. The largest column cross section diameter for tapered column jackets shall constitute one column jacket diameter. The testing procedure and acceptance criteria for tubular members shall conform to the requirements of the AWS D1.1/D1.1M latest edition, Structural Welding Code. 6-03.3(25)A4 Magnetic Particle Inspection 1. Fillet and partial penetration groove welds: At least 30 percent of each size and type of fillet welds (excluding intermittent fillet welds) and partial penetration groove welds in the following welded assemblies or Structures shall be tested by the magnetic particle method: a. Flange-to-web connections in Highway bridges. b. End and intermediate pier diaphragms in Highway bridges. c. Stiffeners and connection plates in Highway bridges. d. Welded connections and splices in earth retaining Structures. e. Boxed members of trusses. f. Bridge bearings and modular expansion joints. g. Sign bridges, cantilever sign Structures, and bridge mounted sign brackets. h. Light, signal, and strain pole standards, as defined in Section 9-29.6. 2. Longitudinal butt joint welds in beam and girder webs: At least 30 percent of each longitudinal butt joint weld in the beam and girder webs shall be tested by the magnetic particle method. 3. Complete penetration groove welds on plates 5/16 inch or thinner (excluding steel column jackets) shall be 100 percent tested by the magnetic particle method. Testing shall apply to both sides of the weld, if backing plate is not used. The ends of each complete penetration groove weld at plate edges shall be tested by the magnetic particle method. 2020 Standard Specifications M 41-10 Page 6-149 Steel Structures 6-03 4. A minimum of 30 percent of complete penetration vertical welds on steel column jackets 5/16 inch or thinner, within 1.50 column jacket diameters of the top and bottom of each column, shall be magnetic particle inspected. The largest column cross section diameter for tapered column jackets shall constitute one column jacket diameter. Where 100 percent testing is not required, the Engineer reserves the right to select the location(s) for testing. If rejectable flaws are found in any test length of weld in item 1 or 2 above, the full length of the weld or 5 feet on each side of the test length, whichever is less, shall be tested. If any rejectable flaws are found in any test length of item 4 above, 100 percent of the weld within the specified limits shall be inspected. 6-03.3(26) Screw Threads Screw threads shall be U.S. Standard and shall fit closely in the nuts. 6-03.3(27) High-Strength Bolt Holes At the Contractor’s option under the conditions described in this section, holes may be punched or subpunched and reamed, drilled or subdrilled and reamed, or formed by numerically controlled drilling operations. The hole for each high-strength bolt shall be ¹/16 inch larger than the nominal diameter of the bolt. In fabricating any connection, the Contractor may subdrill or subpunch the holes then ream full size after assembly or drill holes full size from the solid with all thicknesses of material shop assembled in the proper position. If the Contractor chooses not to use either of these methods, then the following shall apply: 1. Drill bolt holes in steel splice plates full size using steel templates. 2. Drill bolt holes in the main members of trusses, arches, continuous beam spans, bents, towers, plate girders, box girders, and rigid frames at all connections as follows: a. A minimum of 30 percent of the holes in one side of the connection shall be made full size using steel templates. b. A minimum of 30 percent of the holes in the second side shall be made full size assembled in the shop. c. All remaining holes may be made full size in unassembled members using steel templates. 3. Drill bolt holes in crossframes, gussets, lateral braces, and other secondary members full size using steel templates. The Contractor shall submit Type 2 Working Drawings consisting of a detailed outline of the procedures proposed to accomplish the Work from initial drilling through shop assembly. Page 6-150 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(27)A Punched Holes For punched holes, die diameter shall not exceed punch diameter by more than ¹/16 inch. Any hole requiring enlargement to admit the bolt shall be reamed. All holes shall be cut clean with no torn or ragged edges. The Contracting Agency will reject components having poorly matched holes. 6-03.3(27)B Reamed and Drilled Holes Reaming and drilling shall be done with short taper reamers or twist drills, producing cylindrical holes perpendicular to the member. Reamers and drills shall be directed mechanically, not hand-held. Connecting parts that require reamed or drilled holes shall be assembled and held securely as the holes are formed, then match-marked before disassembly. The Contractor shall provide the Engineer a diagram showing these match- marks. The Contracting Agency will reject components having poorly matched holes. Burrs on outside surfaces shall be removed. If the Engineer requires, the Contractor shall disassemble parts to remove burrs. If templates are used to ream or drill full-size connection holes, the templates shall be positioned and angled with extreme care and bolted firmly in place. Templates for reaming or drilling matching members or the opposite faces of one member shall be duplicates. All splice components shall be match-marked unless otherwise approved by the Engineer. 6-03.3(27)C Numerically Controlled Drilled Connections In forming any hole described in Section 6-03.3(27), the fabricator may use numerically controlled (N/C) drilling or punching equipment if it meets the requirements in this Subsection. The Contractor shall submit Type 1 Working Drawings consisting of a detailed outline of proposed N/C procedures. This outline shall: 1. Cover all steps from initial drilling or punching through check assembly; 2. Include the specific members of the Structure to be drilled or punched, hole sizes, locations of the common index and other reference points, makeup of check assemblies, and all other information needed to describe the process fully. N/C holes may be drilled or punched to size through individual pieces, or may be drilled through any combination of tightly clamped pieces. When the Engineer requires, the Contractor shall demonstrate that the N/C procedure consistently produces holes and connections meeting the requirements of these Specifications. 2020 Standard Specifications M 41-10 Page 6-151 Steel Structures 6-03 6-03.3(27)D Accuracy of Punched, Subpunched, and Subdrilled Holes After shop assembly and before reaming, all punched, subpunched, and subdrilled holes shall meet the following standard of accuracy. At least 75 percent of the holes in each connection shall permit the passage of a cylindrical pin ⅛ inch smaller in diameter than nominal hole size. This pin shall pass through at right angles to the face of the member without drifting. All holes shall permit passage of a pin ³/16 inch smaller in diameter than nominal hole size. The Contracting Agency will reject any pieces that fail to meet these standards. 6-03.3(27)E Accuracy of Reamed and Drilled Holes At least 85 percent of all holes in a connection of reamed or drilled holes shall show no offset greater than ¹/32 inch between adjacent thicknesses of metal. No hole shall have an offset greater than ¹/16 inch. Centerlines from the connection shall be inscribed on the template and holes shall be located from these centerlines. Centerlines shall also be used for accurately locating the template relative to the milled or scribed ends of the members. Templates shall have hardened steel bushing inserted into each hole. These bushings may be omitted, however, if the fabricator satisfies the Engineer (1) that the template will be used no more than five times, and (2) that use will produce no template wear. Each template shall be at least ½ inch thick. If necessary, thicker templates shall be used to prevent buckling and misalignment as holes are formed. 6-03.3(27)F Fitting for Bolting Before drilling, reaming, and bolting begins, all parts of a member shall be assembled, well pinned, and drawn firmly together. If necessary, assembled pieces shall be taken apart to permit removal of any burrs or shavings produced as the holes are formed. The member shall be free from twists, bends, and other deformation. In shop-bolted connections, contacting metal surfaces shall be sandblasted clean before assembly. Sandblasting shall meet the requirements of the SSPC Specifications for Commercial Blast Cleaning (SSPC-SP 6). Any drifting done during assembly shall be no more than enough to bring the parts into place. Drifting shall not enlarge the holes or distort the metal. 6-03.3(28) Shop Assembly 6-03.3(28)A Method of Shop Assembly Unless the Contract states otherwise, the Contractor shall choose one of the five shop assembly methods described below that will best fit the proposed erection method. The Contractor shall obtain the Engineer’s approval of both the shop assembly and the erection methods before Work begins. 1. Full Truss or Girder Assembly – Each truss or girder is completely assembled over the full length of the Superstructure. Page 6-152 2020 Standard Specifications M 41-10 6-03 Steel Structures 2. Progressive Truss or Girder Assembly – Each truss or girder is assembled in stages longitudinally over the full length of the Superstructure. a. For Trusses – The first stage shall include at least three adjacent truss panels. Each truss panel shall include all of the truss members in the space bounded by the top and bottom chords and the horizontal distance between adjacent bottom chord Joints. b. For Girders – The first stage shall include at least three adjacent girder shop sections. Shop sections are measured from the end of the girder to the first field splice or from field splice to field splice. c. For Trusses and Girders – After the first stage has been completed, each subsequent stage shall be assembled to include: at least one truss panel or girder shop section of the previous stage and two or more truss panels or girder shop sections added at the advancing end. The previous stages shall be repositioned if necessary, and pinned to ensure accurate alignment. For straight sections of bridges without skews or tapers, girders in each subsequent stage may be assembled to include one girder shop section from the previous stage and one or more girder shop sections at the advancing end. If the bridge is longer than 150 feet, each longitudinal stage shall be at least 150 feet long, regardless of the length of individual continuous truss panels or girder shop sections. The Contractor may begin the assembly sequence at any point on the bridge and proceed in either or both directions from that point. Unless the Engineer approves otherwise, no assembly shall have less than three truss panels or girder shop sections. 3. Full Chord Assembly – The full length of each chord for each truss is assembled with geometric angles at the joints. Chord connection bolt holes are drilled/reamed while members are assembled. The truss web member connections are drilled/reamed to steel templates set by relating geometric angles to the chord lines. At least one end of each web member shall be milled or scribed at right angles to its long axis. The templates at both ends of the member shall be positioned accurately from the milled end or scribed line. 4. Progressive Chord Assembly – Adjacent chord sections are assembled in the same way as specified for Full Chord Assembly, using the procedure specified for Progressive Truss or Girder Assembly. 5. Special Complete Structure Assembly – All structural steel members (Superstructure and Substructure, including all secondary members) are assembled at one time. 6-03.3(28)B Check of Shop Assembly The Contractor shall check each assembly for alignment, accuracy of holes, fit of milled joints, and other assembly techniques. Drilling or reaming shall not begin until the Engineer has given approval. If the Contractor uses N/C drilling, this approval must be obtained before the assembly or stage is dismantled. 2020 Standard Specifications M 41-10 Page 6-153 Steel Structures 6-03 6-03.3(29) Welded Shear Connectors Installation, production control, and inspection of welded shear connectors shall conform to Chapter 7 of the AASHTO/AWS D1.5M/D1.5:2010 Bridge Welding Code. If welded shear connectors are installed in the shop, installation shall be completed prior to applying the shop primer coat in accordance with Section 6-07.3(9)G. If welded shear connectors are installed in the field, the steel surface to be welded shall be prepared to SSPC-SP 11, power tool cleaning, just prior to welding. 6-03.3(30) Painting All painting shall be in accordance with Section 6-07. 6-03.3(30)A Vacant 6-03.3(30)B Vacant 6-03.3(30)C Erection Marks Erection marks to permit identification of members in the field shall be painted on previously painted surfaces. 6-03.3(30)D Machine Finished Surfaces As soon as possible and before they leave the shop, machine-finished surfaces on abutting chord splices, column splices, and column bases shall be covered with grease. After erection, the steel shall be cleaned and painted as specified. All surfaces of iron and steel castings milled to smooth the surface shall be painted with the primer called for in the specified paint system. While still in the shop, machine-finished surfaces and inaccessible surfaces of rocker or pin-type bearings shall receive the full paint system. Surfaces of pins and holes machine- finished to specific tolerances shall not be painted. But as soon as possible and before they leave the shop, they shall be coated with grease. 6-03.3(31) Alignment and Camber Before beginning field bolting, the Contractor shall: 1. Adjust the Structure to correct grade and alignment, 2. Regulate elevations of panel points (ends of floorbeams), and 3. Delay bolting at compression joints until adjusting the blocking to provide full and even bearing over the whole joint. On truss spans, a slight excess camber will be permitted as the bottom chords are bolted. But camber and relative elevations of panel points shall be correct before the top chord joints, top lateral system, and sway braces are bolted. Page 6-154 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(31)A Measuring Camber The Contractor shall provide the Engineer with a diagram for each truss that shows camber at each panel point. This diagram shall display actual measurements taken as the truss is being assembled. 6-03.3(32) Assembling and Bolting To begin bolting any field connection or splice, the Contractor shall install and tighten to snug tight enough bolts to bring all parts into full contact with each other prior to tightening these bolts to the specified minimum tension. “Snug tight” means either the tightness reached by (l) a few blows from an impact wrench or (2) the full effort of a person using a spud wrench. As erection proceeds, all field connections and splices for each member shall be securely drift pinned and bolted in accordance with 1 or 2 below before the weight of the member can be released or the next member is added. Field erection drawings shall specify pinning and bolting requirements that meet or exceed the following minimums: 1. Joints in Normal Structures – Fifty percent of the holes in a single field connection and 50 percent of the holes on each side of a single joint in a splice plate shall be filled with drift pins and bolts. Thirty percent of the filled holes shall be pinned. Seventy percent of the filled holes shall be bolted and tightened to snug tight. Once all these bolts are snug tight, each bolt shall be systematically tightened to the specified minimum tension. “Systematically tightened” means beginning with bolts in the most rigid part, which is usually the center of the joint, and working out to its free edges. The fully tensioned bolts shall be located near the middle of a single field connection or a single splice plate. 2. Joints in Cantilevered Structures – Seventy-five percent of the holes in a single field connection and 75 percent of the holes on each side of a single joint in a splice plate shall be filled with drift pins and bolts. Fifty percent of the filled holes shall be pinned. Fifty percent of the filled holes shall be bolted and tightened to snug tight. Once all these bolts are snug tight, each bolt shall be systematically tightened to the specified minimum tension. The fully tensioned bolts shall be located near the middle of a single field connection or a single splice plate. Cylindrical erection pins (drift pins) shall be placed throughout each field connection and each field joint with the greatest concentration in the outer edges of a splice plate or member being bolted. Drift pins shall be double-tapered barrel pins of hardened steel. The diameter of the drift pins shall be at least 1/32 inch larger than the diameter of the bolts in the connection or the full hole diameter. To complete a joint following one of the methods listed above, the Contractor shall fill all remaining holes of the field connection or splice plate with bolts and tighten to snug tight. Once all of these bolts are snug tight, each bolt shall be systematically tightened to the specified minimum tension. After these bolts are tightened to the specified minimum tension, the Contractor shall replace the drift pins with bolts tightened to the specified minimum tension. 2020 Standard Specifications M 41-10 Page 6-155 Steel Structures 6-03 The Contractor shall complete the joint or connection within ten calendar days of installing the first bolt or within a duration approved by the Engineer. Any bolts inserted in an incomplete connection, either loose or tightened snug-tight, which exceed the specified duration for completing the connection, shall be subject to the following requirements: 1. Three assemblies for each size and length shall be removed from connection(s) that are to be tensioned. Rotational capacity tests shall be performed on the removed assemblies to demonstrate the assembly has sufficient lubricant to be tensioned satisfactorily. 2. Five assemblies shall be removed from the connection to establish the inspection torque. 3. In the case of tension controlled bolts, three assemblies shall be removed and tested in accordance with Section 6-03.3(33)A to verify the minimum specified tension can be achieved prior to shearing of the spline. Assemblies removed for the purpose of rotational capacity testing, determination of the inspection torques, or verification of tension controlled bolt performance shall be replaced with new bolts at no additional expense to the Contracting Agency. To minimize the number of removed assemblies, the Contractor may combine rotational capacity testing and inspection torque determination as approved by the Engineer. The Contractor may complete a field bolted connection or splice in a continuous operation before releasing the mass of the member or adding the next member. The Contractor shall utilize drift pins to align the connection. The alignment drift pins shall fill between 15 and 30 percent of the holes in a single field connection and between 15 and 30 percent of the holes on each side of a single joint in a splice plate. Once the alignment drift pins are in place, all remaining holes shall be filled with bolts and tightened to snug tight starting from near the middle and proceeding toward the outer gage lines. Once all of these bolts are snug tight, the Contractor shall systematically tighten all these bolts to the specified minimum tension. The Contractor shall then replace the drift pins with bolts. Each of these bolts shall be tightened to the specified minimum tension. All bolts shall be placed with heads toward the outside and underside of the bridge. All high-strength bolts shall be installed and tightened before the falsework is removed. The Contractor may erect metal railings as erection proceeds. But railings shall not be bolted or adjusted permanently until the falsework is released and the deck placed. The Contractor shall not begin painting until the Engineer has inspected and accepted field bolting. 6-03.3(33) Bolted Connections Fastener components shall consist of bolts, nuts, washers, tension control bolt assemblies, and direct tension indicators. Fastener components shall meet the requirements of Section 9-06.5(3). After final tightening of the fastener components, the threads of the bolts shall at a minimum be flush with the end of the nut. Page 6-156 2020 Standard Specifications M 41-10 6-03 Steel Structures The Contractor shall submit Type 1 Working Drawings providing documentation of the bolt tension calibrator, including brand, capacity, model, date of last calibration, and manufacturer’s instructions for use. The Contractor shall supply the bolt tension calibrator and all accompanying hardware and calibrated torque wrenches to conduct all testing and inspections described herein. Use of the bolt tension calibrator shall comply with manufacturer’s recommendations. Fastener components shall be protected from dirt and moisture in closed containers at the site of installation. Only as many fastener components as are anticipated to be installed during the Work shift shall be taken from protected storage. Fastener components that are not incorporated into the Work shall be returned to protected storage at the end of the Work shift. Fastener components shall not be cleaned or modified from the as-delivered condition. Fastener components that accumulate rust or dirt shall not be incorporated into the Work. Tension control bolt assemblies shall not be relubricated, except by the manufacturer. All bolted connections are slip critical. Painted structures require either Type 1 or Type 3 bolts. Bolts shall not be galvanized unless specified in the Contract documents. When galvanized bolts are specified, tension-control galvanized bolts are not permitted. Unpainted structures require Type 3 bolts. ASTM F3125 Grade A490 bolts shall not be galvanized and shall not be used in contact with galvanized metal. Washers are required under turned elements for bolted connections and as required in the following: 1. Washers shall be used under both the head and the nut when ASTM F3125 Grade A490 bolts are to be installed in structural carbon steel, as specified in Section 9-06.1. 2. Where the outer face of the bolted parts has a slope greater than 1:20 with respect to a plane normal to the bolt axis, a beveled washer shall be used. 3. Washers shall not be stacked unless otherwise specified by the Engineer. 4. It is acceptable to place a washer under the unturned element. All galvanized nuts shall be lubricated by the manufacturer with a lubricant containing a visible dye so a visual check for the lubricant can be made at the time of field installation. Black bolts shall be lubricated by the manufacturer and shall be “oily” to the touch when installed. After assembly, bolted parts shall fit solidly together. They shall not be separated by washers, gaskets, or any other material. Assembled joint surfaces, including those next to bolt heads, nuts, and washers, shall be free of loose mill scale, burrs, dirt, and other foreign material that would prevent solid seating. 2020 Standard Specifications M 41-10 Page 6-157 Steel Structures 6-03 When all bolts in a joint are tight, each bolt shall carry at least the proof load shown in Table 1 below: Table 1 Minimum Bolt Tension Bolt Size (inches) ASTM F3125 Grade A325 and Grade F1852 (pounds) ASTM F3125 Grade A490 (pounds) ½12,050 14,900 ⅝19,200 23,700 ¾28,400 35,100 ⅞39,250 48,500 1 51,500 63,600 1⅛56,450 80,100 1¼71,700 101,800 1⅜85,450 121,300 1½104,000 147,500 Prior to final tightening of any bolts in a bolted connection, the connection shall be compacted to a snug tight condition. Snug tight shall include bringing all plies of the connection into firm contact and snug tightening all bolts in accordance with Section 6-03.3(32). Final tightening may be done by the Turn-of-Nut Method, the direct-tension indicator method, or the twist off-type tension control structural bolt/nut/washer assembly method. Preferably, the nut shall be turned tight while the bolt is prevented from rotating. However, if required by either turn-of-nut or direct-tension-indicator methods because of bolt entering and/or wrench operational clearances, tightening may be done by turning the bolt while the nut is prevented from rotating. 1. Turn-of-Nut Method – After all specified bolting conditions are satisfied, and before final tightening, the Contractor shall match-mark with crayon or paint the outer face of each nut and the protruding part of the bolt. Each bolt shall be final tightened to the specified minimum tension by rotating the amount specified in Table 2. To ensure this tightening method is followed, the Engineer will (1) observe as the Contractor installs, snug tightens, and final tightens all bolts and (2) inspect each match-mark. Table 2 Turn-of-Nut Tightening Method Nut Rotational From Snug Tight Condition Bolt Length Disposition of Outer Faces of Bolted Parts Condition 1 Condition 2 Condition 3 L <= 4D ⅓-turn ½-turn ⅔-turn 4D < L<= 8D ½-turn ⅔-turn 5⁄6-turn 8D < L<= 12D ⅔-turn 5⁄6-turn 1-turn Bolt length measured from underside of head to top of nut. Condition 1 – Both faces at right angles to bolt axis. Page 6-158 2020 Standard Specifications M 41-10 6-03 Steel Structures Condition 2 – One face at right angle to bolt axis, one face sloped no more than 1:20, without bevel washer. Condition 3 – Both faces sloped no more than 1:20 from right angle to bolt axis, without bevel washer. Nut rotation is relative to the bolt regardless of which element (nut or bolt) is being turned. Tolerances permitted plus or minus 30 degrees (1/12-turn) for final turns of ½-turn or less; plus or minus 45 degrees (⅛-turn) for final turns of ⅔-turn or more. D = nominal bolt diameter of bolt being tightened. When bolt length exceeds 12D, the rotation shall be determined by actual tests in which a suitable tension device simulates actual conditions. 2. Direct Tension Indicator Method (DTIs) – Shall not be used under the turned element. DTIs shall be placed under the bolt head with the protrusions facing the bolt head when the nut is turned. DTIs shall be placed under the nut with the protrusions facing the nut when the bolt is turned. Gap refusal shall be measured with a 0.005 inch tapered feeler gage. After all specified bolting conditions are satisfied, the snug tightened gaps shall meet Table 3 snug tight limits. Each bolt shall be final-tightened to meet Table 3 final-tighten limits. If the bolt is tensioned so that no visible gap in any space remains, the bolt and DTI shall be removed and replaced by a new properly tensioned bolt and DTI. The Contractor shall tension all bolts, inspecting all DTIs with a feeler gage, in the presence of the Engineer. DTIs shall be installed by two-person (or more) crews, with one individual (1) preventing the element at the DTI from turning and (2) measuring the gap of the DTI to determine the proper tension of the bolt. If a bolt, that has had its DTI brought to full load, loosens during the course of bolting the connection, it shall be rejected. Reuse of the bolt and nut are subject to the provisions of this section. The used DTI shall not be reinstalled. Table 3 Direct Tension Indicator Requirements Bolt Size (inches) DTI Spaces Maximum Snug Tight Refusals Minimum Final Tighten Refusals ASTM F3125 Grade A 325 ASTM F3125 Grade A490 ASTM F3125 Grade A 325 ASTM F3125 Grade A490 ASTM F3125 Grade A 325 ASTM F3125 Grade A490 ½4 5 1 2 2 3 ⅝4 5 1 2 2 3 ¾5 6 2 2 3 3 ⅞5 6 2 2 3 3 1 6 7 2 3 3 4 1⅛6 7 2 3 3 4 1¼7 8 3 3 4 4 1⅜7 8 3 3 4 4 1½8 9 3 4 4 5 2020 Standard Specifications M 41-10 Page 6-159 Steel Structures 6-03 3. Twist Off-Type Tension Control Structural Bolt/Nut/Washer Assembly Method (Tension Control Bolt Assembly) – Tension control bolt assemblies shall include the bolt, nut, and washer(s) packaged and shipped as a single assembly. Unless otherwise accepted by the Engineer, tension control bolt assembly components shall not be interchanged for testing or installation and shall comply with all provisions of ASTM F3125 Grade F1852. If accepted by the Engineer, the tension control bolt assembly components may be interchanged within the same component lot for girder web slices or other locations where access to both sides of the connection is restricted. The tension control bolts shall incorporate a design feature intended to either indirectly indicate, or to automatically provide, the minimum tension specified in Table 1. The Contractor shall submit Type 1 Working Drawings of the tension control bolt assembly, including bolt capacities; type of bolt, nut, and washer lubricant; method of packaging and protection of the lubricated bolt; installation equipment; calibration equipment; and installation procedures. The tension control bolt manufacturer’s installation procedure shall be followed for installation of bolts in the verification testing device, in all calibration devices, and in all structure connections. In some cases, proper tensioning of the bolts may require more than one cycle of systematic partial tightening prior to final yield or fracture of the tension control element of each bolt. If yield or fracture of the tension control element of a bolt occurs prior to the final tightening cycle, that bolt shall be replaced with a new one. Additional field verification testing shall be performed as requested by the Engineer. All bolts and connecting hardware shall be stored and handled in a manner to prevent corrosion and loss of lubricant. Bolts that are installed without the same lubricant coating as tested under the verification test will be rejected, and they shall be removed from the joint and be replaced with new lubricated bolts at no additional cost to the Contracting Agency. ASTM F3125 Grade A490 bolts, galvanized ASTM F3125 Grade A325 bolts, and ASTM F3125 Grade F1852 tension control bolt assemblies shall not be reused. Black ASTM F3125 Grade A325 bolts may be reused once if accepted by the Engineer. All bolts to be reused shall have their threads inspected for distortion by reinstalling the used nut on the bolt and turning the nut for the full length of the bolt threads by hand. Bolts to be reused shall be relubricated in accordance with the manufacturer’s recommendation. Used bolts shall be subject to a rotational capacity test as specified in Section 6-03.3(33)A Pre- Erection Testing. Touching up or retightening bolts previously tightened by the Turn-of- Nut Method, which may have been loosened by the tightening of adjacent bolts shall not be considered as reuse, provided the snugging up continues from the initial position and does not require greater rotation, including the tolerance, than that required by Table 2. Page 6-160 2020 Standard Specifications M 41-10 6-03 Steel Structures 6-03.3(33)A Pre-Erection Testing High-strength bolt assemblies (bolt, nut, direct tension indicator, and washer), both black and galvanized, shall be subjected to a field rotational capacity test, as outlined below, prior to any permanent fastener installation. For field installations, the rotational capacity test shall be conducted at the jobsite. Each combination of bolt production lot, nut production lot, washer production lot, and direct tension indicator production lot shall be tested as an assembly, except tension control bolt assemblies, which shall be tested as supplied by the manufacturer. Each rotational capacity test shall include three assemblies. Once an assembly passes the rotational capacity test, it is accepted for use for the remainder of the project unless the Engineer deems further testing is necessary. All tests shall be performed in a bolt tension calibrator by the Contractor in the presence of the Engineer. High-strength bolt assemblies used in this test shall not be reused. The bolt assemblies shall meet the following requirements after being pretensioned to 15 percent of the minimum bolt tension in Table 1. The assembly shall be considered as nonconforming if the assembly fails to pass any one of the following specified requirements: 1. The measured torque to produce the minimum bolt tension shall not exceed the maximum allowed torque value obtained by the following equation: Torque = 0.25 PD Where: Torque = Calculated Torque (foot-pounds) P = Measured Bolt Tension (pounds) D = Normal Bolt Diameter (feet) 2. After placing the assembly through two cycles of the required number of turns, where turns are measured from the 15 percent pretension condition, as indicated in Table 2, a. The maximum recorded tension after the two turns shall be equal to or greater than 1.15 times the minimum bolt tension listed in Table 1. b. Each assembly shall be successfully installed to the specified number of turns. c. The fastener components in the assembly shall not exhibit shear failure or stripping of the threads as determined by visual examination of bolt and nut threads following removal. d. The bolts in the assembly shall not exhibit torsional or torsional/tension failure. 3. If any specimen fails, the assembly will be rejected. Elongation of the bolt between the bolt head and the nut is not considered to be a failure. Bolts that are too short to test in the bolt tension calibrator shall be tested in a steel joint. The Contractor shall (1) install the high-strength bolt assemblies (bolt, nut, direct tension indicator, and washer) in a steel joint of the proper thickness; (2) tighten to the snug tight condition; (3) match-mark the outer face of each nut and the protruding part of the bolt with crayon or paint; (4) rotate to the requirements of Table 2; and (5) record the torque that is required to achieve the required amount of rotation. The assembly shall be considered as nonconforming if the assembly fails to pass any one of the following specified requirements: 2020 Standard Specifications M 41-10 Page 6-161 Steel Structures 6-03 1. The recorded torque to produce the minimum rotation shall not exceed the maximum allowed torque value obtained by the following equation: Torque = 0.25 PD Where: Torque = Calculated Maximum Allowed Torque (foot-pounds) P = Specified Bolt Tension per Table 1, multiplied by a factor of 1.15 (pounds) D = Normal Bolt Diameter (feet) 2. After placing the assembly through two cycles of the required number of turns, where turns are measured from the snug tight condition specified in Section 6-03.3(32): a. Each assembly shall be successfully installed to the specified number of turns. b. The fastener components in the assembly shall not exhibit shear failure or stripping of the threads as determined by visual examination of bolt and nut threads following removal. c. The bolts in the assembly shall not exhibit torsional or torsional/tension failure. 3. If any specimen fails, the assembly will be rejected. Elongation of the bolt between the bolt head and the nut is not considered to be a failure. The Contractor shall submit Type 1 Working Drawings consisting of the manufacturer’s detailed procedure for pre-erection (rotational capacity) testing of tension control bolt assemblies. Three DTIs, per lot, shall be tested in a bolt tension calibrator. The bolts shall be tensioned to 105 percent of the tension shown in Table 1. If all of the DTI protrusions are completely crushed (all five openings with zero gap), this lot of DTIs is rejected. Three twist off-type tension controlled bolt assemblies, per assembly lot, shall be tested in a bolt tension calibrator. The bolts shall first be tensioned to a snug tight condition. Tensioning shall then be completed by tightening the assembly nut in a continuous operation using a spline drive installation tool until the spline shears from the bolt. The bolt assembly tension shall meet the requirements of Table 1. If any specimen fails, the assembly lot is rejected. 6-03.3(33)B Bolting Inspection The Contractor, in the presence of the Engineer, shall inspect the tightened bolt using a calibrated inspection torque wrench, regardless of bolting method. The Contractor shall supply the inspection torque wrench. Inspection shall be performed within seven calendar days from the completion of each bolted connection or as specified by the Engineer. If the bolts to be installed are not long enough to fit in the bolt tension calibrator, five bolts of the same grade, size, and condition as those under inspection shall be tested using Direct-Tension-Indicators (DTIs) to measure bolt tension. This tension measurement test shall be done at least once each inspection day. The Contractor shall supply the necessary DTIs. The DTI shall be placed under the bolt head. A washer shall be placed under the nut, which shall be the element turned during the performance of this Page 6-162 2020 Standard Specifications M 41-10 6-03 Steel Structures tension measurement test. Each bolt shall be tightened by any convenient means to the specified minimum tension as indicated by the DTI. The inspecting wrench shall then be applied to the tightened bolt to determine the torque required to turn the nut 5 degrees (approximately 1 inch at a 12-inch radius) in the tightening direction. The job inspection torque shall be taken as the average of three values thus determined after rejecting the high and low values. Five representative bolts/nuts/washers and DTIs if used (provided by the Contractor) of the same grade, size, and condition as those under inspection shall be placed individually in a bolt tension calibrator to measure bolt tension. This calibration operation shall be done at least once each inspection day. There shall be a washer under the part turned in tightening each bolt if washers are used on the Structure. In the bolt tension calibrator, each bolt shall be tightened by any convenient means to the specified tension. The inspection torque wrench shall then be applied to the tightened bolt to determine the torque required to turn the nut or head 5 degrees (approximately 1 inch at a 12-inch radius) in the tightening direction. The job-inspection torque shall be taken as the average of three values thus determined after rejecting the high and low values. Ten percent (at least two), or as specified by the Engineer, of the tightened bolts on the Structure represented by the test bolts shall be selected at random in each connection. The job-inspection torque shall then be applied to each with the inspecting wrench turned in the tightening direction, with no restraint applied to the opposite end of the bolt. If this torque turns no bolt head or nut, the Contracting Agency will accept the connection as being properly tightened. If the torque turns one or more bolt heads or nuts, the job-inspection torque shall then be applied to all bolts in the connection. Except for tension control bolt assemblies and DTIs with zero gap at all protrusion spaces, any bolt whose head or nut turns at this stage shall be tightened and reinspected. Any tension control bolt assemblies or DTIs that have zero gap at all protrusion spaces shall be replaced if the head or nut turns at this stage. The Contractor shall submit Type 1 Working Drawings consisting of the manufacturer’s detailed procedure for routine observation to ensure proper use of the tension control bolt assemblies. 6-03.3(34) Adjusting Pin Nuts All pin nuts shall be tightened thoroughly. The pins shall be placed so that members bear fully and evenly on the nuts. The pins shall have enough thread to allow burring after the nuts are tightened. 6-03.3(35) Setting Anchor Bolts Anchor bolts shall be set in masonry as required in Section 6-02.3(18). Anchor bolts shall be grouted in after the shoes, masonry plates, and keeper plates have been set and the span or series of continuous spans are completely erected and adjusted to line and camber. 2020 Standard Specifications M 41-10 Page 6-163 Steel Structures 6-03 6-03.3(36) Setting and Grouting Masonry Plates The following procedure applies to masonry plates for all steel spans, including shoes, keeper plates, and turning racks on movable bridges. To set masonry plates, the Contractor shall: 1. Set masonry plates on the anchor bolts; 2. Place steel shims under the masonry plates to position pin centers or bearings to line and grade and in relationship to each other. Steel shims shall be the size and be placed at the locations shown in the Plans; 3. Level the bases of all masonry plates; 4. Draw anchor bolt nuts down tight; 5. Recheck pin centers or bearings for alignment; and 6. Leave at least ¾ inch of space under each masonry plate for grout. After the masonry plates have been set and the span or series of continuous spans are completely erected and swung free, the space between the top of the masonry and the top of the concrete bearing seat shall be filled with grout. Main masonry plates for cantilever spans shall be set and grouted in before any steel Work is erected. Grout shall conform to Section 9-20.3(2) and placement shall be as required in Section 6-02.3(20). 6-03.3(37) Setting Steel Bridge Bearings Masonry plates, shoes, and keeper plates of expansion bearings shall be set and adjusted to center at a normal temperature of 64ºF. Adjustment for an inaccuracy in fabricated length shall be made after dead-load camber is out. 6-03.3(38) Placing Superstructure The concrete in piers and crossbeams shall reach at least 80 percent of design strength before girders are placed on them. 6-03.3(39) Swinging the Span Forms weighing less than 5 pounds per square foot of bridge deck area and uniformly distributed along the steel spans may be placed before the spans swing free on their supports. Steel reinforcing bars or concrete bridge deck shall not be placed on steel spans until the spans swing free on their supports and elevations are recorded. No simple span or any series of continuous spans will be considered as swinging free until all temporary supports have been released. Reinforcing steel or concrete bridge decks shall not be placed on any simple or continuous span steel girder bridge until all its spans are adjusted and its masonry plates, shoes, and keeper plates grouted. For this specification, the structure shall be considered as continuous across hinged joints. Page 6-164 2020 Standard Specifications M 41-10 6-03 Steel Structures After the falsework is released (spans swung free), the masonry plates, shoes, and keeper plates are grouted, and before any load is applied, the Contractor (or the Engineer if the Contracting Agency is responsible for surveying) shall survey elevations at the tenth points along the centerline on top of all girders and floorbeams. The Contractor shall calculate the theoretical top of girder or floorbeam flange elevations and compare the calculated elevations to the surveyed elevations. The theoretical pad or haunch depth shown in the Plans shall be increased or decreased by the difference between the theoretical and surveyed top of girder or floorbeam elevations. The soffit (deck formwork) shall be set based on the Plan bridge deck thickness and the adjusted pad or haunch depth. The Contractor shall submit all survey data and calculations to the Engineer for review ten working days prior to placing any load, beyond the maximum five pounds per square foot of form weight allowed, on the Structure. 6-03.3(40) Draining Pockets The Contractor shall provide enough holes to drain all water from pockets in trusses, girders, and other members. Unless shown on approved shop plans, drain holes shall not be drilled without the written approval of the Engineer. All costs related to providing drain holes shall be included in the unit Contract prices for structural or cast steel. 6-03.3(41) Vacant 6-03.3(42) Surface Condition As the Structure is erected, the Contractor shall keep all steel surfaces clean and free from dirt, concrete, mortar, oil, paint, grease, and other stain-producing foreign matter. Any surfaces that become stained shall be cleaned as follows: Painted steel surfaces shall be cleaned by methods required for the type of staining. The Contract shall submit a Type 1 Working Drawing of the cleaning method. Unpainted steel surfaces shall be cleaned by sandblasting. Sandblasting to remove stains on publicly visible surfaces shall be done to the extent that, in the Engineers opinion, the uniform weathering characteristics of the Structure are preserved. 6-03.3(43) Castings, Steel Forgings, and Miscellaneous Metals Castings, steel forgings, and miscellaneous metals shall be built to comply with Section 9-06. 6-03.3(43)A Shop Construction, Castings, Steel Forgings, and Miscellaneous Metals This section’s requirements for structural steel (including painting requirements) shall also apply to castings, steel forgings, and miscellaneous metals. 2020 Standard Specifications M 41-10 Page 6-165 Steel Structures 6-03 Castings shall be: 1. True to pattern in form and dimensions; 2. Free from pouring faults, sponginess, cracks, blow holes, and other defects in places that would affect strength, appearance, or value; 3. Clean and uniform in appearance; 4. Filleted boldly at angles; and 5. Formed with sharp and perfect arises. Iron and steel castings and forgings shall be annealed before any machining, unless the Plans state otherwise. 6-03.4 Measurement Cast or forged metal (kind) shown in the Plans will be measured by the pound or will be paid for on a lump sum basis, whichever is shown on the Proposal. 6-03.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Structural Carbon Steel”, lump sum. The lump sum Contract price for “Structural Carbon Steel” shall be full pay for all costs in connection with furnishing all materials, labor, tools, and equipment necessary for the manufacture, fabrication, transportation, erection, and painting of all structural carbon steel used in the completed Structure, including the providing of such other protective coatings or treatment as may be shown in the Plans or specified in the Special Provisions. For steel Structures, the estimated weight of the structural carbon steel in the project will be shown in the Plans or in the Special Provisions. In the event any change in the Plans is made which will affect the weight of materials to be furnished, payment for the additional structural carbon steel required as a result of the change in the Plans will be made at a unit price per pound obtained by dividing the Contractor’s lump sum Bid for structural carbon steel by the total estimated weight of structural carbon steel shown in the Plans or in the Special Provisions. Reductions in weight due to a change in the Plans will be made at the same rate as determined above and will be deducted from payments due the Contractor. Prospective Bidders shall verify the estimated weight of structural carbon steel before submitting a Bid. No adjustment other than for approved changes shall be made in the lump sum Bid even though the actual weight may deviate from the stated estimated weight. Page 6-166 2020 Standard Specifications M 41-10 6-03 Steel Structures For concrete and timber Structures, where the structural carbon steel is a minor item, no estimated weight will be given for the structural carbon steel. In the event any change in the Plans is necessary which will affect the weight of material to be furnished for this type of Structure, the payment or reduction for the revision in quantity will be made at a unit price per pound obtained by dividing the Contractor’s lump sum Bid for the structural carbon steel by the calculated weight of the original material. The calculated weight will be established by the Engineer and will be based on an estimated weight of 490 pounds per cubic foot for steel. Any change in the Plans which affects the weight of material to be furnished as provided herein will be subject to the provisions of Section 1-04.4. “Structural Low Alloy Steel”, lump sum. “Structural High Strength Steel”, lump sum. Payment for “Structural Low Alloy Steel” and “Structural High Strength Steel” shall be made on the same lump sum basis as specified for structural carbon steel. “(Cast or Forged) Steel”, lump sum or per pound. “(Cast, Malleable, or Ductile) Iron”, lump sum or per pound. “Cast Bronze”, lump sum or per pound. Payment for “(Cast or Forged) Steel”, “(Cast, Malleable or Ductile) Iron”, and “Cast Bronze” will be made at the lump sum or per pound Contract prices as included in the Proposal. For the purpose of payment, such minor items as bearing plates, pedestals, forged steel pins, anchor bolts, field bolts, shear connectors, etc., unless otherwise provided, shall be considered as structural carbon steel even though made of other materials. When no Bid item is included in the Proposal and payment is not otherwise provided, the castings, forgings, miscellaneous metal, and painting shall be considered as incidental to the construction, and all costs therefore shall be included in the unit Contract prices for the payment items involved and shown. 2020 Standard Specifications M 41-10 Page 6-167 Timber Structures 6-04 6-04 Timber Structures 6-04.1 Description This Work is the building of any Structure or parts of Structures (except piling) made of treated timber, untreated timber, or both. The Contractor shall erect timber Structures on prepared foundations. The Structures shall conform to the dimensions, lines, and grades required by the Plans, the Engineer, and these Specifications. Any part of a timber Structure made of nontimber materials shall comply with the sections of these Specifications that govern those materials. 6-04.2 Materials Materials shall meet the requirements of the following sections: Structural Steel and Related Material 9-06 Bolts, Washers, Other Hardware 9-06.22 Paints 9-08 Timber and Lumber 9-09 6-04.3 Construction Requirements 6-04.3(1) Storing and Handling Material At the Work site, the Contractor shall store all timber and lumber in piles. Weeds and rubbish under and around these piles shall have been removed before the lumber is stacked. Untreated lumber shall be open stacked at least 12 inches above the ground. It shall be piled to shed water and prevent warping. Treated timber shall be: 1. Cut, framed, and bored (whenever possible) before treatment; 2. Close stacked and piled to prevent warping; 3. Covered against the weather if the Engineer requires it; 4. Handled carefully to avoid sudden drops, broken outer fibers, and surface penetration or bruising with tools; and 5. Lifted and moved with rope or chain slings (without use of cant dogs, peaveys, hooks, or pike poles). 6-04.3(2) Workmanship The Contractor shall employ only competent bridge carpenters. All their Work shall be true and exact. Nails and spikes shall be driven with just enough force to leave heads flush with wood surfaces. The Contractor shall discharge any worker who displays poor workmanship by leaving deep hammer marks in wood surfaces. Workmanship on metal parts shall comply with requirements for steel Structures. Page 6-168 2020 Standard Specifications M 41-10 6-04 Timber Structures 6-04.3(3) Shop Details The Contractor shall submit Type 2 Working Drawings consisting of shop detail plans for all treated timber. These plans shall show dimensions for all cut, framed, or bored timbers. 6-04.3(4) Field Treatment of Cut Surfaces, Bolt Holes, and Contact Surfaces All cut surfaces, bolt holes, and contact surfaces shall be treated in accordance with Section 9-09.3 for all timber and lumber requiring preservative treatment. All cuts and abrasions in treated piles or timbers shall be trimmed carefully and treated in accordance with Section 9-09.3. 6-04.3(5) Holes for Bolts, Dowels, Rods, and Lag Screws Holes shall be bored: 1. For drift pins and dowels – with a bit 1/16 inch smaller in diameter than the pins and dowels. 2. For truss rods or bolts – with a bit the same diameter as the rods or bolts. 3. For lag screws – in two parts: (a) with the shank lead hole the same diameter as the shank and as deep as the unthreaded shank is long; and (b) with the lead hole for the threaded part approximately ⅔ of the shank diameter. 6-04.3(6) Bolts, Washers, and Other Hardware Bolts, dowels, washers, and other hardware, including nails, shall be black or galvanized as specified in the Plans, but if not so specified shall be galvanized when used in treated timber Structures. Washers of the size and type specified shall be used under all bolt heads and nuts that would otherwise contact wood. All bolts shall be checked by burring the threads after the nuts have been finally tightened. Vertical bolts shall have nuts on the lower ends. Wherever bolts fasten timber to timber, to concrete, or to steel, the members shall be bolted tightly together at installation and retightened just before the Contracting Agency accepts the Work. These bolts shall have surplus threading of at least ⅜ inch per foot of timber thickness to permit future tightening. 6-04.3(7) Countersinking Countersinking shall be done wherever smooth faces are required. Each recess shall be treated in accordance with Section 9-09.3. 2020 Standard Specifications M 41-10 Page 6-169 Timber Structures 6-04 6-04.3(8) Framing The Contractor shall cut and frame lumber and timber to produce close-fitting, full- contact joints. Each mortise shall be true to size for its full depth, and its tenon shall fit it snugly. Neither shimmed nor open joints are permitted. 6-04.3(9) Framed Bents Mudsills shall be of pressure-treated timber, firmly and evenly bedded to solid bearing, and tamped in place. Concrete pedestals that support framed bents shall be finished so that sills will bear evenly on them. To anchor the sills, the Contractor shall set dowels in the pedestals when they are cast. The dowels shall be at least ¾ inch in diameter and protrude at least 6 inches above the pedestal tops. Pedestal concrete shall comply with Section 6-02. Each sill shall rest squarely on mudsills, piles, or pedestals. It shall be drift-bolted to mudsills or piles with ¾-inch diameter or larger bolts that extend at least 6 inches into them. When possible, the Contractor shall remove any earth touching the sills to permit free air circulation around them. Each post shall be fastened to sills with ¾-inch diameter or larger dowels that extend at least 6 inches into the post. 6-04.3(10) Caps Timber caps shall rest uniformly across the tops of posts or piles and cap ends shall be aligned evenly. Each cap shall be fastened with a drift bolt ¾ inch in diameter or larger that penetrates the post or pile at least 9 inches. The bolt shall be approximately in the center of the pile or post. If the Roadway grade exceeds 2 percent, each cap shall be beveled to match the grade. 6-04.3(11) Bracing When pile bents are taller than 10 feet, each shall be braced transversely and every other pair shall be braced longitudinally. No single cross-bracing shall brace more than 20 feet of vertical distance on the piles. If the vertical distance exceeds 20 feet, more than one cross-bracing shall be used. Each brace end shall be bolted through the pile, post, or cap with a bolt ¾ inch in diameter or larger. Other brace/pile intersections shall be bolted or boat-spiked as the Plans require. Cross-bracing shall lap both upper or lower caps and shall be bolted to the caps or sills at each end. 6-04.3(12) Stringers All stringers that carry laminated decking or vary more than ⅛ inch in depth shall be sized to an even depth at bearing points. Outside stringers shall be butt jointed and spliced. Interior stringers shall be lapped so that each rests over the full width of the cap or floorbeam at each end. Except on sharp horizontal and vertical curves, stringers may cover two spans. In this case, joints shall be staggered and the stringers either Page 6-170 2020 Standard Specifications M 41-10 6-04 Timber Structures toenailed or drift bolted as the Plans require. To permit air circulation on untreated timber Structures, the ends of lapped stringers shall be separated. This separation shall be done by fastening across the lapping face a 1 by 3-inch wood strip cut 2 inches shorter than the depth of the stringer. Any cross-bridging or solid bridging shall be neatly and accurately framed, then securely toenailed at each end (with two nails for cross-bridging and four nails for solid bridging). The Plans show bridging size and spacing. 6-04.3(13) Wheel Guards and Railings Wheel guards and railings shall be built as Section 6-06.3(1) requires. 6-04.3(14) Single-Plank Floors Single-plank floors shall be made of a single thickness of plank on stringers or joists. Unless the Engineer directs otherwise, the planks shall be: 1. Laid heart side down with tight joints, 2. Spiked to each joist or nailing strip with at least two spikes that are at least 4 inches longer than the plank thickness, 3. Spiked at least 2½ inches from the edges, 4. Cut off on a straight line parallel to the centerline of the Roadway, 5. Arranged so that no adjacent planks vary in thickness by no more than 1/16 inch, and 6. Surfaced on one side and one edge (S1S1E) unless otherwise specified. 6-04.3(15) Laminated Floors The strips shall be placed on edge and shall be drawn down tightly against the stringer or nailing strip and the adjacent strip and, while held in place, shall be spiked. Each strip shall extend the full width of the deck, unless some other arrangement is shown in the Plans or permitted by the Engineer. Each strip shall be spiked to the adjacent strip at intervals of not more than 2 feet, the spikes being staggered 8 inches in adjacent strips. The spikes shall be of sufficient length to pass through two strips and at least halfway through the third. In addition, unless bolting is specified in the Plans, each strip shall be toenailed to alternate stringers with 40d common nails and adjacent strips shall be nailed to every alternate stringer. The ends of all pieces shall be toenailed to the outside stringer. The ends of the strips shall be cut off on a true line parallel to the centerline of the Roadway. When bolts are used to fasten laminated floors to stringers, the bolts shall be placed at the spacing shown in the Plans, and the pieces shall be drawn down tightly to the bolting strips. The bolt heads shall be driven flush with the surface of the deck. Double nuts or single nuts and lock nuts shall be used on all bolts. The strips shall be spiked together in the same manner as specified above. 2020 Standard Specifications M 41-10 Page 6-171 Timber Structures 6-04 6-04.3(16) Plank Subfloors for Concrete Decks Any plank subfloor shall be laid surfaced side down with close joints at right angles to the centerline of the Roadway. Planks shall be spiked in place as required in Section 6-04.3(14). Floor planks shall be treated in accordance with Section 9-09.3. 6-04.3(17) Trusses Completed trusses shall show no irregularities of line. From end to end, chords shall be straight and true in horizontal projection. In vertical projection they shall show a smooth curve through panel points that conforms to the correct camber. The Engineer will reject any pieces cut unevenly or roughly at bearing points. Before placement of the hand railing, the Contractor shall complete all trusses, swing them free of their falsework, and adjust them for line and camber (unless the Engineer directs otherwise). 6-04.3(18) Painting Section 6-07.3(13) governs painting of timber Structures. 6-04.4 Measurement The criteria in Section 6-03.4 will be used to determine the weight of structural metal other than hardware. Timber and lumber (treated or untreated) will be measured by the 1,000-board feet (MBM), using nominal thicknesses and widths. Lengths will be actual lengths of individual pieces in the finished Structure with no deduction for daps, cuts, or splices. To measure laminated timber decking, the Contracting Agency will use the number and after-dressing sizes of pieces required in the Plans. The length of each lamination shall be the length remaining in the finished Structure. 6-04.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: 1. “Timber and Lumber (untreated or name treatment)”, per MBM. 2. “Structural Metal”, lump sum. Where no item for structural metal is included in the Proposal, full pay for furnishing and placing metal parts shall be included in the unit Contract price per MBM for “Timber and Lumber”. When no Bid item is included in the Proposal and is not otherwise provided, painting shall be considered as incidental to the construction, and all costs therefore shall be included in the unit Contract prices for the payment items involved and shown. Page 6-172 2020 Standard Specifications M 41-10 6-05 Piling 6-05 Piling 6-05.1 Description This Work consists of furnishing and driving piles (timber, precast concrete, cast-in-place concrete, and steel) of the sizes and types the Contract or the Engineer require. This Work also includes cutting off or building up piles when required. In furnishing and driving piles, the Contractor shall comply with the requirements of this Section, the Contract, and the Engineer. 6-05.2 Materials Materials shall meet the requirements of the following sections: Reinforcing Steel 9-07 Prestressing Steel 9-07.10 Timber Piling 9-10.1 Concrete Piling 9-10.2 Cast-In-Place Concrete Piling 9-10.3 Steel Pile Tips and Shoes 9-10.4 Steel Piling 9-10.5 Mortar 9-20.4 6-05.3 Construction Requirements 6-05.3(1) Piling Terms Concrete Piles – Concrete piling may be precast or precast-prestressed concrete, or steel casings driven to the ultimate bearing resistance called for in the Contract which are filled with concrete (cast-in-place) after driving. Steel Piles – Steel piles may be open-ended or closed-ended pipe piles, or H-piles. Overdriving – Over-driving of piles occurs when the ultimate bearing resistance calculated from the equation in Section 6-05.3(12), or the wave equation driving criteria if applicable, exceeds the ultimate bearing resistance required in the Contract in order to reach the minimum tip elevation specified in the Contract, or as required by the Engineer. Maximum Driving Resistance – The maximum driving resistance is either the pile ultimate bearing resistance, or ultimate bearing resistance plus overdriving to reach minimum tip elevation as specified in the Contract, whichever is greater. Wave Equation Analysis – Wave equation analysis is an analysis performed using the wave equation analysis program (WEAP) with a version dated 1987 or later. The wave equation may be used as specified herein to verify the Contractor’s proposed pile driving system. The pile driving system includes, but is not necessarily limited to, the pile, the hammer, the helmet, and any cushion. The wave equation may also be used by the Engineer to determine pile driving criteria as may be required in the Contract. 2020 Standard Specifications M 41-10 Page 6-173 Piling 6-05 Ultimate Bearing Resistance – Ultimate bearing resistance refers to the vertical load carrying resistance (in units of force) of a pile as determined by the equation in Section 6-05.3(12), the wave equation analysis, pile driving analyzer and CAPWAP, static load test, or any other means as may be required by the Contract, or the Engineer. Allowable Bearing Resistance – Allowable bearing resistance is the ultimate bearing resistance divided by a factor of safety. The Contract may state the factor of safety to be used in calculating the allowable bearing resistance from the ultimate bearing resistance. In the absence of a specified factor of safety, a value of three shall be used. Rated Hammer Energy – The rated energy represents the theoretical maximum amount of gross energy that a pile driving hammer can generate. The rated energy of a pile driving hammer will be stated in the hammer manufacturer’s catalog or Specifications for that pile driving hammer. Developed Hammer Energy – The developed hammer energy is the actual amount of gross energy produced by the hammer for a given blow. This value will never exceed the rated hammer energy. The developed energy may be calculated as the ram weight times the drop (or stroke) for drop, single acting hydraulic, single acting air/steam, and open-ended diesel hammers. For double acting hydraulic and air/steam hammers, the developed hammer energy shall be calculated from ram impact velocity measurements or other means approved by the Engineer. For closed-ended diesel hammers, the developed energy shall be calculated from the measured bounce chamber pressure for a given blow. Hammer manufacturer calibration data may be used to correlate bounce chamber pressure to developed hammer energy. For a single acting diesel hammer the developed energy is determined using the blows per minute. Transferred Hammer Energy – The transferred hammer energy is the amount of energy transferred to the pile for a given blow. This value will never exceed the developed hammer energy. Factors that cause transferred hammer energy to be lower than the developed hammer energy include friction during the ram down stroke, energy retained in the ram and helmet during rebound, and other impact losses. The transferred energy can only be measured directly by use of sensors attached to the pile. A pile driving analyzer (PDA) may be used to measure transferred energy. Pile Driving Analyzer – A pile driving analyzer (PDA) is a device which can measure the transferred energy of a pile driving system, the compressive and tensile stresses induced in the pile due to driving, the bending stresses induced by hammer misalignment with the pile, and estimate the ultimate resistance of a pile at a given blow. Pile Driving System – The pile driving system includes, but is not necessarily limited to, the hammer, leads, helmet or cap, cushion and pile. Page 6-174 2020 Standard Specifications M 41-10 6-05 Piling Helmet – The helmet, also termed the cap, drive cap, or driving head, is used to transmit impact forces from the hammer ram to the pile top as uniformly as possible across the pile top such that the impact force of the ram is transmitted axially to the pile. The term helmet can refer to the complete impact force transfer system, which includes the anvil or striker plate, hammer cushion and cushion block, and a pile cushion if used, or just the single piece unit into which these other components (anvil, hammer cushion, etc.) fit. The helmet does not include a follower, if one is used. For hydraulic hammers, the helmet is sometimes referred to as the anvil. Hammer Cushion – The hammer cushion is a disk of material placed on top of the helmet but below the anvil or striker plate to relieve impact shock, thus protecting the hammer and the pile. Pile Cushion – The pile cushion is a disk of material placed between the helmet and the pile top to relieve impact shock, primarily to protect the pile. Follower – A follower is a structural member placed between the hammer assembly, which includes the helmet, and the pile top when the pile head is below the reach of the hammer. Pile Driving Refusal – Pile driving refusal is defined as 15 blows per inch for the last 4 inches of driving. This is the maximum blow count allowed during overdriving. Minimum Tip Elevation – The minimum tip elevation is the elevation to which the pile tip shall be driven. Driving deeper in order to obtain the required ultimate bearing resistance may be required. 6-05.3(2) Ordering Piling The Contractor shall order all piling (except cast-in-place concrete and steel piles) from an itemized list the Engineer will provide. This list, showing the number and lengths of piles required, will be based on test-pile driving (or other) data. The list will show lengths below the cutoff point. The Contractor shall supply (and bear the cost of supplying) any additional length required for handling or driving. The Contractor shall assume all responsibility for buying more or longer piles than those shown on the list provided by the Engineer. All piles purchased on the basis of the Engineer’s list but not used in the finished Structure shall become the property of the Contracting Agency. The Contractor shall deliver these as the Engineer directs. The Contractor shall keep pile cutoffs that are 8 feet or under and any longer ones the Contracting Agency does not require. When ordering steel casings for cast-in-place concrete and steel piling, the Contractor shall base lengths on information derived from driving test piles and from subsurface data. The Contractor shall also select the wall thickness of steel piles or steel casings for cast-in-place piles which will be necessary to prevent damage during driving and handling. The selection of wall thickness for steel piles or steel casings shall also consider the effects of lateral pressures from the soil or due to driving of adjacent piles. Steel piles and steel casings must be strong and rigid enough to resist these pressures without deforming 2020 Standard Specifications M 41-10 Page 6-175 Piling 6-05 or distorting. The Contractor shall select the wall thickness based on information derived from test piles, subsurface data and/or wave equation analysis. Wave equation analysis is required prior to ordering piling for piles with specified ultimate bearing resistances of 300 tons or greater. If a wave equation analysis is performed, the Contractor shall base the selection of wall thickness on the maximum driving resistance identified in the Contract to reach the minimum tip elevation, if the maximum driving resistance is greater than the specified ultimate bearing resistance and if a minimum tip elevation is specified. The wave equation analysis shall be submitted by the Contractor as required in Section 6-05.3(9)A. The Engineer will not supply any list for piling of these types. 6-05.3(3) Manufacture of Precast Concrete Piling Precast concrete piles shall consist of concrete sections reinforced to withstand handling and driving stresses. These may be reinforced with deformed steel bars or prestressed with steel strands. The Plans show dimensions and details. If the Plans require piles with square cross-sections, the corners shall be chamfered 1 inch. Precast or prestressed piles shall meet the requirements of the Standard Plans. Temporary stress in the prestressing reinforcement of prestressed piles (before loss from creep and shrinkage) shall be 75 percent of the minimum ultimate tensile strength. (For short periods during manufacture, the reinforcement may be overstressed to 80 percent of ultimate tensile strength if stress after transfer to concrete does not exceed 75 percent of that strength.) Prestressed concrete piles shall have a final (effective) prestress of at least 1,000 psi. Unless the Engineer approves splices, all piles shall be full length. The Contracting Agency intends to perform Quality Assurance Inspection. By its inspection, the Contracting Agency intends only to facilitate the Work and verify the quality of that Work. This inspection shall not relieve the Contractor of any responsibility for identifying and replacing defective material and workmanship. 6-05.3(3)A Casting and Stressing Reinforcing bars, hoops, shoes, etc., shall be placed as shown in the Contract, with all parts securely tied together and placed to the specified spacing. No concrete shall be cast until all reinforcement is in place in the forms. The Contractor shall perform quality control inspection. The manufacturing plant for precast concrete piling shall be certified by the Precast/Prestressed Concrete Institute’s Plan Certification Program for the type of precast piling to be produced and shall be approved by WSDOT as a Certified Precast Concrete Fabricator prior to start of production. WSDOT Certification will be established or renewed during the annual precast plant review and approval process. Page 6-176 2020 Standard Specifications M 41-10 6-05 Piling Prior to the start of production of the piling, the Contractor shall advise the Engineer of the production schedule. The Contractor shall give the Inspector safe and free access to the Work. If the Inspector observes any nonspecification Work or unacceptable quality control practices, the Inspector will advise the plant manager. If the corrective action is not acceptable to the Engineer, the piling(s) will be subject to rejection by the Engineer. In casting concrete piles, the Contractor shall: 1. Cast them either vertically or horizontally; 2. Use metal forms (unless the Engineer approves otherwise) with smooth joints and inside surfaces that can be reached for cleaning after each use; 3. Brace and stiffen the forms to prevent distortion; 4. Place concrete continuously in each pile, guarding against horizontal or diagonal cleavage planes; 5. Ensure that the reinforcement is properly embedded; 6. Use internal vibration around the reinforcement during concrete placement to prevent rock pockets from forming; and 7. Cast test cylinders with each set of piles as concrete is placed. Forms shall be metal and shall be braced and stiffened to retain their shape under pressure of wet concrete. Forms shall have smooth joints and inside surfaces easy to reach and clean after each use. That part of a form which will shape the end surface of the pile shall be a true plane at right angles to the pile axis. Each pile shall contain a cage of nonprestressed reinforcing steel. The Contractor shall follow the Contract in the size and location of this cage, and shall secure it in position during concrete placement. Spiral steel reinforcing shall be covered by at least 1½ inches of concrete measured from the outside pile surface. Prestressing steel shall be tensioned as required in Section 6-02.3(25)C. The Plans specify tensioning stress for strands or wires. Tension shall be measured by jack pressure as described in Section 6-02.3(25)C. Mechanical locks or anchors shall temporarily maintain cable tension. All jacks shall have hydraulic pressure gauges (accurately calibrated and accompanied by a certified calibration curve no more than 180 days old) that will permit stress calculations at all times. All tensioned piles shall be pretensioned. Post-tensioning is not allowed. The Contractor shall not stress any pile until test cylinders made with it reach a compressive strength of at least 3,300 psi. 2020 Standard Specifications M 41-10 Page 6-177 Piling 6-05 6-05.3(3)B Finishing As soon as the forms for precast concrete piles are removed, the Contractor shall fill all holes and irregularities with mortar conforming to Section 9-20.4(2) mixed at a 1:2 cement/aggregate ratio. That part of any pile that will be underground or below the low- water line and all parts of any pile to be used in salt water or alkaline soil shall receive only this mortar treatment. That part of any pile that will show above the ground or water line shall be given a Class 2 finish as described in Section 6-02.3(14)B. 6-05.3(3)C Curing Precast Concrete Piles – The Contractor: 1. Shall keep the concrete continuously wet with water after placement for at least 10 days with Type I or II portland cement or at least 3 days with Type III. 2. Shall remove side forms no sooner than 24 hours after concrete placement, and then only if the surrounding air remains at no less than 50°F for 5 days with Type I or II portland cement or 3 days with Type III. 3. May cure precast piles with saturated steam or hot air, as described in Section 6-02.3(25)D, provided the piles are kept continuously wet until the concrete has reached a compressive strength of 3,300 psi. Precast-Prestressed Concrete Piles – These piles shall be cured as required in Section 6-02.3(25)D. 6-05.3(4) Manufacture of Steel Casings for Cast-In-Place Concrete Piles The diameter of steel casings shall be as specified in the Contract. A full-penetration groove weld between welded edges is required. 6-05.3(5) Manufacture of Steel Piles Steel piles shall be made of rolled steel H-pile sections, steel pipe piles, or of other structural steel sections described in the Contract. A full penetration groove weld between welded edges is required. At least 14-days prior to the start of production of the piling, the Contractor shall advise the Engineer of the production schedule. The Contractor shall give the Inspector safe and free access to the Work. If the Inspector observes any nonspecification Work or unacceptable quality control practices, the Inspector will advise the plant manager. If the corrective action is not acceptable to the Engineer, the piling(s) will be subject to rejection by the Engineer. Page 6-178 2020 Standard Specifications M 41-10 6-05 Piling 6-05.3(6) Splicing Steel Casings and Steel Piles The Engineer will normally permit steel piles and steel casings for cast-in-place concrete piles to be spliced. But in each case, the Contractor shall submit Type 2 Working Drawings supporting the need and describing the method for splicing. Welded splices shall be spaced at a minimum distance of 10 feet. Only welded splices will be permitted. Splice welds for steel piles shall comply with Section 6-03.3(25) and AWS D1.1/D1.1M, latest edition, Structural Welding Code. Splicing of steel piles shall be performed in accordance with an approved weld procedure. The Contractor shall submit a Type 2 Working Drawing consisting of the weld procedure. For ASTM A252 material, mill certification for each lot of pipe to be welded shall accompany the submittal. The ends of all steel pipe piling shall meet the fit-up requirements of AWS D1.1/D1.1M, latest edition, Structural Welding Code Section 5.22.3.1, “Girth Weld Alignment (Tubular),” when the material is spliced utilizing a girth weld. Splice welds of steel casings for cast-in-place concrete piles shall be the Contractor’s responsibility and shall be welded in accordance with AWS D1.1/D1.1M, latest edition, Structural Welding Code. A weld procedure submittal is not required for steel casings used for cast-in-place concrete piles. Casings that collapse or are not watertight, shall be replaced at the Contractor’s expense. 6-05.3(7) Storage and Handling The Contractor shall store and handle piles in ways that protect them from damage. 6-05.3(7)A Timber Piles Timber piling shall be stacked closely and in a manner to prevent warping. The ground beneath and around stored piles shall be cleared of weeds, brush, and rubbish. Piling shall be covered against the weather if the Engineer requires it. The Contractor shall take special care to avoid breaking the surface of treated piles. They shall be lifted and moved with equipment, tools, and lifting devices which do not penetrate or damage the piles. If timber piles are rafted, any attachments shall be within 3 feet of the butts or tips. Any surface cut or break shall be repaired in accordance with Section 9-09.3. The Engineer may reject any pile because of a cut or break. 6-05.3(7)B Precast Concrete Piles The Contractor shall not handle any pile until test cylinders made with the same batch of concrete as the pile reach a compressive strength of at least 3,300 psi. Storing and handling methods shall protect piles from fractures by impact and undue bending stresses. Handling methods shall never stress the reinforcement more than 12,000 psi. An allowance of twice the calculated load shall be made for impact and shock effects. The Contractor shall submit Type 2 Working Drawings consisting of the method of lifting the piles. The Contractor will take extra care to avoid damaging the surface of any pile to be used in seawater or alkaline soil. 2020 Standard Specifications M 41-10 Page 6-179 Piling 6-05 6-05.3(7)C Steel Casings and Steel Piles The Engineer will reject bent, deformed, or kinked piles that cannot be straightened without damaging the metal. 6-05.3(8) Pile Tips and Shoes The Contracting Agency prefers that timber piles be driven with squared ends. But if conditions require, they may be shod with metal shoes. Pile tips and shoes shall be securely attached to the piles in accordance with the manufacturer’s recommendations. Where called for in the Contract, conical steel pile tips shall be used when driving steel casings. The tips shall be inside fit, flush-mounted such that the tip and/or weld bead does not protrude more than 1⁄16 inch beyond the nominal outside diameter of the steel casing. If conical tips are not specified, the lower end of each casing shall have a steel driving plate that is thick enough to keep the casing watertight and free from distortion as it is driven. The diameter of the steel driving plate shall not be greater than the outside diameter of the steel casing. Where called for in the Contract, inside-fit cutting shoes shall be used when driving open- ended steel piles. The cutting shoes shall be flush-mounted such that the shoe and/or weld bead does not protrude more than 1⁄16 inch beyond the nominal outside diameter of the steel pile. The cutting shoe shall be of an inside diameter at least ¾ inch less than the nominal inside diameter of the steel pile. Pile tips or shoes shall be of a type denoted in the Qualified Products List. If pile tips or shoes other than those denoted in the Qualified Products List are proposed, the Contractor shall submit Type 2 Working Drawings consisting of shop drawings of the proposed pile tip along with design calculations, Specifications, material chemistry and installation requirements, along with evidence of a pile driving test demonstrating suitability of the proposed pile tip. The test shall be performed in the presence of the Engineer or an acceptable independent testing agency. The test shall consist of driving a pile fitted with the proposed tip. If the pile cannot be visually inspected (Section 6-05.3(11)F), a sacrificial pile fitted with the proposed tip shall be driven outside the proposed foundation limits. The pile shall be driven to a depth sufficient to develop the required ultimate bearing resistance as called for in the Contract, in ground conditions determined to be equivalent to the ground conditions at the project site. For closed- ended casings or piles, the pile need not be removed if, in the opinion of the Engineer, the pile can be inspected for evidence of damage to the pile or the tip. For open-ended steel casings or piles, timber piles or H-piles, the pile shall be removed for inspection. Page 6-180 2020 Standard Specifications M 41-10 6-05 Piling 6-05.3(9) Pile Driving Equipment 6-05.3(9)A Pile Driving Equipment Approval Prior to driving any piles, the Contractor shall submit Type 2 Working Drawings consisting of details of each proposed pile driving system. The pile driving system shall meet the minimum requirements for the various combinations of hammer type and pile type specified in this section. These requirements are minimums and may need to be increased in order to ensure that the required ultimate bearing resistance can be achieved, that minimum tip elevations can be reached, and to prevent pile damage. The Contractor shall submit Type 2E Working Drawings consisting of a wave equation analysis for all pile driving systems used to drive piling with required maximum driving resistances of greater than 300 tons. The wave equation analysis shall be performed in accordance with the requirements of this section and the user’s manual for the program. The wave equation analysis shall verify that the pile driving system proposed does not produce stresses greater than 50,000 psi or 90 percent of the yield stress whichever is less, for steel piles, or steel casings for cast-in-place concrete piles. For prestressed concrete piles, the allowable driving stress in kips shall be 6-05.3(9)A Pile Driving Equipment Approval 0.095E𝑓𝑓′H plus prestress in tension, and 0.85f’c minus prestress in compression, where f’c is the concrete compressive strength in kips per square inch. For precast concrete piles that are not prestressed, the allowable driving stress shall be 70 percent of the yield stress of the steel reinforcement in tension, and 0. 85f’c in compression. The wave equation shall also verify that the pile driving system does not exceed the refusal criteria at the depth of penetration anticipated for achieving the required ultimate bearing resistance and minimum tip elevation. Furthermore, the wave equation analysis shall verify that at the maximum driving resistance specified in the Contract, the driving resistance is 100 blows per foot or less. Unless otherwise specified in the Contract, or directed by the Engineer, the following default values shall be used as input to the wave equation analysis program: Output option (IOUT) 0 Factor of safety applied to (Rult) 1.0 Type of damping Smith Residual stress option No Rult is the resistance of the pile used in the wave equation analyses. If the ultimate bearing resistance equals the maximum driving resistance, a setup factor of 1.3 may be used in the wave equation analysis to account for pile setup. To use a setup factor in the wave equation analysis, Rult in the analysis is the ultimate bearing resistance divided by 1.3. If the maximum driving resistance exceeds the ultimate bearing resistance, no setup factor should be used, and Rult is equal to the maximum driving resistance of the pile. 2020 Standard Specifications M 41-10 Page 6-181 Piling 6-05 Hammer Efficiencies For Analysis of Driving Resistance For Analysis of Driving Stresses Single acting diesel hammers 0.72 0.84 Closed-ended diesel hammers 0.72 0.84 Single acting air/steam hammers 0.60 0.70 Double acting air/steam hammers 0.45 0.53 Hydraulic hammers or other external combustion hammers having ram velocity monitors that may be used to assign an equivalent stroke. 0.85 1.00 Changes to the pile driving system after completion of the Working Drawing review require a revised Working Drawing Submittal. 6-05.3(9)B Pile Driving Equipment Minimum Requirements For each drop hammer used, the Contractor shall weigh it in the Engineer’s presence or submit a Type 1 Working Drawing consisting of a certificate of its weight. The exact weight shall be stamped on the hammer. Drop hammers shall weigh not less than: 1. 3,000 pounds for piles under 50 feet long that have an ultimate bearing resistance of not more than 60 tons, and 2. 4,000 pounds for piles 50 feet and longer or that have an ultimate bearing resistance of 60 to 90 tons. If a drop hammer is used for timber piles, it is preferable to use a heavy hammer and operate with a short drop. For each diesel, hydraulic, steam, or air-driven hammer used, the Contractor shall submit a Type 1 Working Drawing consisting of the manufacturer’s Specifications and catalog. These shall show all data needed to calculate the developed energy of the hammer used. Underwater hammers may be used only with permission of the Engineer. Drop hammers on timber piles shall have a maximum drop of 10 feet. Drop hammers shall not be used to drive timber piles that have ultimate bearing resistance of more than 60 tons. When used on timber piles, diesel, hydraulic, steam, or air-driven hammers shall provide at least 13,000 foot-pounds of developed energy per blow. The ram of any diesel hammer shall weigh at least 2,700 pounds. Precast concrete and precast-prestressed concrete piles shall be driven with a single- acting steam, air, hydraulic, or diesel hammer with a ram weight of at least half as much as the weight of the pile, but never less than the minimums stated below. The ratio of developed hammer energy to ram weight shall not exceed 6. Steel casings for cast-in- place concrete, steel pipe, and steel H-piles shall also be driven with diesel, hydraulic, steam, or air hammers. These hammers shall provide at least the following developed energy per blow: Page 6-182 2020 Standard Specifications M 41-10 6-05 Piling Minimum Developed Energy per Blow (ft-lbs) Maximum Driving Resistance (Tons) Air or Steam Hammers Open Ended Diesel Hammers Closed Ended Diesel Hammers Hydraulic Hammers Up to 165 21,500 23,000 30,000 18,500 166 to 210 27,500 29,500 38,000 23,500 211 to 300 39,000 41,500 54,000 33,500 301 to 450 59,000 63,000 81,000 50,500 In addition, the ram of any diesel or hydraulic hammer shall have the following minimum weights: Maximum Driving Resistance (Tons)Minimum Ram Weight (lbs) Up to 165 2,700 166 to 210 4,000 211 to 300 5,000 301 to 450 6,500 These requirements for minimum hammer size may be waived if a Type 2E Working Drawing is submitted consisting of a wave equation analysis demonstrating the ability of the hammer to obtain the required bearing resistance and minimum tip elevation without damage to the pile. Vibratory hammers may be used to drive piles provided the location and plumbness requirements of this section are met. The required bearing resistance for all piles driven with vibratory hammers will be determined according to Section 6-05.3(12) by driving the pile at least an additional 2 feet using an impact hammer. This method of determining bearing resistance will be accepted provided the blows per inch are either constant or increasing. If the pile cannot be driven 2 feet, the pile will be considered acceptable for bearing if the pile is driven to refusal. If water jets are used, the number of jets and water volume and pressure shall be enough to erode the material next to the pile at the tip. The equipment shall include a minimum of two water-jet pipes and two ¾ inch jet nozzles. The pump shall produce a constant pressure of at least 100 psi at each nozzle. 6-05.3(9)C Pile Driving Leads All piles shall be driven with fixed-lead drivers. The leads shall be fixed on the top and bottom during the pile driving operation. Leads shall be long enough to eliminate the need for any follower (except for timber piles as specified in Section 6-05.3(11)E). To avoid bruising or breaking the surface of treated timber piles, the Contractor shall use spuds and chocks as little as possible. In building a trestle or foundation with inclined piles, leads shall be adapted for driving batter piles. 2020 Standard Specifications M 41-10 Page 6-183 Piling 6-05 A helmet of the right size for the hammer shall distribute the blow and protect the top of steel piling or casings from driving damage. The helmet shall be positioned symmetrically below the hammer’s striking parts, so that the impact forces are applied concentric to the pile top. Pile driving leads other than those fixed at the top and bottom may be used to complete driving, if permitted by the Engineer, when all of the following criteria are met: 1. Each plumb and battered pile is located and initially driven at least 20 feet in true alignment using fixed leads or other approved means. 2. The pile driving system (hammer, cushion and pile) will be analyzed by Pile Driving Analyzer (PDA) to verify driving stresses in the pile are not increased due to eccentric loading during driving, and transferred hammer energy is not reduced due to eccentric loading during driving, for all test piles and at least one production pile per pier. Unless otherwise specified, the cost of PDA testing shall be incidental to the various unit Contract prices for driving piles. 6-05.3(10) Test Piles If the Contract or the Engineer call for it, the Contractor shall drive test piles to determine pile lengths required to reach the required ultimate bearing resistance, penetration, or both. Test piles shall be: 1. Made of the same material and have the same tip diameter as the permanent piles (although test piles for treated timber piles may be either treated or untreated); 2. Driven with pile tips if the permanent piles will have tips; 3. Prebored when preboring is specified for the permanent piles; 4. Identical in cross-section and other characteristics to the permanent piles when the test piles are steel casings for cast-in-place concrete piles, precast concrete, precast-prestressed concrete or steel pipe or H-pile; 5. Long enough to accommodate any soil condition; 6. Driven with equipment and methods identical to those to be used for the permanent piles; 7. Located as the Engineer directs; and 8. Driven before permanent piles in a given pier. Test piles may also be driven by the Contractor (at no cost to the Contracting Agency) as evidence that the pile driving system selected will not damage the pile or result in refusal prior to reaching any specified minimum tip elevation. Timber test piles shall be driven outside the footing and cut off 1 foot below the finished ground line. Timber test piles shall not be used in place of permanent piles. Steel and all types of concrete test piles shall become permanent piles. The Contracting Agency has reduced the number of permanent piles by the number of test piles. Page 6-184 2020 Standard Specifications M 41-10 6-05 Piling The Contractor shall base test pile length on test-hole data in the Contract. Any test piles that prove to be too short shall be replaced (or spliced if the Contract allows splicing) at the Contractor’s expense. In foundations and trestles, test piles shall be driven to at least 15 percent more than the ultimate bearing resistance required for the permanent piles, except where pile driving criteria is determined by the wave equation. When pile driving criteria is specified to be determined by the wave equation, the test piles shall be driven to the same ultimate bearing resistance as the production piles. Test piles shall penetrate at least to any minimum tip elevation specified in the Contract. If no minimum tip elevation is specified, test piles shall extend at least 10 feet below the bottom of the concrete footing or ground line, and 15 feet below the bottom of the concrete seal. When any test pile to be left as a permanent pile has been so damaged by handling or driving that the Engineer believes it unfit for use, the Contractor shall remove and replace the pile at no additional cost to the Contracting Agency. The Engineer may direct the Contractor to overdrive the test pile to more than 15 percent above the ultimate bearing resistance for permanent piles, or if the wave equation is used to determine driving criteria, the Engineer may direct the Contractor to overdrive the test pile above the ultimate bearing resistance. In these cases, the overdriving shall be at the Contractor’s expense. But if pile damage results from this overdriving, any removal and replacement will be at the Contracting Agency’s expense. 6-05.3(11) Driving Piles 6-05.3(11)A Tolerances For elevated pier caps, the tops of piles at cut-off elevation shall be within 2 inches of the horizontal locations indicated in the Contract. For piles capped below final grade, the tops of piles at cut-off elevation shall be within 6 inches of the horizontal locations indicated in the Contract. No pile edge shall be nearer than 4 inches from the edge of any footing or cap. Piles shall be installed such that the axial alignment of the top 10 feet of the pile is within 4 percent of the specified alignment. No misaligned steel or concrete piles shall be pulled laterally. A properly aligned section shall not be spliced onto a misaligned section for any type of pile. Unless the Contract shows otherwise, all piles shall be driven vertically. 6-05.3(11)B Foundation Pit Preparation The Contractor shall replace (and bear the cost of replacing) any pile damaged or destroyed before or during driving. The Contractor shall completely dig all foundation pits (and build any required cofferdams or cribs) before driving foundation piles. The Contractor shall adjust pit depths to allow for upheaval caused by pile-driving, judging the amount of adjustment by the nature of the soil. Before constructing the footing or pile cap, the Contractor shall restore the pit bottom to correct elevation by removing material or by backfilling with granular material. 2020 Standard Specifications M 41-10 Page 6-185 Piling 6-05 6-05.3(11)C Preparation for Driving Treated and untreated timber piles shall be freshly cut square on the butt ends just before they are driven. If piles will be driven into hard material, caps, collars, or bands shall be placed on the butt ends to prevent crushing or brooming. If the head area of the pile is larger than that of the hammer face, the head shall be snipped or chamfered to fit the hammer. On treated piles, the heads shall be snipped or chamfered to at least the depth of the sapwood to avoid splitting the sapwood from the pile body. The Contractor shall match timber pile sizes in any single bent to prevent sway braces from undue bending or distorting. When driven, pile faces shall be turned as shown in the Plans or as the Engineer directs. No precast-prestressed pile shall be driven until test cylinders poured with it reach at least the specified compressive strength shown in the Contract. On all other precast piles, the cylinders must reach a compressive strength of at least 4,000 psi before the piles are driven. Helmets of approved design shall protect the heads of all precast concrete piles as they are driven. Each helmet shall have fitted into it a cushion next to the pile head. The bottom side of the helmet shall be recessed sufficiently to accommodate the required pile cushion and hold the pile in place during positioning and driving. The inside helmet diameter shall be determined before casting the pile, and the head of the pile shall be formed to fit loosely inside the helmet. Steel Casing, steel pipe or H-piles shall have square-cut ends. 6-05.3(11)D Achieving Minimum Tip Elevation and Bearing Once pile driving has started, each pile shall be driven continuously until the required ultimate bearing resistance shown in the Contract has been achieved. Pauses during pile driving, except for splicing, mechanical breakdown, or other unforeseen events, shall not be allowed. If the Contract specifies a minimum tip elevation, the pile shall be driven to at least the minimum tip elevation, even if the ultimate bearing resistance has been achieved, unless the Engineer directs otherwise. If a pile does not develop the required ultimate bearing resistance at the minimum tip elevation, the Contractor shall continue driving the pile until the required bearing resistance is achieved. If no minimum tip elevation is specified, then the piles shall be driven to the ultimate bearing resistance shown in the Contract and the following minimum penetrations: Pile supporting cross-beams, bents,  elevated pile caps elevation 10 feet below final top of ground Piles supporting foundations 10 feet below bottom of foundation Piles with a concrete seal 15 feet below bottom of seal Page 6-186 2020 Standard Specifications M 41-10 6-05 Piling If overdriving is required in order to reach a specified minimum tip elevation, the Contractor shall provide a pile driving system which will not result in damage to the pile or refusal before the minimum tip elevation is reached. The cost of overdriving shall be incidental to the various unit Contract prices for furnishing and driving piles. So long as the pile is not damaged and the embankment or foundation material being driven through is not permanently damaged, the Contractor shall use normal means necessary to: 1. Secure the minimum depth specified, 2. Penetrate hard material that lies under a soft upper layer, 3. Penetrate through hard material to obtain the specified minimum tip elevation, or 4. Penetrate through a previously placed embankment. Normal means refer to methods such as preboring, spudding, or jetting piles. Blasting or drilling through obstructions are not considered normal means. Prebored holes and pile spuds shall have a diameter no larger than the least outside dimension of the pile. After the pile is driven, the Contractor shall fill all open spaces between the pile and the soil caused by the preboring or spudding with dry sand, or pea gravel, or controlled density fill as approved by the Engineer. If water jets are used, the jets shall be withdrawn before the pile reaches its final penetration, and the pile shall then be driven to its final penetration and ultimate bearing resistance. The pile shall be driven a minimum of 2 feet to obtain the ultimate bearing resistance after the jets are withdrawn, or to refusal, whichever occurs first. If the water jets loosen a pile previously driven, it shall be redriven in place or pulled and replaced by a new pile. To check on pile loosening, the Contractor shall attempt to redrive at least one in every five piles, but no less than one pile per bent or pier. The various unit Contract prices for driving piles shall cover all costs related to the use of water jets, preboring, or spudding. The Contracting Agency will not pay any costs the Contractor incurs in redriving piles loosened as a result of using water jets, preboring, or spudding. If the Engineer requires, the Contractor shall overdrive the pile beyond the ultimate bearing resistance and minimum tip elevation shown in the Contract. In this case, the Contractor will not be required to: 1. Use other than normal means to achieve the additional penetration, 2. Bear the expense of removing or replacing any pile damaged by overdriving, or 3. Bear the expense of overdriving the pile more than 3 feet as specified in Section 6-05.5. In driving piles for footings with seals, the Contractor shall use no method (such as jetting or preboring) that might reduce friction resistance. 2020 Standard Specifications M 41-10 Page 6-187 Piling 6-05 6-05.3(11)E Use of Followers for Driving Followers shall not be used to drive concrete or steel piles. On timber piles, the Contractor may use steel (not wooden) followers if the follower fits snugly over the pile head. If a follower is used, the Contractor shall, in every group of 10 piles, drive one long pile without a follower, but no less than one pile per bent or pier, to the required ultimate bearing resistance and minimum tip elevation. This long pile shall be used to test the bearing resistance of the piles driven with a follower in the group. The tip elevation of the long pile shall be similar to the elevation of the piles driven with the follower. If the tip elevations are significantly different, as determined by the Engineer, the Contractor shall redrive the remaining piles in the group to the tip elevation of the longer pile. 6-05.3(11)F Pile Damage The Contractor shall remove and replace (and bear the cost of doing so) any pile that is damaged as determined by the Engineer. After driving a steel casing for a cast-in-place concrete pile, the Contractor shall leave it empty until the Engineer has inspected and accepted it. The Contractor shall make available to the Engineer a light suitable for inspecting the entire length of its interior. The Engineer will reject any casing that is improperly driven, that shows partial collapse that would reduce its ultimate bearing resistance, or that has been reduced in diameter, or that will not keep out water. The Contractor shall replace (and bear the cost of replacing) any rejected casing. Pile heads which have been broomed, rolled, or otherwise significantly damaged as determined by the Engineer shall be cut back to undamaged material before proceeding with driving as well as final acceptance of the pile. 6-05.3(11)G Pile Cutoff The Contractor shall trim the tops of all piles to the true plane shown in the Contract and to the elevation the Engineer requires. If a pile is driven below cutoff elevation without the Engineer’s permission, the Contractor shall remove and replace it (and bear the costs of doing so), even if this requires a longer pile. Any pile that rises as nearby piles are driven, shall be driven down again if the Engineer requires. Any piles under timber caps or grillages shall be sawed to the exact plane of the Structure above them and fit it exactly. No shimming on top of timber piles to adjust for inaccurate pile top elevations will be permitted. If a timber pile is driven out of line, it shall be straightened without damage before it is cut off or braced. Steel casing shall be cut off at least 6 inches below the finished ground line or at the low water line if the casing will be visible as determined by the Engineer. Page 6-188 2020 Standard Specifications M 41-10 6-05 Piling 6-05.3(11)H Pile Driving From or Near Adjacent Structures The Contractor shall not drive piling from an existing Structure unless all of the following conditions are met: 1. The existing Structure will be demolished within the Contract; 2. The existing Structure is permanently closed to traffic; and 3. Type 2E Working Drawings are submitted in accordance with Sections 1-05.3 and 6-02.3(16), showing the structural adequacy of the existing Structure to safely support all of the construction loads. Freshly placed concrete in the vicinity of the pile driving operation shall be protected against vibration in accordance with Section 6-02.3(6)D. 6-05.3(12) Determination of Bearing Values The following formula shall be used to determine ultimate bearing resistances: P = F × E × Ln(10N) Where: P = ultimate bearing resistance, in tons F = 1.8 for air/steam hammers = 1.2 for open ended diesel hammers and precast concrete or timber piles = 1.6 for open ended diesel hammers and steel piles = 1.2 for closed ended diesel hammers = 1.9 for hydraulic hammers = 0.9 for drop hammers E = developed energy, equal to W times H1, in ft-kips W = weight of ram, in kips H = vertical drop of hammer or stroke of ram, in feet N = average penetration resistance in blows per inch for the last 4 inches of driving Ln = the natural logarithm, in base “e” 1For closed-end diesel hammers (double-acting), the developed hammer energy (E) is to be determined from the bounce chamber reading. Hammer manufacturer calibration data may be used to correlate bounce chamber pressure to developed hammer energy. For double acting hammer hydraulic and air/steam hammers, the developed hammer energy shall be calculated from ram impact velocity measurements or other means acceptable to the Engineer. For open ended diesel hammers (single-acting) use the blows per minute to determine the developed energy (E). The above formula applies only when: 1. The hammer is in good condition and operating in a satisfactory manner. 2. A follower is not used. 3. The pile top is not damaged. 4. The pile head is free from broomed or crushed wood fiber. 5. The penetration occurs at a reasonably quick, uniform rate; and the pile has been driven at least 2 feet after any interruption in driving greater than 1 hour in length. 2020 Standard Specifications M 41-10 Page 6-189 Piling 6-05 6. There is no perceptible bounce after the blow. If a significant bounce cannot be avoided, twice the height of the bounce shall be deducted from “H” to determine its true value in the formula. 7. For timber piles, bearing resistances calculated by the formula above shall be considered effective only when it is less than the crushing strength of the piles. 8. If “N” is greater than or equal to 1.0 blow/inch. If “N” required to achieve the required ultimate bearing resistance using the above formula is less than 1.0 blow/inch, the pile shall be driven until the penetration resistance is a minimum of 1.0 blow/inch for the last 2 feet of driving. The Engineer may require the Contractor to install a pressure gauge on the inboard end of the hose to check pressure at the hammer. If water jets are used in driving, bearing resistances shall be determined either: (1) by calculating it with the driving data and the formula above after the jets have been withdrawn and the pile is driven at least 2 feet, or (2) by applying a test load. 6-05.3(13) Treatment of Timber Pile Heads After cutting timber piles to correct elevation, the Contractor shall thoroughly coat the heads of all untreated piles with two coats of an approved preservative that meets the requirements of Section 9-09 (except concrete-encased piles). After cutting treated timber piles to correct elevation, the Contractor shall brush three coats of a preservative that meets the requirements of Section 9-09 on all pile heads (except those to be covered with concrete footings or concrete caps). The pile heads shall then be capped with alternate layers of an approved roofing asphalt and a waterproofing fabric that conforms to Section 9-11.2. The cap shall be made of four layers of an approved roofing asphalt and three layers of fabric. The fabric shall be cut large enough to cover the pile top and fold down at least 6 inches along all sides of the pile. After the fabric cover is bent down over the pile, its edges shall be fastened with large-head galvanized nails or with three turns of galvanized wire. The edges of the cover shall be neatly trimmed. On any treated timber pile encased in concrete, the cut end shall receive two coats of an approved preservative that meets the requirements of Section 9-09 and then a heavy coat of an approved roofing asphalt. 6-05.3(14) Extensions and Buildups of Precast Concrete Piles The Contractor shall add extensions, or buildups (if necessary) on precast concrete piles after they are driven to the required ultimate bearing resistance and minimum tip elevation. Before adding extensions or buildups to precast-prestressed piles, the Contractor shall remove any spalled concrete, leaving the pile fresh-headed and with a top surface perpendicular to the axis of the pile. The concrete in the buildup shall be Class 5000. Page 6-190 2020 Standard Specifications M 41-10 6-05 Piling Before adding to non-prestressed precast concrete piles, the Contractor shall cut the pile head away to a depth 40 times the diameter of the vertical reinforcing bar. The final cut shall be perpendicular to the axis of the pile. Reinforcement of the same density and configuration as used in the pile shall be used in the buildup and shall be fastened firmly to the projecting steel. Forms shall be placed to prevent concrete from leaking along the pile. The concrete in the buildup shall be Class 4000. Just before placing the concrete for extensions or buildups to precast or precast- prestressed concrete piles, the Contractor shall thoroughly wet the top of the pile. Forms shall remain in place at least 3 days. 6-05.3(15) Completion of Cast-In-Place Concrete Piles After acceptance by the Engineer, driven casings shall be cut off horizontally at the required elevation. They shall be clean and free of water when concrete and reinforcing steel are placed. These piles shall consist of steel casings driven into the ground, reinforced as specified, and filled with Class 4000P concrete. 6-05.3(15)A Reinforcement All bars shall be fastened rigidly into a single unit, then lowered into the casing before the concrete is placed. Loose bars shall not be used. Spiral hooping reinforcement shall be deformed steel bar, plain steel bar, cold-drawn wire, or deformed wire. 6-05.3(15)B Placing Concrete Before placing concrete, the Contractor shall remove all debris and water from the casing. If the water cannot be removed, the casing shall be removed (or cut off 2 feet below the ground and filled with sand) and a new one driven. The Contractor shall place concrete continuously through a 5-foot rigid conduit directing the concrete down the center of the pile casing, ensuring that every part of the pile is filled and the concrete is worked around the reinforcement. The top 5 feet of concrete shall be placed with the tip of the conduit below the top of fresh concrete. The Contractor shall vibrate, as a minimum, the top 10 feet of concrete. In all cases, the concrete shall be vibrated to a point at least 5 feet below the original ground line. 6-05.4 Measurement Measurement for driving (type) pile will be the number of piles driven in place. In these categories, measurement will be the longer of either the number of linear feet driven below cutoff or as shown in the Engineer’s order list: 1. Furnishing timber piling (untreated or name of treatment). 2. Precast concrete and precast-prestressed concrete piling. 2020 Standard Specifications M 41-10 Page 6-191 Piling 6-05 In these categories, measurement will be the number of linear feet driven below cutoff, but no Engineer’s order list will be provided: 1. Cast-in-place concrete piling. 2. Furnishing steel piling. Measurement for furnishing and driving test piles will be the number actually furnished and driven as the Contract requires. Measurement for steel pile tips or shoes will be by the number of tips or shoes actually installed and driven in place on steel casings or steel piles. 6-05.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Furnishing and Driving (type) Test Pile”, per each. The unit Contract price per each for “Furnishing and Driving (type) Test Pile” shall be full pay for furnishing and driving test piles to the ultimate bearing resistance or penetration required by the Engineer, furnishing and installing a pile tip when pile tips are specified for the permanent piles, preboring when preboring is specified for the permanent piles, for pulling the piles or cutting them off as required, and for removing them from the site or for delivery to the Contracting Agency for salvage when ordered by the Engineer. For cast-in-place concrete test piles, this price shall include furnishing, fabricating, and installing the steel reinforcing bar cage, and furnishing, casting, and curing the concrete. This price shall also include all costs in connection with moving all pile driving equipment or other necessary equipment to the site of the Work and for removing all such equipment from the site after the piles have been driven. If, after the test piles have been driven, it is found necessary to eliminate the piling from all or any part of the Structure, no additional pay will be allowed for moving the pile driving equipment to and from the site of the Work. “Driving Timber Pile (untreated or name treatment)”, per each. The unit Contract price per each for “Driving Timber (type) Pile” shall include any metal shoes which the Contractor has determined to be beneficial to the pile driving. “Driving Conc. Pile (size)”, per each. “Driving St. Pile”, per each. The unit Contract price per each for “Driving (type) Pile (____)” shall be full pay for driving the pile to the ultimate bearing and/or penetration specified. “Furnishing Timber Piling (untreated or name treatment)”, per linear foot. “Furnishing Conc. Piling (size)”, per linear foot. “Furnishing St. Piling”, per linear foot. The unit Contract price per linear foot for “Furnishing (type) Piling (____)” shall be full pay for furnishing the piling specified, including furnishing, fabricating, and installing Page 6-192 2020 Standard Specifications M 41-10 6-05 Piling the steel reinforcing bar cage, and furnishing casting, and curing the concrete, as required for concrete piling. Such price shall also be full pay, for furnishing timber, precast concrete, or precast-prestressed concrete piling length ordered from an Engineer’s order sheet but not driven. “Precast Concrete Pile Buildup”, by force account. Payment for buildups of precast or precast-prestressed concrete piles will be made on the basis of force account Work as covered in Section 1-09.6. No payment will be made for buildups or additional lengths of buildup made necessary because of damage to the piling during driving. The length of splice for precast concrete piles includes the length cut off to expose reinforcing steel for the splice. The length of splice for precast-prestressed piles includes the length in which holes are drilled and reinforcing bars are grouted. For the purpose of providing a common Proposal for all Bidders, the Contracting Agency entered an amount for “Precast Concrete Pile Buildup” in the Proposal to become part of the total Bid by the Contractor. “Furnishing Steel Pile Tip or Shoe (size)”, per each. 2020 Standard Specifications M 41-10 Page 6-193 6-06 Bridge Railings 6-06.1 Description This Work consists of providing and building bridge railings that meet the requirements of the Plans, these Specifications, and the Engineer. 6-06.2 Materials Materials shall meet the requirements of the following sections: Timber Railing 9-09 Metal Railing 9-06.18 6-06.3 Construction Requirements 6-06.3(1) Timber Railings Wheel guards and railings shall be true to line and grade and framed accurately. The Contractor shall follow Section 6-04 whenever this Subsection does not specify a construction method. Unless the Plans show otherwise, wheel guards shall be: 1. Beveled and surfaced on the Roadway side and surfaced on the top edge. They may be surfaced on four sides (S4S). 2. Laid in sections at least 12 feet long. 3. Bolted through the floor plank and outside stringer (or nailing piece) with ¾ inch diameter bolts spaced no more than 4 feet apart. All rails and rail post material shall be S4S and painted as required in Section 6-07. Railing members shall be fastened securely together, with the bolts tightened once at installation and again just before the Contracting Agency’s final acceptance of the Contract. 6-06.3(2) Metal Railings Metal railing includes posts, web members, and horizontal members of the sidewalk and Roadway railing. Unless the Plans or Special Provisions show otherwise, these shall be made of aluminum alloy or steel. Before fabricating the railing, the Contractor shall submit Type 2 Working Drawings of the shop plans. The Contractor may substitute other rail connection details for those shown in the Plans if details of these changes show in the shop plans and if the Engineer accepts them in the Working Drawing response comments. In reviewing the shop plans, the Engineer indicates only that they are adequate and complete enough. The review does not indicate a check on dimensions. Page 6-194 2020 Standard Specifications M 41-10 6-06 Bridge Railings Anchor bolts shall be positioned with a template to ensure that bolts match the hole spacing of the bottom channels or anchorage plates. Where specified, cover plates shall fit the bottom channel tightly after being snapped into position. Metal railings shall be installed true to line and grade (or camber). After first setting the railing, the Contractor shall readjust all or part of it, if necessary, to create an overall line and grade pleasing to the eye. 6-06.4 Measurement Timber railing will be measured by the thousand board feet (MBM) as shown in Section 6-04. Metal railing will be measured by the linear foot along the line and slope at the base of the completed railing. 6-06.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Timber and Lumber (untreated or name treatment)”, per MBM. “Bridge Railing Type ____”, per linear foot. In case no item is included in the Contract for “Bridge Railing Type ____” and payment is not otherwise provided, all metal railings shall be included in the lump sum Contract price for “Structural Carbon St”. as specified in Section 6-03. 2020 Standard Specifications M 41-10 Page 6-195 Painting 6-07 6-07 Painting 6-07.1 Description This work consists of containment, surface preparation, shielding adjacent areas from work, testing and disposing of debris, furnishing and applying paint, and cleaning up after painting is completed. The work shall comply with all requirements of the Plans, these Specifications, and the Engineer. Terminology used herein is in accordance with the definitions used in Volume 2, Systems and Specifications, of the SSPC Steel Structures Painting Manual. 6-07.2 Materials Materials shall meet the requirements of the following sections: Paints and Related Materials 9-08 Powder Coating Materials for Coating Galvanized Surfaces 9-08.2 Abrasive Blast Media 9-08.4(1) Lead Abatement Additive 9-08.4(2) Bird Guano Treatment 9-08.5(1) Fungicide Treatment 9-08.5(2) Water 9-08.5(3) Filter Fabric 9-08.6 Single Component Urethane Sealant 9-08.7 Foam Backer Rod 9-08.8 6-07.3 Construction Requirements 6-07.3(1) Work Force Qualifications 6-07.3(1)A Work Force Qualifications for Shop Application of Paint Facilities for shop application of paint shall either be selected from one of the facilities listed in the WSDOT Qualified Products List as an approved coating facility for new steel structures or shall be approved through the WSDOT Request for Approval of Material process. The work force may be accepted based on the approved facility. 6-07.3(1)B Work Force Qualifications for Field Application of Paint The Contractor preparing the surface and applying the paint shall be certified under SSPC-QP 1 or NACE International Institute Contractor Accreditation Program (NIICAP) AS 1. The Contractor removing and otherwise disturbing existing paint containing lead and other hazardous materials shall be certified under SSPC-QP 2, Category A or NIICAP AS 2. In lieu of the above SSPC or NIICAP certifications, the Contractor performing the specified work shall complete both of the following actions: 1. The Contractor may substitute documentation of successful completion of two bridge painting projects in the past ten years involving complete paint removal, Page 6-196 2020 Standard Specifications M 41-10 6-07 Painting including paint containing lead and other hazardous materials, with reapplication of a three-component moisture-cured polyurethane paint system. The documentation shall include the name and size of the project, the dates of the work, the owner’s name, and name and contact information for an owner’s contact person. 2. The Contractor’s quality control inspector(s) for the project shall be NACE-certified CIP Level 3 or SSPC Protective Coating Inspector (PCI) Level 3. 6-07.3(2) Submittals The Contractor shall submit a painting plan consisting of one comprehensive submittal including all components described in this Section. The Contractor shall submit Type 2 Working Drawings of the painting plan components. Each component of the plan shall identify the specification section it represents. For shop application of paint, the painting plan shall include the documents and samples listed in Sections 6-07.3(2)B, 6-07.3(2)C, and 6-07.3(2)E. For field application of paint, the painting plan shall include the documents and samples listed in Section 6-07.3(2)A through 6-07.3(2)F. 6-07.3(2)A Work Force Qualifications Submittal Component The work force qualifications submittal component of the painting plan shall include the following: 1. Documentation of the Contractor’s workforce qualifications as specified in Section 6-07.3(1). 2. Resumé of qualifications and contact information for the Contractor’s on-site supervisors. Each on-site supervisor shall have 3 years’ minimum of industrial painting field experience with 1 year minimum of field supervisory or management experience in bridge painting projects. 6-07.3(2)B Contractor’s Quality Control Program Submittal Component The Contractor’s quality control program submittal component of the painting plan shall include the following: 1. Description of the inspection procedures, tools, techniques and the acceptance criteria for all phases of work. 2. Procedure for implementation of corrective action for non-conformance work. 3. The paint system manufacturer’s recommended methods of preventing defects. 4. The Contractor’s frequency of quality control inspection for each phase of work. 5. Example of each completed form(s) of the daily quality control report used to document the inspection work and tests performed by the Contractor’s quality control personnel. 2020 Standard Specifications M 41-10 Page 6-197 Painting 6-07 6-07.3(2)C Paint System Manufacturer and Paint System Information Submittal Component The paint system manufacturer and paint system information submittal component of the painting plan shall include the following: 1. Product data sheets and Safety Data Sheets (SDS) on the paint materials, paint preparation, and paint application, as specified by the paint manufacturer, including: a. All application instructions, including the mixing and thinning directions. b. Recommended spray nozzles and pressures. c. Minimum and maximum drying time between coats. d. Restrictions on temperature and humidity. e. Repair procedures for shop and field applied coatings. f. Maximum dry film thickness for each coat. g. Minimum wet film thickness for each coat to achieve the specified minimum dry film thickness. 2. Identification of, and contact information for, the paint system manufacturer’s technical representative. 3. For painting of new steel, the friction coefficient of the faying surface, including test results and the paint manufacturer’s Certificate of Compliance in support of the friction coefficient. 6-07.3(2)D Hazardous Waste Containment, Collection, Testing, and Disposal Submittal Component The hazardous waste containment, collection, testing, and disposal shall meet all Federal and State requirements, and the submittal component of the painting plan shall include the following: 1. Abrasive blasting containment system attachment and support in accordance with Section 6-07.3(10)A, with a complete description of each attachment device. 2. Details of jobsite material storage facilities and containment waste storage facilities, including location, security, and environmental control. 3. Methods and materials used to contain, collect, and dispose of all containment waste and all construction-related waste, including transportation of waste. 4. Details of the containment waste sampling plan conforming to WAC 173-303 for waste designated as dangerous waste or extremely hazardous waste. 5. The name of, and contact information for, the accredited analytical laboratory performing the testing of the containment waste samples in accordance with Section 6-07.3(10)F. 6. Process for tracking the disposal of hazardous waste, including a sample form of the tracking documentation. Page 6-198 2020 Standard Specifications M 41-10 6-07 Painting 7. When a wind speed threshold is specified, a description of the method to lower or withdraw tarps, plastic exterior, and other containment components presenting an exposed face to wind, and the estimated time required to accomplish this action. 8. Provisions for dust and debris collection, ventilation, and auxiliary lighting within the containment system. 6-07.3(2)E Cleaning and Surface Preparation Submittal Component The cleaning and surface preparation submittal component of the painting plan shall include the following: 1. Details of the abrasive blast cleaning operation, including: a. Description of the abrasive blast cleaning procedure. b. Type, manufacturer, and brand of abrasive blast material and all associated additives, including Safety Data Sheets (SDS). c. Description of the abrasive blast cleaning equipment to be used. 6-07.3(2)F Paint Application Equipment and Operations Submittal Component The paint application equipment and operations submittal component of the painting plan shall include the following: 1. Description of the equipment used for paint application operations. 2. Details of jobsite material storage facilities, including location, security, and environmental control. 3. Description of the supports and platforms used to support equipment, materials, and workers, including scaffolds, platforms, accordion lifts, and barges, and the methods used to attach, moor, and anchor these supports and platforms. 4. Drip tarps in accordance with Section 6-07.3(10)O. 5. Methods and materials used to protect surrounding structures, equipment, and property from exposure to, and damage from, painting operations. 6. Details of paint application operations for areas of limited and restricted access. 7. Description of the method for the removal of any accidental spills or drips on traffic that occur during the normal painting operations, and provisions for providing a vehicle-cleaning station. 6-07.3(2)G Painting Plan Meeting At the option of the Contracting Agency, a painting plan meeting may be scheduled following review of the Contractor’s initial submittal of the plan. The Contractor shall be represented by the superintendent, on-site supervisors, and quality control inspectors. 2020 Standard Specifications M 41-10 Page 6-199 Painting 6-07 6-07.3(3) Quality Control and Quality Assurance 6-07.3(3)A Quality Control and Quality Assurance for Shop Application of Paint For shop application of paint, quality control procedures shall be as accepted by the Engineer. 6-07.3(3)B Quality Control and Quality Assurance for Field Application of Paint For field application of paint, the Contractor shall conduct quality control inspections as required by SSPC-PA 1, using the personnel and the processes outlined in the painting plan. The Contractor shall maintain current copies of the SSPC Painting Manual, Volumes 1 and 2, at the project site at all times. The Contractor’s quality control operations shall include at a minimum monitoring and documenting the following for each working day: 1. Equipment, personnel, and materials used. 2. Environmental conditions (ambient air temperature and humidity, steel surface temperature, dew point, wind direction, and velocity). 3. Steel surface condition, profile, and preparation. 4. Paint application and film thickness. A Type 1 Working Drawing consisting of the Contractor’s daily quality control report, signed and dated by the Contractor’s quality control inspector, accompanied by copies of the test results of quality control tests performed on the work covered by the daily quality control report, shall be submitted to the Engineer before the end of the next day’s work shift. The Contractor shall provide the Engineer time and access to perform quality assurance testing. Each painting operation phase shall be considered a hold point, from which the Contractor shall not proceed with continuing work until receiving the Engineer’s acceptance. The Engineer may perform quality assurance testing at each of the following phases of painting operations: 1. After SSPC-SP 1 cleaning. 2. After abrasive blast cleaning, hand and power tool surface cleaning, and compressed air surface cleaning. 3. After applying each coat when dry. 4. During final inspection of all work at the end of the project. Page 6-200 2020 Standard Specifications M 41-10 6-07 Painting Quality assurance testing may include the following tests: 1. Environmental conditions for painting in accordance with ASTM E337. 2. Cleanness of abrasive blasting media and ionic contamination of abrasive blasting media in accordance with ASTM D4940. 3. Cleanness of compressed air in accordance with ASTM D4285. 4. Pictorial of surface preparation guides in accordance with SSPC-VIS 1, 3, 4, and 5. 5. Surface profile by Keanne-Tator comparator in accordance with ASTM D4417 and SSPC PA17. 6. Surface profile by replica tape in accordance with ASTM D4417. 7. Wet film thickness in accordance with ASTM D4414. 8. Dry film thickness by magnetic gage in accordance with SSPC-PA 2 modified. 9. Dry film thickness by Tooke gage in accordance with ASTM D4138. The Contractor shall repair all damage to paint resulting from Contracting Agency’s quality assurance inspections at no additional cost or time to the Contracting Agency. 6-07.3(4) Paint System Manufacturer’s Technical Representative The paint system manufacturer’s technical representative shall be present at the jobsite for the pre-painting conference and for the first day of paint application, and shall be available to the Contractor and Contracting Agency for consultation for the full project duration. 6-07.3(5) Pre-Painting Conference A pre-painting conference shall be held 5 to 10 working days before beginning painting operations to discuss the painting plan, construction operations, personnel, and equipment to be used. Those attending shall include: 1. (Representing the Contractor) The superintendent, on-site supervisors, and all crew members in charge of cleaning and preparing the surfaces, containing, collecting and disposing of all removed materials, applying the paint, and performing all quality control inspections, measurements and tests; and the paint system manufacturer’s technical representative; and 2. (Representing the Contracting Agency) The Engineer, key inspection assistants, and representatives of the WSDOT HQ Construction Office. If the Contractor’s key personnel change between any work operations, an additional conference shall be held if requested by the Engineer. For projects that include painting of multiple structures, a separate conference may be held for each structure, at the discretion of the Engineer. 2020 Standard Specifications M 41-10 Page 6-201 Painting 6-07 6-07.3(6) Paint Containers, Storage, and Handling 6-07.3(6)A Paint Containers Paint container labels shall include the following information: 1. Manufacturer’s name and product name, with batch number and date of manufacture. 2. Color name and SAE AMS Standard 595 color number, where applicable. 3. Shelf life of the product, from date of batch manufacture. 4. Storage requirements and temperature limits. Paint containers shall conform to U.S. DOT hazardous material shipping regulations. Paint shall be delivered to the jobsite in the manufacturer’s original unopened containers with the original manufacturer’s label legible and intact. Paint will be rejected if the container has a puncture or if the lid shows signs of paint leakage. Each container shall be filled with paint and sealed airtight. Each container shall be filled with the amount of paint required to yield the specified quantity when measured at 70°F. All paint shall be shipped in new suitable containers having a capacity not greater than 5 gallons. 6-07.3(6)B Paint Storage Paint materials shall not be used or stored on-site after the shelf life expiration date. Paint material shipping, handling, and storage shall conform to Sections 1-06.4 and 9-08.1(4) and the following requirements: 1. Paint materials shall be stored in the manufacturer’s original containers in a weather- tight space where the temperature is maintained within the storage temperature range recommended by the paint manufacturer, but in no case where the temperature is lower than 40°F or greater than 100°F. 2. The Contractor shall monitor and document daily the paint material storage facility with a high-low recording thermometer device. 3. The paint material storage facility shall be separate from the storage facilities used for storing painting equipment and used for storing containment waste and construction-generated waste. 6-07.3(7) Paint Sampling and Testing The Contractor shall provide the Engineer 1 quart of each paint representing each lot. Samples shall be accompanied with a Safety Data Sheet. If the quantity of paint required for each component of the paint system for the entire project is 20 gallons or less, then the paint system components will be accepted as specified in Section 9-08.1(7). Sampling and testing performed by the Contracting Agency shall not be construed as determining or predicting the performance or compatibility of the individual paint or the completed paint system. Page 6-202 2020 Standard Specifications M 41-10 6-07 Painting 6-07.3(8) Equipment 6-07.3(8)A Paint Film Thickness Measurement Gages Paint dry film thickness measurements shall be performed with either a Type 1 pull-off gage or a Type 2 electronic gage as specified in SSPC Paint Application Specification No. 2, Procedure for Determining Conformance to Dry Coating Thickness Requirements. Paint wet film thickness measurement gages shall be stainless steel with notches graduated in 1-mil increments. 6-07.3(9) Painting New Steel Structures All materials classified as nongalvanized structural steel shall be painted with a four-coat paint system as specified in Section 6-07.3(9)A. The primer coat shall be shop-applied. The intermediate, intermediate stripe, and top coats shall be field-applied after erection and following any primer coating repair operations. Steel surfaces embedded in concrete, and faying (contact) surfaces of bolted connections (including all surfaces internal to the connection and all filler plates) shall receive the primer coat only. Stainless steel surfaces are not required to be painted. Welded shear connectors are not required to be painted. Temporary attachments or supports for scaffolding, containment or forms shall not damage the paint system. 6-07.3(9)A Paint System The paint system applied to new steel surfaces shall consist of the following: Option 1 (component based paint system): Primer Coat - Inorganic Zinc Rich 9-08.1(2)C Intermediate Coat - Moisture Cured Polyurethane 9-08.1(2)G Intermediate Stripe Coat - Moisture Cured Polyurethane 9-08.1(2)G Top Coat - Moisture Cured Polyurethane 9-08.1(2)H Option 2 (performance based paint system): Primer Coat - Inorganic Zinc Rich 9-08.1(2)M Intermediate Coat - Epoxy 9-08.1(2)M Intermediate Stripe Coat - Epoxy 9-08.1(2)M Top Coat - Polyurethane 9-08.1(2)M Paints and related materials shall be products listed in the current WSDOT Qualified Products List (QPL). Component based paint systems shall be listed on the QPL in the applicable sections of Section 9-08. Performance based systems shall be listed on the current Northeast Protective Coatings Committee (NEPCOAT) Qualified Products List “A” as listed on the WSDOT QPL in Section 9-08.1(2)M. If the paint and related materials for the component based system is not listed in the current WSDOT QPL, a sample shall be submitted to the State Materials Laboratory in Tumwater for evaluation and acceptance in accordance with Section 9-08. 2020 Standard Specifications M 41-10 Page 6-203 Painting 6-07 All paint coating components of the selected paint system shall be produced by the same manufacturer. The paint system selected shall be used throughout the entire structure. Paint formulations to be used on faying surfaces shall be Class B coatings with a mean slip coefficient not less than 0.50. The slip coefficient shall be determined by testing 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. 6-07.3(9)B Paint Color Each successive coat shall be a contrasting color to the previously applied coat. The color of the top coat shall be as specified in the Plans or Special Provisions and shall conform to Section 9-08.1(8). 6-07.3(9)C Mixing and Thinning Paint The Contractor shall thoroughly mix paint in accordance with the manufacturer’s written recommendations and by mechanical means to ensure a uniform and lump free composition. Paint shall not be mixed by means of air stream bubbling or boxing. Paint shall be mixed in the original containers and mixing shall continue until all pigment or metallic powder is in suspension. Care shall be taken to ensure that the solid material that has settled to the bottom of the container is thoroughly dispersed. After mixing, the Contractor shall inspect the paint for uniformity and to ensure that no unmixed pigment or lumps are present. Catalysts, curing agents, hardeners, initiators, or dry metallic powders that are packaged separately may be added to the base paint in accordance with the paint manufacturer’s written recommendations and only after the paint is thoroughly mixed to achieve a uniform mixture with all particles wetted. The Contractor shall then add the proper volume of curing agent to the correct volume of base and mix thoroughly. The mixture shall be used within the pot life specified by the manufacturer. Unused portions shall be discarded at the end of each work day. Accelerants are not permitted except as allowed by the Engineer. The Contractor shall not add additional thinner at the application site except as allowed by the Engineer. The amount and type of thinner, if allowed, shall conform to the manufacturer’s specifications. If recommended by the manufacturer and allowed by the Engineer, a measuring cup shall be used for the addition of thinner to any paint with graduations in ounces. No unmeasured addition of thinner to paint will be allowed. Any paint found to be thinned by unacceptable methods will be rejected. When recommended by the manufacturer, the Contractor shall constantly agitate paint during application by use of paint pots equipped with mechanical agitators. The Contractor shall strain all paint after mixing to remove undesirable matter, but without removing the pigment or metallic powder. Paint shall be stored and mixed in a secure, contained location to eliminate the potential for spills into State waters and onto the ground and highway surfaces. Page 6-204 2020 Standard Specifications M 41-10 6-07 Painting 6-07.3(9)D Coating Thickness Dry film thickness shall be measured in accordance with SSPC Paint Application Specification No. 2, Procedure for Determining Conformance to Dry Coating Thickness Requirements. The minimum dry film thickness of the primer coat shall not be less than 2.5 mils. The minimum dry film thickness of each coat (combination of intermediate and intermediate stripe, and top) shall be not less than 3.0 mils. The dry film thickness of each coat shall not be thicker than the paint manufacturer’s recommended maximum thickness. The minimum wet film thickness of each coat shall be specified by the paint manufacturer to achieve the minimum dry film thickness. Film thickness, wet and dry, will be measured by gages conforming to Section 6-07.3(8)A . Wet measurements will be taken immediately after the paint is applied in accordance with ASTM D4414. Dry measurements will be taken after the coating is dry and hard in accordance with SSPC Paint Application Specification No. 2. Each painter shall be equipped with wet film thickness gages and shall be responsible for performing frequent checks of the paint film thickness throughout application. Coating thickness measurements may be made by the Engineer after the application of each coat and before the application of the succeeding coat. In addition, the Engineer may inspect for uniform and complete coverage and appearance. One hundred percent of all thickness measurements shall meet or exceed the minimum wet film thickness. In areas where wet film thickness measurements are impractical, dry film thickness measurements may be made. If a question arises about an individual coat’s thickness or coverage, it may be verified by the use of a Tooke gage in accordance with ASTM D4138. If the specified number of coats does not produce a combined dry film thickness of at least the sum of the thicknesses required per coat, if an individual coat does not meet the minimum thickness, or if visual inspection shows incomplete coverage, the coating system will be rejected and the Contractor shall discontinue painting and surface preparation operations and shall submit a Type 2 Working Drawing of the repair proposal. The repair proposal shall include documentation demonstrating the cause of the less-than-minimum thickness, along with physical test results, as necessary, and modifications to Work methods to prevent similar results. The Contractor shall not resume painting or surface preparation operations until receiving the Engineer’s acceptance of the completed repair. 6-07.3(9)E Environmental Condition Requirements Prior to Application of Paint Paint shall be applied only during periods when: 1. Air and steel temperatures are in accordance with the paint manufacturer’s recommendations but in no case less than 35°F nor greater than 115°F. 2020 Standard Specifications M 41-10 Page 6-205 Painting 6-07 2. Steel surface temperature is a minimum of 5°F above the dew point. 3. Steel surface is not wet. 4. Relative humidity is within the manufacturer’s recommended range. 5. The anticipated ambient temperature will remain above 35°F or the manufacturer’s minimum temperature, whichever is greater, during the paint drying and curing period. Application will not be allowed if conditions are not favorable for proper application and performance of the paint. Paint shall not be applied when weather conditions are unfavorable to proper curing. If a paint system manufacturer’s recommendations allow for application of a paint under environmental conditions other than those specified, the Contractor shall submit a Type 2 Working Drawing consisting of a letter from the paint manufacturer specifying the environmental conditions under which the paint can be applied. Application of paint under environmental conditions other than those specified in this section will not be allowed without the Engineer’s concurrence. 6-07.3(9)F Shop Surface Cleaning and Preparation A roughened surface profile shall be provided by an abrasive blasting procedure as accepted by the Engineer. The profile shall be 1-mil minimum or in accordance with the paint manufacturer’s recommendations, whichever is greater. The entire steel surface to be painted, including surfaces specified in Section 6-07.3(9)G to receive a mist coat of primer, shall be cleaned to a near white condition in accordance with SSPC-SP 10, Near-white Metal Blast Cleaning, and shall be in this condition immediately prior to paint application. 6-07.3(9)G Application of Shop Primer Coat After receiving the Engineer’s acceptance of the prepared surface, the primer shall be applied so as to produce a uniform, even coating that has fully bonded with the metal. Primer shall be applied with the spray nozzles and pressures recommended by the manufacturer of the paint system, so as to attain the film thicknesses specified. Repairs of the shop primer coat shall be prepared in accordance with the painting plan. Shop primer coat repair paint shall be selected from the approved component based or performance based paint system in accordance with Section 6-07.3(10)H. Steel girder top flanges and soldier pile flanges to be embedded in concrete shall be prepared in accordance with Section 6-07.3(9)F and shall then receive a mist coat of the specified primer with a dry film thickness of 0.5 to 1.0 mils. The Contractor shall provide access to the steel to permit inspection by the Engineer. The access shall not mar or damage any freshly painted surfaces. High-strength field bolts shall not be painted before erection. Page 6-206 2020 Standard Specifications M 41-10 6-07 Painting 6-07.3(9)H Containment for Field Coating The Contractor shall use a containment system in accordance with Section 6-07.3(10)A for surface preparation and prime coating of all uncoated areas remaining, including bolts, nuts, washers, and splice plates. During painting operations of the intermediate, stripe and top coats the Contractor shall furnish, install, and maintain drip tarps below the areas to be painted to contain all spilled paint, buckets, brushes, and other deleterious material, and prevent such materials from reaching the environment below or adjacent to the structure being painted. Drip tarps shall be absorbent material and hung to minimize puddling. The Contractor shall evaluate the project-specific conditions to determine the specific type and extent of containment needed to control the paint emissions and shall submit a containment plan in accordance with Section 6-07.3(2). 6-07.3(9)I Application of Field Coatings An on-site supervisor shall be present for each work shift at the bridge site. Upon completion of erection Work, all uncoated or damaged areas remaining, including bolts, nuts, washers, and splice plates, shall be prepared in accordance with Section 6-07.3(9)F, followed by a field primer coat of a zinc-rich primer and final coats of paint selected from the approved component or performance based paint system in accordance with Section 6-07.3(10)H. The intermediate, intermediate stripe, and top coats shall be applied in accordance with the manufacturer’s written recommendations. Upon completion of erection Work, welds for steel column jackets may be prepared in accordance with SSPC-SP 15, Commercial Grade Power Tool Cleaning. The minimum drying time between coats shall be as shown in the product data sheets, but not less than 12 hours. The Contractor shall determine whether the paint has cured sufficiently for proper application of succeeding coats. The maximum time between intermediate and top coats shall be in accordance with the manufacturer’s written recommendations. If the maximum time between coats is exceeded, all newly coated surfaces shall be prepared to SSPC-SP 7, Brush-off Blast Cleaning, and shall be repainted with the same paint that was cleaned, at no additional cost to the Contracting Agency. Each coat shall be applied in a uniform layer, completely covering the preceding coat. The Contractor shall correct runs, sags, skips, or other deficiencies before application of succeeding coats. Such corrective work may require re-cleaning, application of additional paint, or other means as determined by the Engineer, at no additional cost to the Contracting Agency. Dry film thickness measurements will be made in accordance with Section 6-07.3(9)D. All paint damage that occurs shall be repaired in accordance with the manufacturer’s written recommendations. On bare areas or areas of insufficient primer thickness, the repair shall include field-applied zinc-rich primer, and the final coats of the paint selected 2020 Standard Specifications M 41-10 Page 6-207 Painting 6-07 from the approved component or performance based paint system in accordance with Section 6-07.3(10)H. On areas where the primer is at least equal to the minimum required dry film thickness, the repair shall include the application of the final two coats of the paint system. All paint repair operations shall be performed by the Contractor at no additional cost or time to the Contracting Agency. 6-07.3(10) Painting Existing Steel Structures Painting existing steel structures includes providing containment, cleaning, preparing the surface, painting metal surfaces, and disposal of generated waste. Painting of existing steel structures shall be done in the following sequence: 1. Containment. 2. Bird guano, fungus, and vegetation removal. 3. Dry cleaning. 4. Surface preparation. 5. Treatment of pack rust and gaps. 6. Paint system application. 6-07.3(10)A Containment The containment system shall be in accordance with SSPC Technology Guide No. 6, Guide for Containing Surface Preparation Debris Generated During Paint Removal Operations Class 1. The containment system shall fully enclose the steel to be painted and not allow any material to escape the containment system. The Contractor shall protect the surrounding environment from all debris or damage resulting from the Contractor’s operations. Except as otherwise specified in the Contract, the containment length shall not exceed the length of a span (defined as pier to pier). The containment system shall not cause any damage to the existing structure. Attachment devices shall not mark or otherwise damage the steel member to which they are attached. Field-welding of attachments to the existing structure will not be allowed. The Contractor shall not drill holes into the existing structure or through existing structural members except as shown in the Contractor’s painting plan Working Drawing submittal. Emissions shall be assessed by Visible Emission Observations (Method A) in SSPC Technology Update No. 7, Conducting Ambient Air, Soil, and Water Sampling of Surface Preparation and Paint Disturbance Activities, Section 6.2 and shall be limited to the Level A Acceptance Criteria Option Level 0 Emissions standard. If visible emissions occur or if failure to the containment system occurs or if signs of failure to the containment system are present, the Contractor shall stop work immediately. Work shall not resume until the failure has been corrected to the satisfaction of the Engineer. The containment system shall not be removed until all cleaned and painted surfaces have been inspected and accepted by the Engineer. Page 6-208 2020 Standard Specifications M 41-10 6-07 Painting Prior to beginning work each day, all containment systems shall be inspected by the Contractor to verify they are in place and functioning properly. Any necessary maintenance to restore full function shall be completed prior to beginning work. 6-07.3(10)B Bird Guano, Fungus, and Vegetation Removal Bird guano and bird nesting materials shall be removed in the dry. Following dry removal, the Contractor shall apply a treatment solution in accordance with Section 9-08.5(1), followed by hand-scrubbing and rinsing with water in accordance with Section 9-08.5(3). The bird guano, bird nesting materials, and treatment solution shall be contained and collected. The Contractor shall treat all areas of fungus growth and vegetative growth. The Contractor shall apply a treatment solution in accordance with Section 9-08.5(2) to the fungus areas for a period recommended by the solution manufacturer or as specified by the Engineer, but in no case less than 5 minutes. The fungus, vegetative growth, and treatment solution shall be contained and collected. Bird guano, bird nesting materials, fungus, and vegetative growth shall be disposed of at a land disposal site accepted by the Engineer. The Contractor shall submit a Type 1 Working Drawing consisting of one copy of the disposal receipt, which shall include a description of the disposed material. 6-07.3(10)C Dry Cleaning Dry cleaning shall include removal of accumulated dirt and debris on the surfaces to be painted. Collected dirt and debris shall be disposed of at a land disposal site accepted by the Engineer. The Contractor shall submit a Type 1 Working Drawing consisting of a copy of the disposal receipt, which shall include a description of the disposed material. 6-07.3(10)D Surface Preparation Prior to Overcoat Painting The Contractor shall remove any visible oil, grease, and road tar in accordance with SSPC-SP 1, Solvent Cleaning. Following any preparation by SSPC-SP1, all steel surfaces to be painted shall be prepared in accordance with SSPC-SP 7, Brush-Off Blast Cleaning. Surfaces inaccessible to brush- off blast shall be prepared in accordance with SSPC-SP 3, Power Tool Cleaning, as allowed by the Engineer. Following brush-off blast cleaning, the Contractor shall perform spot abrasive blast cleaning in accordance with SSPC-SP 6, Commercial Blast Cleaning. Spot abrasive blast cleaning shall be performed in such a manner that the adjacent areas of work are protected from damage. Areas exhibiting coating failure down to the steel substrate, and those exhibiting visible corrosion, shall be prepared down to clean bare steel in accordance with SSPC-SP 6. Exposed steel areas that have an average exposed diameter of less than 1½ inches and no other similar area closer than 4 inches do not require spot abrasive blast cleaning or edge feathering unless required by the Engineer. The Contractor shall provide a sharp angular surface profile by an abrasive blasting procedure as accepted by the Engineer. The profile shall be 1 mil minimum or in accordance with the paint 2020 Standard Specifications M 41-10 Page 6-209 Painting 6-07 manufacturer’s recommendations, whichever is greater. For small areas, as allowed by the Engineer, the Contractor may substitute cleaning in accordance with SSPC-SP 15, Commercial Grade Power Tool Cleaning. The prepared area shall extend at least 2 inches into adjacent tightly adhering, intact coating. Following spot abrasive blast cleaning of exposed steel surfaces, edges of tightly adherent coating remaining shall be feathered so that the recoated surface has a smooth appearance. Immediately prior to painting, the Contractor shall clean all steel surfaces and staging areas with dry, oil-free compressed air conforming to ASTM D4285. 6-07.3(10)E Surface Preparation – Full Paint Removal For structures where full removal of existing paint is specified, the Contractor shall remove any visible oil, grease, and road tar in accordance with SSPC-SP 1. Following preparation by SSPC-SP 1, all steel surfaces to be painted shall be prepared in accordance with SSPC-SP 10, Near-White Metal Blast Cleaning. Surfaces inaccessible to Near-White Metal Blast Cleaning shall be prepared in accordance with SSPC-SP 11, Power Tool Cleaning to Bare Metal, as allowed by the Engineer. 6-07.3(10)F Collecting, Testing, and Disposal of Containment Waste The sealed waste containers shall be labeled as required by State and Federal laws. All confined materials shall be collected and secured in sealed containers at the end of each shift or daily at a minimum to prevent the weight of the confined materials from causing failure to the containment system. The sealed waste containers shall be stored in accordance with Section 1-06.4, the painting plan, and the following requirements: 1. The containers shall be stored on an impermeable surface that accommodates sweeping or vacuuming. 2. Landside storage of the containers shall be at an elevation above the ordinary high water level (OHWL) elevation. The container storage area shall not be in a stormwater runoff course and shall not be in an area of standing water. 3. The container storage area shall be a fenced, secured site, separate from the storage facilities for paint materials and paint equipment. 4. The containers shall not be stored at the on-site landside storage site for longer than 90 calendar days. All material collected by and removed from the containment system shall be taken to a landside staging area, provided by the Contractor, for further processing and storage prior to transporting for disposal. Handling and storage of material collected by and removed from the containment system shall conform to Section 1-06.4. Storage of containment waste materials shall be in a facility separate from the storage facilities used for paint materials and paint equipment. Containment waste is defined as all paint chips and debris removed from the steel surface and all abrasive blast media, as contained by the containment system. After all waste from the containment system has been collected, the Contractor shall collect representative Page 6-210 2020 Standard Specifications M 41-10 6-07 Painting samples of the components that field screening indicates are lead-contaminated material. The Contractor shall collect at least one representative sample from each container. The Contractor may choose to collect a composite sample of each container, but the composite sample must consist of several collection points (a minimum of 3 random samples) that are representative of the entire contents of the container and representative of the characteristics of the type of waste in the container. In accordance with WAC 173–303-040, a representative sample means “a sample which can be expected to exhibit the average properties of the sample source.” The debris shall be tested for metals using the Toxicity Characteristics Leaching Procedure (TCLP) and EPA Methods 1311 and 6010. At a minimum, the materials should be analyzed for the Resource Conservation and Recovery Act (RCRA) 8 Metals (arsenic, barium, cadmium, chromium, lead, mercury, selenium, and silver). Pursuant to the Dangerous Waste (DW) Regulations Chapter 173-303-90(8)(c) WAC, “Any waste that contains contaminants which occur at concentrations at or above the DW threshold must be designated as DW.” All material within each individual container or containment system that designates as DW shall be disposed of at a legally permitted Subtitle C Hazardous Waste Landfill. All material within each individual container or containment system that designate below the DW threshold, will be designated as “Solid Waste” and shall be disposed of at a legally permitted Subtitle D Landfill. Disposal shall be in accordance with WAC 173-303 for waste designated “Dangerous Waste” and pursuant to WAC 173- 350 for waste designated as “Solid Waste”. The Contractor shall submit a Type 1 Working Drawing consisting of two copies of the transmittal documents or bill of lading listing the waste material shipped from the construction site to the waste disposal site. One copy of the shipment list shall show the signature of the Engineer and shall have the waste site operator’s confirmation for receipt of the waste. In the event that the containment wastes are designated as “Dangerous Wastes” or “Extremely Hazardous Waste” under WAC 173-303, the Contracting Agency will provide to the Contractor the appropriate EPA identification number. Unless noted otherwise, a waste site will not be provided by the Contracting Agency for the disposal of excess materials and debris. The Contractor shall submit a Type 1 Working Drawing of all TCLP results. The Contractor shall submit a Type 1 Working Drawing consisting of waste disposal documentation within 15 working days of each disposal. This documentation shall include the quantity and type of waste disposed of with each disposal shipment. 6-07.3(10)G Treatment of Pack Rust and Gaps Pack rust is defined as the condition where two or more pieces of steel fastened together by rivets or bolts have been pressed apart by crevice corrosion caused by the buildup of corrosion products at the interface of the steel pieces. 2020 Standard Specifications M 41-10 Page 6-211 Painting 6-07 Pack rust forming a gap between steel surfaces of 1/16 to 1/4 inch shall be cleaned to a depth of at least one half of the gap width. The gaps shall be cleaned and prepared in accordance with SSPC-SP6. The cleaned gap shall be treated with rust penetrating sealer, prime coated, and then caulked to form a watertight seal along the top edge and the two sides of the steel pieces involved, using the rust penetrating sealer and caulk as accepted by the Engineer. The bottom edge or lowest edge of the steel pieces involved shall not be caulked. The type of rust penetrating sealer and caulk used shall be compatible with the paint system used and shall be applied in accordance with the rust penetrating sealer and caulk manufacturer’s instructions. Caulk shall be a single-component urethane sealant conforming to Section 9-08.7. When caulking joints where only one steel piece edge is exposed, a fillet of caulk shall be formed that is not less than ⅛ inch or the width of the pack rust gap. The fillet is not required where there is no separation of the steel pieces due to pack rust. At locations where gaps between steel surfaces exceed ¼ inch, the Contractor shall clean and prepare the gap in accordance with SSPC-SP6, apply the rust penetrating sealer, apply the prime coat, and then fill the gap with foam backer rod material as accepted by the Engineer. The foam backer rod material shall be of sufficient diameter to fill the crevice or gap. The Contractor shall apply caulk over the foam backer rod material to form a watertight seal. Caulk and backer rod, if needed, shall be placed prior to applying the top coat. The Contractor, with the concurrence of the Engineer, may apply the rust penetrating sealer after application of the prime coat provided the primer is removed in the areas to be sealed. The areas to be sealed shall be re-cleaned and re-prepared in accordance with SSPC-SP6. 6-07.3(10)H Paint System The paint system applied to existing steel surfaces shall consist of the following five-coat system: Option 1 (component based system): Primer Coat - Zinc-filled Moisture Cured Polyurethane 9-08.1(2)F Primer Stripe Coat - Moisture Cured Polyurethane 9-08.1(2)F Intermediate Coat - Moisture Cured Polyurethane 9-08.1(2)G Intermediate Stripe Coat - Moisture Cured Polyurethane 9-08.1(2)G Top Coat - Moisture Cured Polyurethane 9-08.1(2)H Option 2 (performance based system): Primer Coat - Zinc-rich Epoxy 9-08.1(2)N Primer Stripe Coat - Epoxy 9-08.1(2)N Intermediate Coat - Epoxy 9-08.1(2)N Intermediate Stripe Coat - Epoxy 9-08.1(2)N Top Coat - Polyurethane 9-08.1(2)N Page 6-212 2020 Standard Specifications M 41-10 6-07 Painting Paints and related materials shall be a product listed in the current WSDOT Qualified Products List (QPL). Component based paint systems shall be listed on the QPL in the applicable sections of Section 9-08. Performance based systems shall be listed on the current Northeast Protective Coatings Committee (NEPCOAT) Qualified Products List “B” as listed on the WSDOT QPL in Section 9-08.1(2)N. If the paint and related material for the component based system is not listed in the current WSDOT QPL, a sample shall be submitted to the State Materials Laboratory in Tumwater for evaluation and acceptance in accordance with Section 9-08. All paint coating components of the selected paint system shall be produced by the same manufacturer. Only one paint system from a singular manufacturer shall be used throughout the project unless otherwise allowed in writing by the Engineer. The Contractor shall not change to a different paint system once the initial paint system has been applied to any portion of the bridge unless otherwise allowed in writing by the Engineer. 6-07.3(10)I Paint Color Each of the five coats shall be a contrasting color to the previously applied full coat. The color of the top coat shall be as specified in the Plans or Special Provisions and shall conform to Section 9-08.1(8). Tinting shall occur at the factory at the time of manufacture and placement in containers, prior to initial shipment. Application site tinting will not be allowed except as otherwise allowed by the Engineer. 6-07.3(10)J Mixing and Thinning Paint Mixing and thinning paint shall be in accordance with Section 6-07.3(9)C. 6-07.3(10)K Coating Thickness Coating thickness shall be in accordance with Section 6-07.3(9)D except the minimum dry film thickness of each coat (combination of primer and primer stripe, combination of intermediate and intermediate stripe, and top) shall not be less than 3.0 mils. 6-07.3(10)L Environmental Condition Requirements Prior to Application of Paint Environmental conditions shall be in accordance with Section 6-07.3(9)E. 6-07.3(10)M Steel Surface Condition Requirements Prior to Application of Paint The steel surface to be painted shall be free of moisture, dirt, dust, grease, oil, loose, peeling or, chalky paint, abrupt paint edges, salts, rust, mill scale, and other foreign matter and substances that would prevent the bond of the succeeding application. The Contractor shall protect freshly painted surfaces from contamination by abrasives, dust, or foreign materials from any other source. The Contractor shall prepare contaminated surfaces to the satisfaction of the Engineer before applying additional paint. Prepared surfaces shall be kept clean at all times, before painting and between coats. 2020 Standard Specifications M 41-10 Page 6-213 Painting 6-07 Edges of existing paint shall be feathered in accordance with SSPC-PA 1, Shop, Field, and Maintenance Coating of Metals, Note 15.20. 6-07.3(10)N Field Coating Application Methods The Contractor shall apply paint materials in accordance with manufacturer’s recommendations by air or airless spray, brush, roller, or any combination of these methods unless otherwise specified. Spray application of the paint shall be accomplished with spray nozzles and at pressures as recommended by the paint manufacturer to ensure application of paint at the specified film thickness. The Contractor may apply stripe coat paint using spray or brush but shall follow spray application using a brush to ensure complete coverage around structural geometric irregularities and to push the paint into gaps between existing steel surfaces and around rivets and bolts. All application techniques shall conform to Section 7, SSPC-PA 1. Painters using brushes shall work from pails containing a maximum of 2 gallons of paint. This is intended to minimize the impact of any spill. 6-07.3(10)O Applying Field Coatings An on-site supervisor shall be present for each work shift at the bridge site. The first coat shall be a primer coat applied to steel surfaces cleaned to bare metal. The second coat shall be a primer stripe coat applied to all steel surfaces cleaned to bare metal and defined to receive a stripe coat. The third coat shall be an intermediate coat. The fourth coat shall be an intermediate stripe coat applied to steel surfaces defined to receive a stripe coat. The fifth coat shall be the top coat. The intermediate (third) and top (fifth) coats shall encapsulate the entire surface area of the structure members specified to be painted. Prior to the application of paint, the Contractor shall clean the bridge deck surface for the purpose of dust control. During painting operations the Contractor shall furnish, install, and maintain drip tarps below the areas to be painted to contain all spilled paint, buckets, brushes, and other deleterious material, and prevent such materials from reaching the environment below or adjacent to the structure being painted. Drip tarps shall be absorbent material and hung to minimize puddling. In addition to the requirements of the Specifications, paint application shall conform to: 1. The best practices of the trade. 2. The written recommendations of the paint manufacturer. 3. All applicable portions of the SSPC-PA 1. No primer paint shall be applied to any surface until the surface has been inspected and accepted by the Engineer. Any area to which primer paint has been applied without the Engineer’s inspection and acceptance will be considered improperly cleaned. The unauthorized application shall be completely removed and the entire area recleaned to the satisfaction of the Engineer. After the area has been recleaned, inspected, and approved, the Contractor may again initiate the painting sequence. No Page 6-214 2020 Standard Specifications M 41-10 6-07 Painting additional compensation or extension of time in accordance with Section 1-08.8 will be allowed for the removal of any unauthorized paint application and recleaning of the underlying surface. All steel surfaces cleaned to bare metal by abrasive blast cleaning shall receive the primer coat within the same working day as the cleaning to bare metal and before any rust begins to form. Each successive coat shall be applied as soon as possible over the previous coat, accounting for drying time of the preceding coat, weather, atmospheric temperature and other environmental conditions, and the paint manufacturer’s recommendations. Each coat shall be dry before recoating and shall be sufficiently cured so that succeeding or additional coats may be applied without causing damage to the previous coat. Recoat times shall be as shown in the paint manufacturer’s recommendations, but not less than 12 hours. Revision of recoat times to other than recommended by the paint manufacturer requires the concurrence of the Engineer. If the maximum time between coats is exceeded, all affected areas shall be prepared to SSPC-SP 7, Brush-off Blast Cleaning, and recoated with the Contract-specified system at no additional expense or time to the Contracting Agency. Each coat shall be applied in a uniform layer, completely covering the preceding coat. The Contractor shall correct runs, sags, skips, or other deficiencies before application of succeeding coats. Such corrective work may require recleaning, application of additional paint, or other means as determined by the Engineer, at no additional cost to the Contracting Agency. If fresh paint is damaged by the elements, the Contractor shall replace or repair the paint to the satisfaction of the Engineer at no additional cost to the Contracting Agency. After applying the primer or intermediate coats, the Contractor shall apply a primer or intermediate stripe coat, respectively, on all edges, corners, seams, crevices, interior angles, junction of joint members, rivet or bolt heads, nuts and threads, weld lines, and any similar surface irregularities. The coverage of each stripe coat shall extend at least 1 inch beyond the irregular surface. The stripe coat shall be of sufficient thickness to completely hide the surface being covered and shall be followed as soon as feasible by the application of the subsequent coat to its specified thickness. If the primer coat leaves unsealed cracks or crevices, these shall be sealed with single- component urethane sealant conforming to Section 9-08.7 (applied in accordance with the manufacturer’s recommendations) before the intermediate coats are applied. The Contractor shall correct paint deficiencies before application of succeeding coats. Such corrective work may require recleaning, application of additional paint, or other corrective measures in accordance with the paint manufacturer’s recommendations and as specified by the Engineer. Such corrective work shall be completed at no additional expense or time to the Contracting Agency. Each application of primer, primer stripe, intermediate, intermediate stripe, and top coat shall be considered as separately applied coats. The Contractor shall not use a preceding or subsequent coat to remedy a deficiency in another coat. The Contractor shall apply the top coat to at least the minimum specified top coat thickness, to provide a uniform appearance and consistent finish coverage. 2020 Standard Specifications M 41-10 Page 6-215 Painting 6-07 If roadway or sidewalk planks lie so close to the metal that they prevent proper cleaning and painting, the Contractor shall remove or cut the planks to provide at least a 1-inch clearance. Any plank removal or cutting shall be done with the concurrence of the Engineer. The Contractor shall replace all planks after painting. If removal breaks or damages the planks and makes them unfit for reuse, the Contractor shall replace them at no expense to the Contracting Agency. 6-07.3(10)P Field Coating Repair Paint repair shall conform to SSPC-PA 1. Repair areas shall be cleaned of all damaged paint and the system reapplied using all coats typical to the paint system and shall meet the minimum coating thickness. Each coat shall be thoroughly dry before applying subsequent coats. Paint repair shall be in accordance with the paint manufacturer’s recommendations and as accepted by the Engineer. 6-07.3(10)Q Cleanup Cleaning of equipment shall not be done in State waters nor shall resultant cleaning runoff be allowed to enter State waters. No paint cans, lids, brushes, or other debris shall be allowed to enter State waters. Solvents, paints, paint sludge, cans, buckets, rags, brushes, and other waste associated with this project shall be collected and disposed of off-site. Paint products, petroleum products, or other deleterious material shall not be wasted into, or otherwise enter, State waters as a result of project activities. Cleanup of the project site shall conform to Sections 1-04.11 and 6-01.12 6-07.3(11) Painting or Powder Coating of Galvanized Surfaces Galvanized surfaces specified to be coated after galvanizing shall receive either paint in accordance with Section 6-07.3(11)A or powder coating in accordance with Section 6-07.3(11)B. The color of the finish coat shall be as specified in the Special Provisions. 6-07.3(11)A Painting of Galvanized Surfaces All galvanized surfaces receiving paint shall be prepared for painting in accordance with the ASTM D6386. The method of preparation shall be brush-off in accordance with SSPC- SP16 Brush-Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels, and Non-Ferrous Metals or as otherwise allowed by the Engineer. The Contractor shall not begin painting until receiving the Engineer’s acceptance of the prepared galvanized surface. For galvanized bolts used for replacement of deteriorated existing rivets, the Contractor, with the concurrence of the Engineer and after successful demonstration testing, may prepare galvanized surfaces in accordance with SSPC-SP1 followed by SSPC- SP2, Hand Tool Cleaning or SSPC-SP3, Power Tool Cleaning. The demonstration testing shall include adhesion testing of the first coat of paint over galvanized bolts, nuts, and washers or a representative galvanized surface. Adhesion testing shall be performed in accordance with ASTM D4541 for 600 psi minimum adhesion. A minimum of 3 successful tests shall be performed on the galvanized surface prepared and painted using the same methods and materials to be used on the galvanized bolts, nuts and washers in the field. Page 6-216 2020 Standard Specifications M 41-10 6-07 Painting 6-07.3(11)A1 Environmental Conditions Steel surfaces shall be: • Greater than 35ºF, and • Less than 115ºF. or in accordance with the manufacturer’s recommendations, whichever is more stringent. 6-07.3(11)A2 Paint Coat Materials The Contractor shall paint the dry surface as follows: 1. The first coat over a galvanized surface shall be an epoxy polyamide conforming to Section 9-08.1(2)E. In the case of galvanized bolts used for replacement of deteriorated existing rivets and for small surface areas less than or equal to one square foot, an intermediate moisture cured polyurethane conforming to Section 9-08.1(2)G may be used as a first coat. In both cases the first coat shall be compatible with galvanizing and as recommended by the top coat manufacturer. 2. The second coat shall be a top coat moisture cured aliphatic polyurethane conforming to Section 9-08.1(2)H or a top coat polyurethane conforming to Section 6-07.3(10)H Option 2 NEPCOAT performance based paint specification compatible with the first coat as recommended by the manufacturer. Each coat shall be dry before the next coat is applied. All coats applied in the shop shall be dried hard before shipment. 6-07.3(11)B Powder Coating of Galvanized Surfaces Powder coating of galvanized surfaces shall consist of the following coats: 1. The first coat shall be an epoxy powder primer coat conforming to Section 9-08.2. 2. The second coat shall be a polyester finish coat conforming to Section 9-08.2. 6-07.3(11)B1 Submittals The Contractor shall submit Type 2 Working Drawings consisting of the following information: 1. The name, location, and contact information (mail address, phone, and email) for the firm performing the powder coating operation. 2. Quality control (QC) programs established and followed by the firm performing the powder coating operation. Forms to document inspection and testing of coatings as part of the QC program shall be included in the submittal. 3. Project-specific powder coating plan, including identification of the powder coating materials used (and manufacturer), and specific cleaning, surface preparation, preheating, powder coating application, curing, shop and field coating repair, handling, and storage processes to be taken for the assemblies being coated for this project. 4. Product data and MSDS sheets for all powder coating and coating repair materials. 2020 Standard Specifications M 41-10 Page 6-217 Painting 6-07 6-07.3(11)B2 Galvanizing Prior to the galvanizing operation, the Contractor shall identify to the galvanizer the specific assemblies and surfaces receiving the powder coating after galvanizing, to ensure that the galvanizing method used on these assemblies is compatible with subsequent application of a powder coating system. Specifically, such assemblies shall neither be water-quenched nor receive a chromate conversion coating as part of the galvanizing operation. 6-07.3(11)B3 Galvanized Surface Cleaning and Preparation Galvanized surfaces receiving the powder coating shall be cleaned and prepared for coating in accordance with ASTM D6386, and the project-specific powder coating plan. Assemblies conforming to the ASTM D7803 definition for newly galvanized steel shall receive surface smoothing and surface cleaning in accordance with ASTM D7803, Section 5, and surface preparation in accordance with ASTM D7803, Section 5.1.3. Assemblies conforming to the ASTM D7803 definition for partially weathered galvanized steel shall be checked and prepared in accordance with ASTM D7803, Section 6, before then receiving surface smoothing and surface cleaning in accordance with ASTM D7803, Section 5, and surface preparation in accordance with ASTM D7803, Section 5.1.3. Assemblies conforming to the ASTM D7803 definition for weathered galvanized steel shall be prepared in accordance with ASTM D7803, Section 7 before then receiving surface smoothing and surface cleaning in accordance with ASTM D7803, Section 5, and surface preparation in accordance with ASTM D7803, Section 5.3 except as follows: 1. Ferrous metal abrasives are prohibited as a blast media for surface preparation. 2. Surface preparation shall be accomplished using dry abrasive blasting through a blast nozzle with compressed air. Abrasive blasting with a centrifugal wheel is prohibited. The Contractor shall notify the Engineer of all surface cleaning and preparation activities and shall provide the Engineer opportunity to perform quality assurance inspection, in accordance with Section 1-05.6, at the completion of surface cleaning and preparation activities prior to beginning powder coating application. 6-07.3(11)B4 Powder Coating Application and Curing After surface preparation, the two-component powder coating shall be applied in accordance with the powder coating manufacturer’s recommendations, the project- specific powder coating plan, and as follows: 1. Preheat. The preheat shall be sufficient to prevent pinholes from forming in the finished coating system. 2. Apply the epoxy primer coat, followed by a partial cure. 3. Apply the polyester finish coat, followed by the finish cure. Page 6-218 2020 Standard Specifications M 41-10 6-07 Painting 6-07.3(11)B5 Testing The firm performing the powder coating operation shall conduct, or make arrangements for, QC testing on all assemblies receiving powder coating for this project, in accordance with the powder coating firm’s QC program as documented in item 2 of the Submittal Subsection above. Testing may be performed on coated surfaces of production fabricated items, or on a representative test panel coated alongside the production fabricated items being coated. There shall be a minimum of one set of tests representing each cycle of production fabricated items coated and cured. Additional tests shall be performed at the request of the Engineer. Repair of damaged coatings on production fabricated items shall be the responsibility of the firm applying the powder coating, and shall be in accordance with the project-specific powder coating plan. At a minimum, the QC testing shall test for the following requirements: 1. Visual inspection for the presence of coating holidays and other unacceptable surface imperfections. 2. Coating thickness measurement in accordance with Section 6-07.3(5). The minimum thickness of the epoxy primer coating and polyester finish coating shall be 3 mils each. 3. Hardness testing in accordance with ASTM D3363, with the finish coat providing a minimum hardness value of H. 4. Adhesion testing in accordance with ASTM D4541 for 600 psi minimum adhesion for the complete two-component coating system. 5. Powder Coating Institute (PCI) #8 recommended procedure for solvent cure test. The results of the QC testing shall be documented in a QC report and submitted as a Type 2 Working Drawing. The Engineer shall be provided notice and access to all assemblies at the powder coating facility for the purposes of Contracting Agency acceptance inspection, including notice and access to witness all hardness and adhesion testing performed by the firm conducting the QC testing, in accordance with Section 1-05.6. Assemblies not meeting the above requirements will be subject to rejection by the Engineer. Rejected assemblies shall be repaired or recoated by the Contractor, at no additional expense to the Contracting Agency, in accordance with the powder coating manufacturer’s recommendation as detailed in the project-specific powder coating plan, until the assemblies satisfy the acceptance testing requirements. Assemblies shall not be shipped from the powder coating firm’s facility to the project site until the Contractor receives the Engineer’s acceptance of the QC Report and assembly inspection performed by the Engineer. 2020 Standard Specifications M 41-10 Page 6-219 Painting 6-07 6-07.3(11)B6 Coating Protection for Shipping, Storage, and Field Erection After curing and acceptance, the Contractor shall protect the coated assemblies with multiple layers of bubble wrap or other protective wrapping materials specified in the project-specific powder coating plan. During storage and shipping, each assembly shall be separated from other assemblies by expanded polystyrene spacers and other spacing materials specified in the project- specific powder coating plan. After erection, all coating damage due to the Contractor’s shipping, storage, handling, and erection operations shall be repaired by the Contractor in accordance with the project- specific powder coating plan. The Contractor shall provide the Engineer access to all locations of all powder-coated members for verification of coating conditions prior to and following all coating repairs. 6-07.3(12) Painting Ferry Terminal Structures Painting of ferry terminal structures shall be in accordance with Section 6-07.3 as supplemented below. 6-07.3(12)A Painting New Steel Ferry Terminal Structures Painting of new steel Structures shall be in accordance with Section 6-07.3(9) except that all coatings (primer, intermediate, intermediate stripe, and top) shall be applied in the shop with the following exceptions: 1. Steel surfaces to be field welded. 2. Steel surfaces to be greased. 3. The length of piles designated in the Plans not requiring painting. The minimum drying time between coats shall be as shown in the product data sheets, but not less than 12 hours. The Contractor shall determine whether the paint has cured sufficiently for proper application of succeeding coats. 6-07.3(12)A1 Paint Systems Paint systems for Structural Steel, which includes vehicle transfer spans and towers, pedestrian overhead loading structures and towers, upland structural steel and other elements as designated in the Special Provisions shall be as specified in Section 6-07.3(9)A. Paint systems for Piling, Landing Aids and Life Ladders shall be as specified in the Special Provisions. 6-07.3(12)A2 Paint Color Paint colors shall be as specified in the Special Provisions. Page 6-220 2020 Standard Specifications M 41-10 6-07 Painting 6-07.3(12)A3 Coating Thickness Coating thicknesses shall be as specified in the Special Provisions. 6-07.3(12)A4 Application of Field Coatings An on-site supervisor shall be present for each work shift at the project site. Upon completion of erection Work, all uncoated or damaged areas remaining, including bolts, nuts, washers, splice plates, and field welds shall be prepared in accordance with SSPC-SP 1, Solvent Cleaning, followed by SSPC-SP 11, Power Tool Cleaning to Bare Metal. Surface preparation shall be measured according to SSPC-VIS 3. SSPC-SP 11 shall be performed for a minimum distance of 1 inch from the uncoated or damaged area. In addition, intact shop-applied coating surrounding the area shall be abraded or sanded for a distance of 6 inches out from the properly prepared clean/bare metal areas to provide adequate roughness for application of field coatings. All sanding dust and contamination shall be removed prior to application of field coatings. Field applied paint for Structural Steel shall conform to Section 6-07.3(10)H, as applicable. Field applied paint for Piling, Landing Aids and Life Ladders shall be as specified in the Special Provisions. For areas above the tidal zone, the minimum drying time between coats shall be as shown in the product data sheets, but not less than 12 hours. For areas within the tidal zone, the minimum drying time between coats shall be as recommended by the paint system manufacturer. The Contractor shall determine whether the paint has cured sufficiently for proper application of succeeding coats. The maximum time between intermediate and top coats shall be in accordance with the manufacturer’s written recommendations. If the maximum time between coats is exceeded, all newly coated surfaces shall be prepared to SSPC-SP 3, Power Tool Cleaning, and shall be repainted with the same paint that was cleaned, at no additional cost to the Contracting Agency. Each coat shall be applied in a uniform layer, completely covering the preceding coat. The Contractor shall correct runs, sags, skips, or other deficiencies before application of succeeding coats. Such corrective work may require re-cleaning, application of additional paint, or other means as determined by the Engineer, at no additional cost to the Contracting Agency. Surface preparation for underwater locations shall consist of removing all dirt, oil, grease, loose paint, loose rust, and marine growth from the area that is to be repaired. The sound paint surrounding the damaged area shall be roughened to meet the requirements of the manufacturer. Paint for underwater applications shall be as specified in the Special Provisions and shall be applied in accordance with the manufacturer’s recommendations. 6-07.3(12)B Painting Existing Steel Ferry Terminal Structures Painting of existing steel structures shall be in accordance with Section 6-07.3(10) as supplemented by the following. 2020 Standard Specifications M 41-10 Page 6-221 Painting 6-07 6-07.3(12)B1 Containment Containment for full removal shall be in accordance with Section 6-07.3(10)A. Containment for overcoat systems shall be in accordance with all applicable Permits as required in the Special Provisions. Prior to cleaning the Contractor shall enclose all exposed electrical and mechanical equipment to seal out dust, water, and paint. Non-metallic surfaces shall not be abrasive blasted or painted. Unless otherwise specified, the following metallic surfaces shall not be painted and shall be protected from abrasive blasting and painting: 1. Galvanized and stainless steel surfaces not previously painted, 2. Non-skid surfaces, 3. Unpainted intentionally greased surfaces, 4. Equipment labels, identification plates, tags, etc., 5. Fire and emergency containers or boxes, 6. Mechanical hardware such as hoist sheaves, hydraulic cylinders, gear boxes, wire rope, etc. The Contractor shall submit a Type 2 Working Drawing consisting of materials and equipment used to shield components specified to not be cleaned and painted. The Contractor shall shut off the power prior to working around electrical equipment. The Contractor shall follow the lock-out/tag-out safety provisions of the WAC 296-803 and all other applicable safety standards. 6-07.3(12)B2 Surface Preparation For applications above high water and within the tidal zone, surface preparation for overcoat painting shall be in accordance with SSPC-SP 1, Solvent Cleaning, followed by SSPC-SP 3, Power Tool Cleaning. Use of wire brushes is not allowed. After SP 3 cleaning has been completed all surfaces exhibiting coating failure down to the steel substrate, and those exhibiting visible corrosion, shall be prepared down to clean bare steel in accordance with SSPC-SP 15, Commercial Grade Power Tool Cleaning. Surface preparation shall be measured according to SSPC-VIS 3. SSPC-SP 15 shall be performed for a minimum distance of 1 inch from the area exhibiting failure or visible corrosion. In addition, intact shop-applied coating surrounding the repair area shall be abraded or sanded for a distance of 6 inches out from the properly prepared clean/bare metal areas to provide adequate roughness for application of repair coatings. All sanding dust and contamination shall be removed prior to application of repair coatings. Surface preparation for full paint removal shall be in accordance with Section 6-07.3(10)E except SSPC-SP 11 will be permitted as detailed in the Contractor’s painting plan and as allowed by the Engineer. Surface preparation for underwater locations shall consist of removing all dirt, oil, grease, loose paint, loose rust, and marine growth from the area that is to be repaired. The sound paint surrounding the damaged area shall be roughened as required by the coating manufacturer. Page 6-222 2020 Standard Specifications M 41-10 6-07 Painting Removed marine growth may be released to state waters provided the marine growth is not mixed with contaminants (paint, oil, rust, etc.) and it shall not accumulate on the sea bed. All marine growth containing contaminants shall be collected for proper disposal. Surface preparation for the underside of bridge decks (consisting of either a steel grid system of main bars or tees and a light gauge metal form, in-filled with concrete or a corrugated light gauge metal form, infilled with concrete) shall be in accordance with SSPC-SP 2, Hand Tool Cleaning or SSPC-SP 3, Power Tool Cleaning with the intent of not causing further damage to the light gauge metal form. Following removal of any pack rust and corroded sections from the underside of the bridge deck, cleaning and flushing to remove salts and prior to applying the primer coat, the Contractor shall seal the entire underside of the deck system with rust-penetrating sealer. Damage to galvanized metal forms and/or grids shall be repaired in accordance with ASTM A 780, with the preferred method of repair using paints containing zinc dust. 6-07.3(12)B3 Paint Systems Paint systems for Structural Steel, which includes vehicle transfer spans and towers, pedestrian overhead loading structures and towers, upland structural steel and other elements as designated in the Special Provisions shall be as specified in Section 6-07.3(10)H. Paint systems for Piling, Landing Aids, Life Ladders, underside of vehicle transfer span bridge decks, non-skid surface treated areas, and anti-graffiti coatings shall be as specified in the Special Provisions. 6-07.3(12)B4 Paint Color Paint colors shall be as specified in the Special Provisions. 6-07.3(12)B5 Coating Thickness Coating thicknesses shall be as specified in the Special Provisions. 6-07.3(12)B6 Application of Field Coatings Application of field coatings shall be in accordance with Section 6-07.3(10)O and Section 6-07.3(12)A2 except for the following: 1. All coatings applied in the field shall be applied using a brush or roller. Spray application methods may be used if allowed by the Engineer. 2. Applied coatings shall not be immersed until the coating has been cured as required by the coating manufacturer. 3. Non-skid surface treatment products shall be applied in accordance with the manufacturer’s recommendations. 4. Anti-graffiti coatings shall be applied in one coat following application of the top coat, where specified in the Plans. 2020 Standard Specifications M 41-10 Page 6-223 Painting 6-07 6-07.3(13) Painting Timber Structures Timber structures shall be painted as specified in the Special Provisions. 6-07.3(14) Metallic Coatings 6-07.3(14)A General Requirements This specification covers the requirements for thermal spray metallic coatings, with and without additional paint coats, as a means to prevent corrosion. The coating system consists of surface preparation by wash cleaning and abrasive blast cleaning, thermal spray application of a metallic coating using a material made specifically for that purpose, and, when specified, shop primer coat or shop primer coat plus top coat in accordance with Section 6-07.3(11)A. The system also includes inspection and acceptance requirements. 6-07.3(14)B Reference Standards SSPC-SP 10/NACE No. 2 Near-White Blast Cleaning SSPC CS 23.00 Specification for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for the Corrosion Protection of Steel ASTM C633 Standard Test Method for Adhesion or Cohesion Strengths of Thermal Spray Coatings ASTM D4417 Standard Test Methods for Field Measurement of Surface Profile of Blast-Cleaned Steel ASTM D6386 Standard Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and Hardware Surfaces for Painting ASTM D4541 Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers ANSI/AWS C2.18 Guide for the Protection of Steel with Thermal Sprayed Coatings of Aluminum, Zinc and their Alloys and Composites 6-07.3(14)C Quality Assurance A representative sample of each lot of the coating material used shall be submitted to the Engineer for analysis prior to use. Zinc shall have a minimum purity of 99.9 percent. Zinc Aluminum 85/15 wire shall be 14 to 16 percent maximum aluminum. The thermal sprayed coating shall have a uniform appearance. The coating shall not contain any blisters, cracks, chips or loosely adhering particles, oil or other surface contaminants, nodules, or pits exposing the substrate. The thermal spray coating shall adhere to the substrate with a minimum bond of 700 psi. The Contractor’s QA program shall include thermal spray coating bond testing. Page 6-224 2020 Standard Specifications M 41-10 6-07 Painting The Engineer may cut through the coating with a knife or chisel. If upon doing so, any part of the coating lifts away from the base metal ¼ inch or more ahead of the cutting blade without cutting the metal, then the bond is considered not effective and is rejected. Coated areas which have been rejected or damaged in the inspection procedure described shall have the defective sections blast cleaned to remove all of the thermal sprayed coating and shall then be recoated. Before resubmittal and inspection, those sections where coating has not reached the required thickness shall be sprayed with additional metal until that thickness is achieved. 6-07.3(14)D Submittals The Contractor shall submit to the Engineer, prior to abrasive blast cleaning, a 12 inch square steel plate, of the same material and approximate thickness of the steel to be coated, blasted clean in accordance with Section 6-07.3(14)E. The sample plate will be checked for specified angular surface pattern, the abrasive grit size and type used, and the procedure used. This plate shall be used as the visual standard to determine the acceptability of the cleaned surface. In the event the Contractor’s cleaning operation is inferior to the sample plate, the Contractor shall be required to correct the cleaning operation to do a job comparable to the specimen submitted. At the same time as submitting the abrasive blast cleaned steel plate sample, the Contractor shall submit to the Engineer, a second 12 inch square steel plate of the same material and thickness, cleaned and thermal spray coated in accordance with the same processes and with the same equipment as intended for use in applying the thermal spray coatings. The Engineer may request additional cleaned and thermal spray coated samples to be produced and submitted coincident with thermal spray coating of the items specified in the Plans to receive thermal spray coatings. 6-07.3(14)E Surface Preparation Surface irregularities (e.g., sharp edges and/or carburized edges, cracks, delaminations, pits, etc.) interfering with the application of the coating shall be removed or repaired, prior to wash cleaning. Thermal cut edges shall be ground to reduce hardness to attain the surface profile required from abrasive blast cleaning. All dirt, oil, scaling, etc. shall be removed prior to blast cleaning. All surfaces shall be wash cleaned with either clean water at 8000 psi or water and detergent at 2000 psi with two rinses with clean water. The surface shall be abrasive blast cleaned to near white metal (SSPC-SP 10). The surface profile shall be measured using a surface profile comparator, replica tape, or other method suitable for the abrasive being used in accordance with ASTM D4417. Where zinc coatings up to and including 0.009 inch thick are to be applied, one of the following abrasive grits shall be used with pressure blast equipment to produce a 3.0 mils AA anchor tooth pattern: 1. Aluminum oxide or silicon carbide mesh size: SAE G-25 to SAE G-40 2. Hardened steel grit mesh size: SAE G-25 to SAE G-40 2020 Standard Specifications M 41-10 Page 6-225 Painting 6-07 3. Garnet, flint, or crushed nickel or black beauty coal slag mesh size: SAE G-25 to SAE G-50 Where zinc coatings greater than 0.010 inch thick are to be applied, one of the following abrasive grits shall be used with pressure blast equipment to produce a 5.0 mils AA anchor tooth pattern: 1. Aluminum oxide or silicon carbide mesh size: SAE G-18 to SAE G-25 2. Hardened steel grit mesh size: SAE G-18 to SAE G-25 3. Garnet, flint, or crushed nickel or black beauty coal slag mesh size: SAE G-18 to SAE G-25 The pressure of the blast nozzle, as measured with a needle probe gauge, with pressure type blasting equipment shall be as follows: 1. With aluminum oxide, silicon carbide, flint, or slag - 50 psi minimum and 60 psi maximum. 2. With garnet or steel grit - 75 psi minimum. The pressure at the blast nozzle, with siphon blasting (suction blasting), shall be as follows: 1. With aluminum oxide, silicon carbide, flint, or slag - 75 psi maximum. 2. With garnet or steel grit - 90 psi maximum. The abrasive blast stream shall be directed onto the substrate surface at a spray angle of 75 to 90 degrees, and moved side to side. The nozzle to substrate distance shall be 4 to 12 inches. 6-07.3(14)F Application of Metallic Coating No surface shall be sprayed which shows any sign of condensed moisture or which does not comply with Section 6-07.3(14)E. If rust bloom occurs within the holding time between abrasive blast cleaning and thermal spraying, the surface shall be reblasted at a blast angle as close to perpendicular to the surface as possible to achieve a 2.0 to 4.0 mil anchor tooth pattern. Thermal spraying shall not take place when the relative humidity is 90 percent or greater, when the steel temperature is less than 5F above the dew point, or when the air or steel temperature is less than 40F. Clean, dry air shall be used with not less than 50 psi air pressure at the air regulator. Not more than 50 feet of 3/8 inch. ID hose shall be used between the air regulator and the metallizing gun. The metallizing gun shall be started and adjusted with the spray directed away from the work. During the spraying operation and depending upon the equipment being used, the gun shall be held as close to perpendicular as possible to the surface from 5 to 8 inches from the surface of the work. Manual spraying shall be done in a block pattern, typically 2 feet by 2 feet square. The sprayed metal shall overlap on each pass to ensure uniform coverage. The specified Page 6-226 2020 Standard Specifications M 41-10 6-07 Painting thickness of the coating shall be applied in multiple layers. In no case are fewer than two passes of thermal spraying, overlapping at right angles, acceptable. At least one single layer of coating shall be applied within 4 hours of blasting and the surface shall be completely coated to the specified thickness within 8 hours of blasting. The minimum coating thickness shall be 6 mils unless otherwise shown in the Plans. 6-07.3(14)G Applications of Shop Coats and Field Coats The surface shall be wiped clean with solvent immediately before applying the wash primer. The wash primer shall have a low viscosity appropriate for absorption into the thermal spray coating, and shall be applied within 8 hours after completion of thermal spraying or before oxidation occurs. The dry film thickness of the wash primer shall not exceed 0.5 mils or be less than 0.3 mils. It shall be applied using an appropriate spray gun except in those areas where brush or roller application is necessary. The subsequent shop primer or field coats shall be applied no less than one-half hour after a wash primer. The shop primer coat, when specified, shall be applied in accordance with Section 6-07.3(11)A and the paint manufacturer’s recommendations. All field coats, when specified, shall be applied in accordance with Section 6-07.3(11)A and the paint manufacturer’s recommendations. The color of the top coat shall conform to Section 6-03.3(30) as supplemented in these Special Provisions. 6-07.4 Measurement Cleaning, sealing, and caulking pack rust will be measured by the linear foot along the edge of the steel connection interface cleaned, sealed, and caulked. Spot abrasive blast cleaning of steel surfaces in accordance with Section 6-07.3(10)D will be measured by the square foot of surface area to be cleaned to bare metal as specified by the Engineer. 6-07.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Cleaning and Painting - _____”, lump sum. The lump sum Contract price for “Cleaning and Painting – _____” shall be full pay for the Work as specified, including developing all submittals; arranging for and accommodating contact and on-site attendance by the paint manufacturer’s technical representative; furnishing and placing all necessary staging and rigging; furnishing, operating, and mooring barges; furnishing and operating fixed and movable work platforms; accommodating Contracting Agency inspection access; conducting the Contractor’s quality control inspection program; providing material, labor, tools, and equipment; furnishing containers for containment waste, collecting and storing containment waste; collecting, storing, testing, and disposing of all containment waste not conforming to the definition in Section 6-07.3(10)F; 2020 Standard Specifications M 41-10 Page 6-227 Painting 6-07 performing all cleaning and preparation of surfaces to be painted; applying all coats of paint and sealant; correcting coating deficiencies; completing coating repairs; and completing project site cleanup. When a weather station is specified, all costs in connection with furnishing, installing, operating, and removing the weather station, including furnishing mounting hardware and repeaters, accessories and wireless display console units, processing and submitting daily weather data reports, maintenance and upkeep, shall be included in the lump sum Contract price for “Cleaning And Painting – _____”. Progress payments for “Cleaning and Painting – _____” will be made on a monthly basis and will be based on the percentage of the total estimated area satisfactorily cleaned and coated as determined by the Engineer. Payment will not be made for areas that are otherwise complete but have repairs outstanding. “Cleaning, Sealing, and Caulking Pack Rust”, per linear foot. The unit contract price per linear foot for “Cleaning, Sealing, and Caulking Pack Rust” shall be full pay for performing the work as specified, including cleaning out the pack rust, preparing the gap for the rust penetrating sealer and caulk, and applying the rust penetrating sealer and caulk. “Spot Abrasive Blast Cleaning”, per square foot. The unit contract price per square foot for “Spot Abrasive Blast Cleaning” shall be full pay for performing the spot abrasive blast cleaning work in accordance with Section 6-07.3(10)D. “Containment of Abrasives”, lump sum. The lump sum contract price for “Containment of Abrasives” shall be full payment for all costs incurred by the Contractor in complying with the requirements as specified in Section 6-07.3(10)A to design, construct, maintain, and remove containment systems for abrasive blasting operations. “Testing and Disposal of Containment Waste”, by force account as provided in Section 1-09.6. All costs in connection with testing containment waste, transporting containment waste for disposal, and disposing of containment waste in accordance with Section 6-07.3(10)F will be paid by force account in accordance with Section 1-09.6. For the purpose of providing a common proposal for all bidders, the Contracting Agency has entered an amount for the item “Testing and Disposal of Containment Waste” in the bid proposal to become part of the total bid by the Contractor. All costs in connection with producing the metallic coatings as specified shall be included in the unit contract price for the applicable item or items of work. Payment for painting new steel structures and painting or powder coating of galvanized surfaces will be in accordance with Section 6-03.5. Painting of timber structures will be in accordance with Section 6-04.5. Page 6-228 2020 Standard Specifications M 41-10 6-08 Bituminous Surfacing on Structure Decks 6-08 Bituminous Surfacing on Structure Decks 6-08.1 Description This Work consists of removing and placing Hot Mix Asphalt (HMA) or Bituminous Surface Treatment (BST) directly on or over a Structure. This Work also includes performing concrete bridge deck repair, applying waterproofing membrane, and sealing paving joints. 6-08.2 Materials Materials shall meet the requirements of the following sections: Bituminous Surface Treatment 5-02.2 Hot Mix Asphalt 5-04.2 Joint Sealants 9-04.2 Closed Cell Foam Backer Rod 9-04.2(3)A Waterproofing Membrane (Deck Seal) 9-11 Bridge Deck Repair Material 9-20.5 6-08.3 Construction Requirements 6-08.3(1) Definitions Adjusted Removal Depth – the Bituminous Pavement removal depth specified by the Engineer to supersede the Design Removal Depth after review of the Contractor survey of the existing Bituminous Pavement grade profile. Bituminous Pavement – the surfacing material containing an asphalt binder. Design Removal Depth – the value shown in the “pavement schedule” or elsewhere in the Plans to indicate the design thickness of Bituminous Pavement to be removed. Final Grade Profile – the compacted finished grade surface of completed Bituminous Pavement surfacing consisting of a vertical profile and superelevation cross-slope, developed by the Engineer for Grade Controlled Structure Decks based on the Contractor survey. Grade Controlled – a Structure Deck requiring restriction of Bituminous Pavement work, including restriction of pavement removal methods and restriction of overlay pavement thicknesses. Structure Deck – the bridge deck (concrete or timber), bridge approach slab, top of concrete box culvert, or other concrete surfaces over or upon which existing Bituminous Pavement is removed and new Bituminous Pavement is applied. 2020 Standard Specifications M 41-10 Page 6-229 Bituminous Surfacing on Structure Decks 6-08 6-08.3(2) Contractor Survey for Grade Controlled Structure Decks Prior to removing existing Bituminous Pavement from a Grade Controlled Structure Deck, the Contractor shall complete a survey of the existing surface for use in establishing the existing cross section and grade profile elevations. When removal of Bituminous Pavement is to be achieved by rotary milling/planing, the Contractor’s survey shall also include the depths of the existing surfacing at each survey point. The Contractor is responsible for all calculations, surveying, installation of control points, and measuring required for setting, maintaining and resetting equipment and materials necessary for the construction of the overlay to the Final Grade Profile. 6-08.3(2)A Survey Requirements The Contractor shall establish at least two primary survey control points for controlling actual Bituminous Pavement removal depth and the Final Grade Profile. Horizontal control shall be by station and offset which shall be tied to either the Roadway centerline or the Structure centerline. Vertical control may be an assumed datum established by the Contractor. Primary control points shall be described by station or milepost and offset on the baseline selected by the Contractor. The Contractor may expand the survey control information to include secondary horizontal and vertical control points as needed for the project. Survey information collected shall include station or milepost, offset, and elevation for each lane line and curb line. Survey information shall be collected at even 20 foot station intervals, and along the centerline of each bridge expansion joint. The survey shall extend 300’-0” beyond the bridge back of pavement seat or end of Structure Deck. The survey information shall include the top of Bituminous Pavement elevation and, when rotary milling/planing equipment is used, the corresponding depth of Bituminous Pavement to the Structure Deck. The Contractor shall ensure a surveying accuracy to within ± 0.01 feet for vertical control and ± 0.2 feet for horizontal control. Voids in HMA created by the Contractor’s Bituminous Pavement depth measurements shall be filled by material conforming to Section 9-20 or another material acceptable to the Engineer. 6-08.3(2)B Survey Submittal The Contractor’s survey records shall include descriptions of all survey control points including station/milepost, offset, and elevations of all secondary control points. The Contractor shall maintain survey records of sufficient detail to allow the survey to be reproduced. The Contractor shall submit a Type 2 Working Drawing consisting of the compiled survey records and information. Survey data shall be submitted as an electronic file in Microsoft Excel format. Page 6-230 2020 Standard Specifications M 41-10 6-08 Bituminous Surfacing on Structure Decks 6-08.3(2)C Final Grade Profile and Adjusted Removal Depth Based on the results of the survey, the Engineer may develop a Final Grade Profile and Adjusted Removal Depth. If they are developed, the Final Grade Profile and Adjusted Removal Depth will be provided to the Contractor within three working days after receiving the Contractor’s survey information. When provided, the Adjusted Removal Depth supersedes the Design Removal Depth to become the Bituminous Pavement removal depth for that Structure Deck. 6-08.3(3) General Bituminous Pavement Removal Requirements Contractor shall remove Bituminous Pavement and associated deck repair material from Structure Decks to the horizontal limits shown in the Plans and to either the specified or adjusted Bituminous Pavement removal depth as applicable. Removal of Bituminous Pavement within 12-inches of existing permanent features that limit the reach of the machine or the edge of the following items shall be by hand or by hand operated (nominal 30-pounds class) power tools: existing bridge expansion joint headers; steel expansion joint assemblies; concrete butt joints between back of pavement seats and bridge approach slabs, bridge drain assemblies; thrie beam post steel anchorage assemblies fastened to the side or top of the Structure Deck. When removing Bituminous Pavement with a planer, Section 5-04.3(14) shall apply. If the planer contacts the Structure Deck in excess of the specified planing depth tolerance, or contacts steel reinforcing bars at any time, the Contractor shall immediately cease planing operations and notify the Engineer. Planing operations shall not resume until completion of the appropriate adjustments to the planing machine and receiving the Engineer’s concurrence to resume. 6-08.3(4) Partial Depth Removal of Bituminous Pavement from Structure Decks The depth of surfacing removal, as measured to the bottom of the lowest milling groove generated by the rotary milling/planing machine shall be +0.01, -0.02-feet of the specified or Adjusted Removal Depth as applicable. 6-08.3(5) Full Depth Removal of Bituminous Pavement from Structure Decks 6-08.3(5)A Method of Removal The Contractor shall perform full depth removal by a method that does not damage or remove the Structure Deck in excess of the specified Bituminous Pavement removal tolerance. The Contractor shall submit a Type 2 Working Drawing consisting of the proposed methods and equipment to be used for full depth removal. 6-08.3(5)B Planer Requirements for Full Depth Removal The final planed surface shall have a finished surface with a tolerance of +0.01, -0.02 feet within the planed surface profile, as measured from a 10-foot straight edge. Multiple passes of planing to achieve smoothness will not be allowed. 2020 Standard Specifications M 41-10 Page 6-231 Bituminous Surfacing on Structure Decks 6-08 In addition to Section 6-08.3(3), the planing equipment shall conform to the following additional requirements: 1. The cutting tooth spacing on the rotary milling head shall be less than or equal to ¼ inch. 2. The rotary milling/planing machine shall have cutting teeth that leave a uniform plane surface at all times. All teeth on the mill head shall be kept at a maximum differential tolerance of ⅜-inch between the shortest and longest tooth, as measured by a straight edge placed the full width of the rotary milling head. 3. Cutting tips shall be replaced when 30 percent of the total length of the cutting tip material remains. Prior to each day’s Bituminous Pavement removal operations, the Contractor shall confirm to the satisfaction of the Engineer that the rotary head cutting teeth are within the specified tolerances. 6-08.3(5)C Structure Deck Cleanup after Bituminous Pavement Removal Waterproofing membrane that is loose or otherwise not firmly bonded to the Structure Deck shall be removed as an incidental component of the Work of surfacing removal. Existing waterproofing membrane bonded to the Structure Deck need not be removed. 6-08.3(6) Repair of Damage due to Bituminous Pavement Removal Operations All concrete bridge deck, pavement seat, and steel reinforcing bar damage due to the Contractor’s surfacing removal operations shall be repaired by the Contractor in accordance with Section 1-07.13, and as specified below. Damaged concrete in excess of the specified Bituminous Pavement removal tolerance shall be repaired in accordance with Section 6-08.3(7), with the bridge deck repair material placed to the level of the surrounding bridge deck and parallel to the final grade paving profile. Damaged steel reinforcing bar shall be repaired as follows: 1. Damage to steel reinforcing bar resulting in a section loss less than 20-percent of the bar with no damage to the surrounding concrete shall be left in place and shall be repaired by removing the concrete to a depth ¾-inches around the top steel reinforcing bar and placing bridge deck repair material accepted by the Engineer to the level of the bridge deck and parallel to the final grade paving profile. 2. Damage to steel reinforcing bar resulting in a section loss of 20-percent or more in one location, bars partially or completely removed from the bridge deck, or where there is a lack of bond to the concrete, shall be repaired by removing the adjacent concrete and splicing a new bar of the same size. Concrete shall be removed to provide a ¾-inch minimum clearance around the bars. The splice bars shall extend a minimum of 40 bar diameters beyond each end of the damage. Page 6-232 2020 Standard Specifications M 41-10 6-08 Bituminous Surfacing on Structure Decks 6-08.3(7) Concrete Deck Repair This Work consists of repairing the concrete deck after Bituminous Pavement has been removed. 6-08.3(7)A Concrete Deck Preparation The Contractor, with the Engineer, shall inspect the exposed concrete deck to establish the extent of bridge deck repair in accordance with Section 6-09.3(6). Areas of Structure Deck left with existing well bonded waterproof membrane after full depth Bituminous Pavement removal are exempt from this inspection requirement. All loose and unsound concrete within the repair area shall be removed with jackhammers no heavier than the nominal 30 pound class or chipping hammers no heavier than the nominal 15 pound class, or other mechanical means acceptable to the Engineer, and operated at angles less than 45 degrees as measured from the surface of the deck to the tool. If unsound concrete exists around the existing steel reinforcing bars, or if the bond between concrete and steel reinforcing bar is broken, the Contractor shall remove the concrete to provide a ¾ inch minimum clearance to the bar. The Contractor shall take care to prevent damage to the existing steel reinforcing bars and concrete to remain. After removing sufficient concrete to establish the limits of the repair area, the Contractor shall make ¾ inch deep vertical saw cuts and maintain square edges at the boundaries of the repair area. The exposed steel reinforcing bars and concrete in the repair area shall be abrasive blasted and blown clean just prior to placing the bridge deck repair material. 6-08.3(7)B Ultra-Low Viscosity, Two-Part Liquid, Polyurethane-Hybrid Polymer Concrete The ultra-low viscosity, two-part liquid, polyurethane-hybrid polymer concrete shall be mixed in accordance with the manufacturer’s recommendations. Aggregate shall conform to the gradation limit requirements recommended by the manufacturer. The aggregate and the ultra-low viscosity, two-part liquid, polyurethane- hybrid polymer concrete shall be applied to the repair areas in accordance with the sequence and procedure recommended by the manufacturer. All repairs shall be float finished flush with the surrounding surface within a tolerance of ⅛ inch of a straight edge placed across the full width and breadth of the repair area. 6-08.3(7)C Pre-Packaged Cement Based Repair Mortar The Contractor shall mix the pre-packaged cement based repair mortar using equipment, materials and proportions, batch sizes, and process as recommended by the manufacturer. All repairs shall be float finished flush with the surrounding surface within a tolerance of ⅛ inch of a straight edge placed across the full width and breadth of the repair area. 2020 Standard Specifications M 41-10 Page 6-233 Bituminous Surfacing on Structure Decks 6-08 6-08.3(7)D Cure All bridge deck repair areas shall be cured in accordance with the manufacturer’s recommendations and attain a minimum compressive strength of 2,500 psi before allowing vehicular and foot traffic on the repair and placing waterproofing membrane on the bridge deck over the repair. 6-08.3(8) Waterproof Membrane for Structure Decks This work consists of furnishing and placing a waterproof sheet membrane system over a prepared Structure Deck prior to placing an HMA overlay. The waterproof membrane system shall consist of a sheet membrane adhered to the Structure Deck with a primer. The Contractor shall comply with all membrane manufacturer’s installation recommendations. 6-08.3(8)A Structure Deck Preparation The Structure Deck and ambient air temperatures shall be above 50°F and the Structure Deck shall be surface-dry at the time of the application of the primer and membrane. All areas of a Structure Deck that have fresh cast bridge deck concrete less than 28 days old (not including bridge deck repair concrete placed in accordance with Section 6-08.3(7)) shall cure for a period of time recommended by the membrane manufacturer, or as specified by the Engineer, before application of the membrane. The entire Structure Deck and the sides of the curb and expansion joint headers to the height of the HMA overlay shall be free of all foreign material such as dirt, grease, etc. Prior to applying the primer or sheet membrane, all dust and loose material shall be removed from the Structure Deck. All surface defects such as spalled areas, cracks, protrusions, holes, sharp edges, ridges, etc., and other surface imperfections greater than ¼ inch in width shall be corrected prior to application of the membrane. 6-08.3(8)B Applying Primer The primer shall be applied to the cleaned deck surfaces at the rate according to the procedure recommended by the membrane manufacturer. All surfaces to be covered by the membrane shall be thoroughly and uniformly coated with primer. Structure Deck areas left with existing well bonded waterproof membrane after bituminous surfacing removal shall receive an application of primer in accordance with the membrane manufacturer’s recommendations. Precautionary measures shall be taken to ensure that pools and thick layers of primer are not left on the deck surface. The membrane shall not be applied until the primer has cured or volatile material has substantially dissipated, in accordance with the membrane manufacturer’s recommendations. The primer and waterproof membrane shall extend from the bridge deck up onto the curb face and expansion joint header face the thickness of the HMA overlay. The membrane shall adhere to the vertical surface. Page 6-234 2020 Standard Specifications M 41-10 6-08 Bituminous Surfacing on Structure Decks 6-08.3(8)C Placing Waterproof Membrane Membrane application shall begin at the low point on the deck, and continue in a lapped shingle pattern. The overlap shall be a minimum of six inches or greater if recommended by the membrane manufacturer. Membrane seams shall be sealed as recommended by the membrane manufacturer. Hand rollers or similar tools shall be used on the applied membrane to assure firm and uniform contact with the primed Structure surfaces. The fabric shall be neatly cut and contoured at all expansion joints and drains. The cuts at bridge drains shall be two right angle cuts made to the inside diameter of the bridge deck drain outlet, after which the corners of the waterproof membrane shall be turned down into the drains and laid in a coating of primer. 6-08.3(8)D Membrane Repair and Protection The waterproof membrane will be visually inspected by the Engineer for uniformity, tears, punctures, bonding, bubbles, wrinkles, voids and other defects. All such deficiencies shall be repaired in accordance with the membrane manufacturer’s recommendations prior to placement of the HMA overlay. The membrane material shall be protected from damage due to the paving operations in accordance with the membrane manufacturer’s recommendations. No traffic or equipment except that required for the actual waterproofing and paving operations will be permitted to travel or rest on the membrane until it is covered by the HMA overlay. The use of windrows is not allowed for laydown of HMA on a membrane. Where waterproofing membrane is placed in stages or applied at different times, a strip of temporary paper shall be used to protect the membrane overlap from the HMA hand removal methods. 6-08.3(9) Placing Bituminous Pavement on Structure Decks HMA overlay shall be applied on Grade Controlled Structure Decks using reference lines for vertical control in accordance with Section 5-04.3(3)C. The compacted elevation of the HMA overlay on Structure Decks shall be within ± 0.02 feet of the specified overlay thickness or Final Grade Profile as applicable. Deviations from the final grade paving profile in excess of the specified tolerance and areas of non-conforming surface smoothness shall be corrected in accordance with Section 5-04.3(13). Final grade Roadway transitions to a Structure Deck with Bituminous Pavement shall not exceed a 0.20 percent change in grade in accordance with the bridge deck transition for HMA overlay Standard Plan, unless shown otherwise in the Plans. Final grade compacted HMA elevations shall be higher than an adjacent concrete edge by ¼ inch ± ⅛ inch at all expansion joint headers and concrete butt joints as shown in the concrete to asphalt butt joint details of the bridge paving joint seals Standard Plan. This also applies to steel edges within the limits of the overlay such as bridge drain frames and steel joint riser bars at bridge expansion joints. 2020 Standard Specifications M 41-10 Page 6-235 Bituminous Surfacing on Structure Decks 6-08 6-08.3(9)A Protection of Structure Attachments and Embedments The Contractor is responsible for protecting all Structure attachments and embedments from the application of BST and HMA. Drainage inlets that are to remain open, and expansion joints, shall be cleaned out immediately after paving is completed. Materials passing through expansion joints shall be removed from the bridge within 10 working days. All costs incurred by the Contractor in protective measures and clean up shall be included in the unit Contract prices for the associated Bid items of Work. 6-08.3(10) HMA Compaction on Structure Decks Compaction of HMA on Structure Decks shall be in accordance with Section 5-04.3(10). Work rejected in accordance with Section 5-04.3(11) shall include the materials, work, and incidentals to repair an existing waterproof membrane damaged by the removal of the rejected work. 6-08.3(11) Paved Panel Joint Seals and HMA Sawcut and Seals Bridge paving joint seals shall be installed in accordance with Section 5-04.3(12)B and the details shown in the Plans and Standard Plans. When concrete joints are exposed after removal of Bituminous Pavement, the joints shall be cleaned and sealed in accordance with Section 5-01.3(8) and the paved panel joint seal details of the bridge paving joint seals Standard Plan, including placement of the closed cell backer rod at the base of the cleaned joint. If waterproofing membrane is required, the membrane shall be slack or folded at the concrete joint to allow for Structure movements without stress to the membrane. After placement of the HMA overlay, the second phase of the paved panel joint seal shall be completed by sawing the HMA and sealing the sawn joint in accordance with Section 5-04.3(12)B2. 6-08.4 Measurement Removing existing Bituminous Pavement from Structure Decks will be measured by the square yard of Structure Deck surface area with removed overlay. Bridge deck repair will be measured by the square foot surface area of deck concrete removed with the measurement taken at the plane of the top mat of steel reinforcing bars. Waterproof membrane will be measured by the square yard surface area of Structure Deck and curb and header surface area covered by membrane. Page 6-236 2020 Standard Specifications M 41-10 6-08 Bituminous Surfacing on Structure Decks 6-08.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Structure Surveying”, lump sum. “Removing Existing Overlay From Bridge Deck___”, per square yard. The unit Contract price per square yard for “Removing Existing Overlay From Bridge Deck___”, shall be full pay for performing the Work as specified for full removal of Bituminous Pavement on Structure Decks, including the removal of existing waterproof membrane and disposing of materials. “Bridge Deck Repair Br. No.___”, per square foot. The unit Contract price per square foot for “Bridge Deck Repair Br. No.___” shall be full pay for performing the Work as specified, including removing and disposing of the concrete within the repair area and furnishing, placing, finishing, and curing the repair concrete. “Waterproof Membrane Br. No.___”, per square yard. The unit Contract price per square yard for “Waterproof Membrane Br. No.___” shall be full pay for performing the Work as specified, including repairing any damaged or defective waterproofing membrane and repair of damaged HMA overlay. 2020 Standard Specifications M 41-10 Page 6-237 Modified Concrete Overlays 6-09 6-09 Modified Concrete Overlays 6-09.1 Description This Work consists of scarifying concrete bridge decks, preparing and repairing bridge deck surfaces designated and marked for further deck preparation, and placing, finishing, and curing modified concrete overlays. 6-09.2 Materials Materials shall meet the requirements of the following Sections: Portland Cement 9-01.2(1) Blended Hydraulic Cement 9-01.2(1)B Fine Aggregate 9-03.1 Coarse Aggregate 9-03.1 Mortar 9-20.4 Burlap Cloth 9-23.5 Admixtures 9-23.6 Fly Ash 9-23.9 Microsilica Fume 9-23.11 Water 9-25.1 Portland cement shall be either Type I or Type II. Type III portland cement will not be allowed. Blended hydraulic cement shall be Type IP(X)MS and shall only be used in modified fly ash overlay. The required proportions for Type I cement and Type F fly ash shall be in accordance with Section 6-09.3(3)C. Only Type IP(X)MS that is blended with Type F fly ash is permitted for use. Type IP(X)MS that is blended with natural pozzolans are not allowed. Fine aggregate shall be Class 1. Coarse aggregate shall be AASHTO grading No. 7 or No. 8. Fly ash shall be Class F only. Microsilica admixture shall be either a dry powder or a slurry admixture. Microsilica will be accepted based on submittal of a Manufacturer’s Certificate of Compliance in accordance with Section 1-06.3. If the microsilica is a slurry admixture, the microsilica content of the slurry shall be certified as a percent by mass. Page 6-238 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays 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. The latex admixture shall be homogeneous and uniform in composition, and shall conform to the following: Polymer Type Styrene Butadiene Stabilizers: Latex Non-ionic surfactants Portland Cement Polydimethyl siloxane Percent Solids 46.0 to 49.0 Weight per Gallon 8.4 pounds at 77ºF Color White PH (as shipped) 9 minimum Freeze/Thaw Stability 5 cycles (5ºF to 77ºF) Shelf Life 2 years minimum Latex admixture will be accepted based on submittal of a Manufacturer’s Certificate of Compliance in accordance with Section 1-06.3. High Molecular Weight Methacrylate (HMWM) resin for crack and joint sealing shall conform to the following: Viscosity <25 cps (Brookfield RVT with UL adaptor, 50 rpm at 77°F) … California Test 434 Density 8.5 to 8.8 pounds per gallon at 77°F… ASTM D2849 Flash Point >200°F, PMCC (Pinsky-Martens CC) Vapor Pressure <0.04 inches Hg at 77°F, ASTM D323 Tg (DSC) >136°F, ASTM D3418 Gel Time 60 minutes minimum The promoter/initiator system for the methacrylate resin shall consist of a metal drier and peroxide. Sand for abrasive finish shall be crushed sand, oven dried, and stored in moisture proof bags. The sand shall conform to the following gradation: Sieve Size Percent Passing Minimum Maximum No. 10 98 100 No. 16 55 75 No. 20 30 50 No. 30 8 25 No. 50 0 5 No. 100 0 3 All percentages are by weight. 2020 Standard Specifications M 41-10 Page 6-239 Modified Concrete Overlays 6-09 6-09.3 Construction Requirements 6-09.3(1) Equipment 6-09.3(1)A Power Driven Hand Tools Power driven hand tools may be used for concrete scarification in areas not accessible to scarification machines, and for further deck preparation Work, and shall meet the following: 1. Jack hammers no heavier than the nominal 30-pound class. 2. Chipping hammers no heavier than the nominal 15-pound class. 3. Other mechanical means acceptable to the Engineer. The power driven hand tools shall be operated at angles less than 45 degrees as measured from the surface of the deck to the tool. 6-09.3(1)B Rotary Milling Machines Rotary milling machines used to remove an upper layer of existing concrete overlay, when present, shall have a maximum operating weight of 50,000 pounds and conform to Section 6-08.3(5)B. 6-09.3(1)C Hydro-Demolition Machines Hydro-demolition machines shall consist of filtering and pumping units operating in conjunction with a remote-controlled robotic device, using high-velocity water jets to remove sound concrete to the lesser of 2 inches or the nominal scarification depth shown in the Plans with a single pass of the machine, and with the simultaneous removal of all deteriorated concrete. If the nominal scarification depth is greater than 2 inches then the multiple passes shall be required. Rotary heads are required for the final pass of the hydro-demolition machine. Hydro-demolition machines shall also clean any exposed reinforcing steel of all rust and corrosion products. 6-09.3(1)D Vacant 6-09.3(1)E Air Compressor Air compressors shall be equipped with oil traps to eliminate oil from being blown onto the bridge deck. 6-09.3(1)F Vacuum Machine Vacuum machines shall be capable of collecting all dust, concrete chips, freestanding water and other debris encountered while cleaning during deck preparation. The machines shall be equipped with collection systems that allow the machines to be operated in air pollution sensitive areas and shall be equipped to not contaminate the deck during final preparation for concrete placement. Page 6-240 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays 6-09.3(1)G Water Spraying System The water spraying system shall include a portable high-pressure sprayer with a separate water supply of potable water. The sprayer shall be readily available to all parts of the deck being overlaid and shall be able to discharge water in a fine mist to prevent accumulation of free water on the deck. Sufficient water shall be available to thoroughly soak the deck being overlaid and to keep the deck wet prior to concrete placement. The Contractor shall certify that the water spraying system meets the following requirements: Pressure 2,200 psi minimum Flow Rate 4.5 gpm minimum Fan Tip 15° to 25° Range 6-09.3(1)H Mobile Mixer for Latex Modified Concrete Proportioning and mixing shall be accomplished in self-contained, self-propelled, continuous-mixing units conforming to the following requirements: 1. The mixer shall be equipped so that it can be grounded. 2. The mixer shall be equipped to provide positive measurement of the portland cement being introduced into the mix. A recording meter, visible at all times and equipped with a ticket printout, shall be used. 3. The mixer shall be equipped to provide positive control of the flow of water and latex admixture into the mixing chamber. Water flow shall be indicated by a flow meter with a minimum readability of ½ gallon per minute, accurate to ± 1 percent. The water system shall have a bypass valve capable of completely diverting the flow of water. Latex flow shall also be indicated by a flow meter with a minimum readability of 2 gallons per minute, accurate to ± 1 percent. The latex system shall be equipped with a bypass valve suitable for obtaining a calibrated sample of admixture. 4. The mixer shall be equipped to be calibrated to automatically proportion and blend all components of the specified mix on a continuous or intermittent basis as required by the finishing operation, and shall discharge mixed material through a conventional chute directly in front of the finishing machine. Inspection of each mobile mixer shall be done by the Contractor in the presence of the Engineer and in accordance with the following requirements: 1. Check the manufacturer’s inspection plate or mix setting chart for the serial number, the proper operating revolutions per minute (rpm), and the approximate number of counts on the cement meter to deliver 94 pounds of cement. 2. Make a general inspection of the mobile mixer to ensure cleanliness and good maintenance practices. 3. Check to see that the aggregate bins are empty and clean and that the bin vibrators work. 2020 Standard Specifications M 41-10 Page 6-241 Modified Concrete Overlays 6-09 4. Verify that the cement aeration system operates, that the vent is open, and that the mixer is equipped with a grounding strap. Check the cement meter feeder to ensure that all fins and pockets are clean and free from accumulated cement. If the operator cannot demonstrate, through visual inspection, that the cement meter feeder is clean, all cement shall be removed from the bin and the cement meter feeder inspected. The aeration system shall be equipped with a gauge or indicator to verify that the system is operating. 5. Verify that the main belt is clean and free of any accumulated material. 6. Check the latex strainer to ensure cleanliness. The initial calibration shall consist of the following items: 1. Cement Meter a. Refer to the truck manufacturer’s mix setting chart to determine the specified operating rpm and the approximate number of counts required on the cement meter to deliver 94 pounds of cement. b. Place at least 40 bags (about 4,000 pounds) of cement in the cement bin. c. Ensure the mixer is resting on a level surface. d. Ensure the mixer is grounded. e. Adjust the engine throttle to obtain the specified rpm. Operate the unit, discharging cement until the belt has made one complete revolution. Stop the belt. Reset the cement meter to zero. Position a suitable container to catch the cement and discharge approximately one bag of cement. With a stopwatch, measure the time required to discharge the cement. Record the number of counts on the cement meter and determine the weight of the cement in the container. Repeat the process of discharging approximately one bag of cement until six runs have been made. Reset the cement meter to zero for each run. Example: Run No.Cement Counts Weight of Cement Time In Seconds 1 66 95 31 2 68 96 31.2 3 67 95.5 31.0 4 66 95 29.8 5 67 95.25 30.5 6 66 95 30.8 TOTAL 400 571.75 184.3 Pounds of cement per count on cement meter: Weight of Cement No. of Counts =571.75 400 =1.43 LB./Count Page 6-242 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays Counts per bag (94 pounds): 94 1.43 =65.7 Counts Bag Pounds of cement discharged per second: Weight of Cement Time in Seconds =571.75 184.3 =3.10 LB./SEC. Required time to discharge one bag: Time =94 3.10 =30.32 SEC./Bag 2. Latex Throttling Valve a. Check to be sure that the latex strainer is unobstructed. b. The latex throttling valve shall be adjusted to deliver 3.5 gallons of latex (29.4 pounds) for each bag of cement. From the above calculation 30.32 seconds are required to deliver one bag of cement. c. With the unit operating at the specified rpm, discharge latex into a container for 30.3 seconds and determine the weight of latex. Continue adjusting the valve until 29.4 to 29.5 pounds of latex is discharged in 30.3 seconds. Verify the accuracy of this valve setting three times. 3. Water Flow Meter a. Set the water flow meter by adjusting it to flow at ½ gallon per minute. b. Collect and weigh the water discharged during a 1-minute interval with the equipment operating at the specified rpm. Divide the weight of water by 8.34 to determine the number of gallons. c. Repeat items a. and b., above, with the flow meter adjusted to 1½ gallons per minute. 4. Aggregate Bin Gates a. Set the gate openings to provide the amount of aggregate required to produce concrete having the specified proportions. b. Discharge a representative sample of the aggregates through the gates and separate on the No. 4 sieve. Aggregates shall meet the requirements for proportions in accordance with Section 6-09.3(3)E. c. Adjust the gate openings if necessary to provide the proper ratio of fine aggregate to total aggregate. 5. Production of Trial Mix – Each mobile mixer shall be operated to produce at least ½ cubic yard of concrete, which shall be in compliance with these Specifications, prior to acceptance of the mobile mixer for job use. The Engineer will perform yield, slump, and air tests on the concrete produced by each mixer. Calibration of each mobile mixer shall be done by the Contractor in the presence of the Engineer. A complete calibration is required on each mixer on each concrete placement unless, after the 2020 Standard Specifications M 41-10 Page 6-243 Modified Concrete Overlays 6-09 initial calibration, the personnel having the responsibility of mixer calibration on subsequent concrete placement were present during the initial calibration of the mixer and during the concrete placement operations and are able to verify the dial settings of the initial calibration and concrete placement. If these criteria are met, a complete calibration need not be repeated provided that a single trial run verifies the previous settings of the cement meter, latex throttling valve, water flow meter, and aggregate gradations, and that the mixer has not left the project and the Engineer is satisfied that a complete calibration is not needed. 6-09.3(1)I Ready-Mix Trucks and Batch Plants for Concrete Class M, Fly Ash Modified and Microsilica Modified Concrete Ready-mix trucks and batch plants shall conform to Section 6-02.3(4)A. 6-09.3(1)J Finishing Machine The finishing machine shall meet the requirements of Section 6-02.3(10) and the following requirements: The finishing machine shall be equipped with augers, followed by an oscillating, vibrating screed, vibrating roller tamper, or a vibrating pan, followed by a rotating cylindrical double drum screed. The vibrating screed, roller tamper or pan shall be of sufficient length and width to properly consolidate the mixture. The vibrating frequency of the vibrating screed, roller tamper or pan shall be variable with positive control. 6-09.3(2) Submittals The Contractor shall submit the following Working Drawings in accordance with Section 1-05.3: 1. A Type 1 Working Drawing consisting of catalog cuts and operating parameters of the hydro-demolition machine selected by the Contractor for use in this project to scarify concrete surfaces. 2. A Type 1 Working Drawing consisting of catalog cuts, operating parameters, axle loads, and axle spacing of the rotary milling machine (if used to remove an upper layer of existing concrete overlay when present). 3. A Type 2 Working Drawing of the Runoff Water Disposal Plan. The Runoff Water Disposal Plan shall describe all provisions for the containment, collection, filtering, and disposal of all runoff water and associated contaminants and debris generated by the hydro-demolition process, including containment, collection and disposal of runoff water and debris escaping through breaks in the bridge deck. 4. A Type 2 Working Drawing of the method and materials used to contain, collect, and dispose of all concrete debris generated by the scarifying process, including provisions for protecting adjacent traffic from flying debris. Page 6-244 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays 5. A Type 1 Working Drawing of the mix design for concrete Class M, and either fly ash modified concrete, microsilica modified concrete, or latex modified concrete, as selected by the Contractor for use in this project in accordance with Section 6-09.3(3). 6. A Type 1 Working Drawing of samples of the latex admixture and the portland cement for testing and compatibility (if latex modified concrete is used). 7. A Type 2 Working Drawing of the paving equipment Specifications and details of the screed rail support system, including details of anchoring the rails and providing rail continuity. 6-09.3(3) Concrete Overlay Mixes 6-09.3(3)A General For fly ash, microsilica, and latex modified concrete, the Contractor shall adjust the slump to accommodate the gradient of the bridge deck, subject to the maximum slump specified. For fly ash and microsilica modified concrete, the maximum water/cement ratio shall be calculated using all of the available mix water, including the free water in both the coarse and fine aggregate, and in the microsilica slurry if a slurry is used. For fly ash and microsilica modified concrete, all water-reducing and air entraining admixtures, and superplasticizers, shall be used in accordance with the admixture manufacturer’s recommendations. 6-09.3(3)B Concrete Class M Concrete Class M for further deck preparation patching concrete shall be proportioned in accordance with the following mix design: Portland Cement 705 pounds Fine Aggregate 1,280 pounds Coarse Aggregate 1,650 pounds Water/Cement Ratio 0.37 maximum Air (± 1½ percent) 6 percent Slump (± 1 inch) 5 inches The use of a water-reducing admixture conforming to AASHTO M194 Type A will be required to produce patching concrete with the desired slump, and shall be used in accordance with the admixture manufacturer’s recommendations. Air entraining admixtures shall conform to AASHTO M154 and shall be used in accordance with the admixture manufacturer’s recommendations. The use of accelerating admixtures or other types of admixtures is not allowed. 2020 Standard Specifications M 41-10 Page 6-245 Modified Concrete Overlays 6-09 6-09.3(3)C Fly Ash Modified Concrete Fly ash modified concrete shall be a workable mix, uniform in composition and consistency. Mix proportions per cubic yard shall be as follows: Portland Cement 611 pounds Fly Ash 275 pounds Fine Aggregate 38 percent of total aggregate Coarse Aggregate 62 percent of total aggregate Water/Cement Ratio 0.30 maximum Air (± 1½ percent) 6 percent Slump 7 inches maximum 6-09.3(3)D Microsilica Modified Concrete Microsilica modified concrete shall be a workable mix, uniform in composition and consistency. Mix proportions per cubic yard shall be as follows: Portland Cement 658 pounds Microsilica Fume 52 pounds Fine Aggregate 1,515 pounds Coarse Aggregate 1,515 pounds Water/Cement Ratio 0.33 maximum Air (± 1½ percent) 6 percent Slump 7 inches maximum 6-09.3(3)E Latex Modified Concrete Latex modified concrete shall be a workable mix, uniform in composition and consistency. Mix proportions per cubic yard shall be as follows: Portland Cement 1.00 parts by weight Fine Aggregate 2.40 to 2.75 parts by weight Coarse Aggregate 1.75 to 2.00 parts by weight Latex Admixture 3.50-gallons per bag of cement Water/Cement Ratio 0.33 maximum Air Content of Plastic Mix 6 percent maximum Slump 7 inches maximum The aggregates shall be proportioned such that the amount of aggregate passing the No. 4 sieve is 65 ± 5 percent of the total aggregate (fine plus coarse). All calculations shall be based on dry weights. The moisture content of the fine aggregate and coarse aggregate shall be no more than 3.0 and 1.0 percent, respectively, above the saturated surface dry condition. The water limit for calculating the water/cement ratio shall include the added water, the free water in the aggregates, and 52 percent of the latex admixture. Page 6-246 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays 6-09.3(4) Storing and Handling 6-09.3(4)A Vacant 6-09.3(4)B Latex Admixture The admixture shall be kept in suitable containers that will protect it from freezing and from exposure to temperatures in excess of 85ºF. Containers of the admixture shall not be stored in direct sunlight for periods in excess of 10 days. When stored in direct sunlight the top and sides of the containers shall be covered with insulating blanket material. Storage of the admixture may extend over a period greater than 10 days as long as the conditions specified above are maintained and the latex admixture is agitated or stirred once every 10 days. Stirring or agitation of the admixture shall be done mechanically in accordance with the manufacturer’s recommendation. If the ambient temperature is higher than 85ºF at any time during the storage period, the admixture shall be covered by insulated blankets or other means that will maintain the admixture temperature below 85ºF. The admixture shall be strained through a Number 10 strainer at the time it is introduced into the mixing tank from the storage containers. 6-09.3(4)C High Molecular Weight Methacrylate Resin (HMWM) The HMWM resin shall be stored in a cool dry place and protected from freezing and exposure to temperature in excess of 100ºF. The promoter and initiator, if supplied separate from the resin, shall not contact each other directly. Containers of promoters and initiators shall not be stored together in a manner that will allow leakage or spillage from one to contact the containers or material of the other. 6-09.3(5) Scarifying Concrete Surface 6-09.3(5)A General The Contractor shall not begin scarifying a concrete bridge deck surface unless completion of the scarification and concrete overlay can be accomplished within the current construction season. The Contractor shall protect adjacent traffic from flying debris generated by the scarification process in accordance with item 4 of Section 6-09.3(2). The Contractor shall collect, contain, and dispose of all concrete debris generated by the scarification process in accordance with item 4 of Section 6-09.3(2). All areas of the deck that are inaccessible to the selected scarifying machine shall be scarified to remove the concrete surface matrix by a method acceptable to the Engineer. The maximum scarified depth shall be equal to the nominal scarification depth shown in the Plans or as otherwise allowed in areas of existing dense, sound bridge deck concrete repair material. If these areas are hand-chipped then the equipment shall meet the requirements as specified in Section 6-09.3(1)A. 2020 Standard Specifications M 41-10 Page 6-247 Modified Concrete Overlays 6-09 Dense, sound areas of existing bridge deck concrete repair material shall be sufficiently scarified to provide 1-inch minimum clearance to the top of the fresh modified concrete overlay. Concrete process water generated by scarifying concrete surface and removing existing concrete overlay operations shall be contained, collected, and disposed of in accordance with Sections 5-01.3(11) and 6-09.3(5)C, and the Section 6-09.3(2) Runoff Water Disposal Plan. 6-09.3(5)B Testing of Hydro-Demolition Machines A trial area shall be performed to demonstrate that the equipment and methods of operation are capable of producing results satisfactory to the Engineer. The trial area shall consist of a patch approximately 30 square feet in sound concrete as determined by the Engineer. The equipment shall be programmed to remove concrete to the nominal scarification depth shown in the Plans, but no more than 2 inches, with a single pass of the machine. The Engineer will grant acceptance of the equipment based on successful results from the trial area test. 6-09.3(5)C Hydro-Demolishing Once the operating parameters of the Hydro-Demolition machine are defined by programming and calibration as specified in Section 6-09.3(5)B, they shall be monitored every 20 feet as the machine progresses across the bridge deck, in order to prevent the unnecessary removal of sound concrete below the required nominal removal depth. The Contractor shall maintain a minimum production rate of 250-square feet per hour during the deck scarifying process. All water used in the Hydro-Demolition process shall be potable. Stream or lake water will not be permitted. All bridge drains and other outlets within 100 feet of the Hydro-Demolition machine shall be temporarily plugged during the Hydro-Demolition operation. When scarifying a bridge deck passing over traffic lanes, the Contractor shall protect the traffic below by restricting and containing scarifying operations, and implementing traffic control measures. The Contractor shall provide for the collection, filtering and disposal of all runoff water generated by the Hydro-Demolition process, in accordance with the Runoff Water Disposal Plan in accordance with item 3 of Section 6-09.3(2). The Contractor shall comply with applicable regulations concerning such water disposal. 6-09.3(5)D Vacant Page 6-248 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays 6-09.3(5)E Removing Existing Concrete Overlay Layer by Rotomilling When the Contractor elects to remove the upper layer of existing concrete overlay, when present, by rotomilling prior to final scarifying, the entire concrete surface of the bridge deck shall be milled to remove the surface matrix to the depth specified in the Plans with a tolerance as specified in Section 6-08.3(5)B. The operating parameters of the rotary milling machine shall be monitored in order to prevent the unnecessary removal of concrete below the specified removal depth. 6-09.3(5)F Repair of Steel Reinforcing Bars Damaged by Scarifying Operations All reinforcing steel damaged due to the Contractor’s operations shall be repaired by the Contractor. For bridge decks not constructed under the same Contract as the concrete overlay, damage to existing reinforcing steel shall be repaired and paid for in accordance with Section 1-09.6 if the existing concrete cover is ½ inch or less. All other reinforcing steel damaged due to the Contractor’s operations shall be repaired by the Contractor at no additional expense to the Contracting Agency. The repair shall be as follows or as directed by the Engineer: 1. Damage to epoxy coating, when present on existing steel reinforcing bars, shall be repaired in accordance with Section 6-02.3(24)H. 2. Damage to bars resulting in a section loss of 20 percent or more of the bar area shall be repaired by chipping out the adjacent concrete and splicing a new bar of the same size. Concrete shall be removed to provide a ¾-inch minimum clearance around the bars. The splice bars shall extend a minimum of 40 bar diameters beyond each end of the damage. 3. Any bars partially or completely removed from the deck shall have the damaged portions removed and spliced with new bars as outlined in item 2 above. 6-09.3(5)G Cleanup Following Scarification After scarifying is completed, the entire lane or strip being overlaid shall be thoroughly cleaned of all dust, freestanding water and loose particles. 6-09.3(6) Further Deck Preparation Once the lane or strip being overlaid has been cleaned of debris from scarifying, the entire scarified surface shall be inspected by the Contractor, in the presence of the Engineer, in accordance with ASTM D4580, Method B. The Contractor shall mark those areas of the existing bridge deck requiring further deck preparation. Further deck preparation will be required when any one of the following conditions is present: 1. Unsound concrete in accordance with ASTM D4580, Method B. 2. Lack of bond between existing concrete and reinforcing steel. 3. All existing nonconcrete patches. 2020 Standard Specifications M 41-10 Page 6-249 Modified Concrete Overlays 6-09 Dense, sound areas of existing bridge deck material shall be sufficiently scarified to the limits shown in the plans in accordance with 6-09.3(5)A and is not considered further deck preparation. If the concrete overlay is placed on a bridge deck as part of the same Contract as the bridge deck construction, then all Work associated with the further deck preparation shall be performed at no additional expense to the Contracting Agency. 6-09.3(6)A Equipment for Further Deck Preparation Further deck preparation shall be performed using either power driven hand tools conforming to Section 6-09.3(1)A, or hydro-demolition machines conforming to Section 6-09.3(1)C. 6-09.3(6)B Deck Repair Preparation All material in the repair area shall be removed by chipping, hydro demolishing, or other approved mechanical means to a depth necessary to remove all loose and unsound material. Care shall be taken in removing the deteriorated material to not damage any of the existing deck or steel reinforcing bars that are to remain in place. All removal shall be accomplished by making vertical edges at the boundaries of the repair area. In no case shall the depth of a sawn vertical cut exceed ¾ inch or to the top of the top steel reinforcing bars, whichever is less. The exposed steel reinforcing bars and concrete in the repair area shall be sandblasted or hydro-blasted and blown clean just prior to placing concrete. Where existing steel reinforcing bars inside deck repair areas show deterioration greater than 20-percent section loss, the Contractor shall furnish and place steel reinforcing bars alongside the deteriorated bars in accordance with the details shown in the Standard Plans. Payment for such extra Work will be by force account as provided in Section 1-09.6. Bridge deck areas outside the repair area or steel reinforcing bar inside or outside the repair area damaged by the Contractor’s operations, shall be repaired by the Contractor at no additional expense to the Contracting Agency, and to the satisfaction of the Engineer. 6-09.3(6)C Placing Deck Repair Concrete Deck repair concrete for modified concrete overlays shall be either modified concrete or concrete Class M as specified below. Before placing any deck repair concrete, the Contractor shall flush the existing concrete in the repair area with water and make sure that the existing concrete is well saturated. The Contractor shall remove any freestanding water prior to placing the deck repair concrete. The Contractor shall place the deck repair concrete onto the existing concrete while it is wet. Page 6-250 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays Type 1 deck repairs, defined as deck repair areas with a maximum depth of one-half the periphery of the bottom bar of the top layer of steel reinforcement or, where depths are greater, the exposed bar length does not exceed 12-continuous inches along the length of the bar, may be filled during the placement of the concrete overlay. The Work of Type 1 further deck preparation shall consist of removing and disposing of the concrete within the repair area. Type 2 deck repairs, defined as deck repair areas not conforming to the definition of Type 1 deck repairs, shall be repaired with concrete Class M to the scarification depth shown in the plans and wet cured for 42 hours in accordance with Section 6-09.3(13), prior to placing the concrete overlay. The Work of Type 2 further deck preparation shall consist of removing and disposing of concrete within the repair area, and furnishing, placing, finishing, and curing the repair concrete. During the curing period, all vehicular and foot traffic shall be prohibited on the repair area. 6-09.3(7) Surface Preparation for Concrete Overlay Following the completion of any required further deck preparation the entire lane or strip being overlaid shall be cleaned to be free from oil and grease, rust and other foreign material that may still be present. These materials shall be removed by detergent-cleaning or other method accepted by the Engineer followed by sandblasting. After detergent cleaning and sandblasting is completed, the entire lane or strip being overlaid shall be cleaned in final preparation for placing concrete. Hand tool chipping, sandblasting and cleaning in areas adjacent to a lane or strip being cleaned in final preparation for placing concrete shall be discontinued when final preparation is begun. Scarifying and hand tool chipping shall remain suspended until the concrete has been placed and the requirement for curing time has been satisfied. Sandblasting and cleaning shall remain suspended for the first 24 hours of curing time after the completion of concrete placing. Scarification, and removal of the upper layer of concrete overlay when present, may proceed during the final cleaning and overlay placement phases of the Work on adjacent portions of the Structure so long as the scarification and concrete overlay removal operations are confined to areas which are a minimum of 100 feet away from the defined limits of the final cleaning or overlay placement in progress. If the scarification and concrete overlay removal impedes or interferes in any way with the final cleaning or overlay placement as determined by the Engineer, the scarification and concrete overlay removal Work shall be terminated immediately and the scarification and concrete overlay removal equipment removed sufficiently away from the area being prepared or overlaid to eliminate the conflict. If the grade is such that water and contaminants from the scarification and concrete overlay removal operation will flow into the area being prepared or overlaid, the scarification and concrete overlay removal operation shall be terminated and shall remain suspended for the first 24 hours of curing time after the completion of concrete placement. 2020 Standard Specifications M 41-10 Page 6-251 Modified Concrete Overlays 6-09 If, after final cleaning, the lane or strip being overlaid becomes wet, the Contractor shall flush the surface with high-pressure water, prior to placement of the overlay. All freestanding water shall be removed prior to concrete placement. Concrete placement shall begin within 24 hours of the completion of deck preparation for the portion of the deck to be overlaid. If concrete placement has not begun within 24 hours, the lane or strip being overlaid shall be cleaned by a light sand blasting followed by washing with the high- pressure water spray or by cleaning with the high-pressure spray. Traffic other than required construction equipment will not be permitted on any portion of the lane or strip being overlaid that has undergone final preparation for placing concrete unless allowed by the Engineer. To prevent contamination, all equipment allowed on the deck after final cleaning shall be equipped with drip guards. 6-09.3(8) Quality Assurance 6-09.3(8)A Quality Assurance for Microsilica Modified and Fly Ash Modified Concrete Overlays The Engineer will perform slump, temperature, and entrained air tests for acceptance in accordance with Section 6-02.3(5)D and as specified in this section after the Contractor has turned over the concrete for acceptance testing. Concrete samples for testing shall be supplied to the Engineer in accordance with Section 6-02.3(5)E. Concrete from the first truckload shall not be placed until tests for acceptance have been completed by the Engineer and the results indicate that the concrete is within acceptable limits. Sampling and testing will continue for each load until two successive loads meet all applicable acceptance test requirements. Except for the first load of concrete, up to ½ cubic yard may be placed prior to testing for acceptance. After two successive tests indicate that the concrete is within specified limits, the sampling and testing frequency may decrease to one for every three truckloads. Loads to be sampled will be selected in accordance with the random selection process outlined in FOP for WAQTC TM2. When the results of any subsequent acceptance test indicates that the concrete does not conform to the specified limits, the sampling and testing frequency will be resumed for each truckload. Whenever two successive subsequent tests indicate that the concrete is within the specified limits, the random sampling and testing frequency of one for every three truck loads may resume. 6-09.3(8)B Quality Assurance for Latex Modified Concrete Overlays The Engineer will perform slump, temperature, and entrained air tests for acceptance in accordance with Section 6-02.3(5)D and as specified in this section after the Contractor has turned over the concrete for acceptance testing. The Engineer will perform testing as the concrete is being placed. Samples shall be taken on the first charge through each mobile mixer and every other charge thereafter. The sample shall be taken after the first 2 minutes of continuous mixer operation. Concrete samples for testing shall be supplied to the Engineer in accordance with Section 6-02.3(5)E. Page 6-252 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays During the initial proportioning, mixing, placing, and finishing operations, the Engineer may require the presence of a technical representative from the latex admixture manufacturer. The technical representative shall be capable of performing, demonstrating, inspecting, and testing all of the functions required for placement of the latex modified concrete as specified in Section 6-09.3(11). This technical representative shall aid in the proper installation of the latex modified concrete. Recommendations made by the technical representative on or off the jobsite shall be adhered to by the Contractor. The Engineer will advise the Contractor in writing a minimum of 5 working days before such services are required. 6-09.3(9) Mixing Concrete For Concrete Overlay 6-09.3(9)A Mixing Microsilica Modified or Fly Ash Modified Concrete Mixing of concrete shall be in accordance with Section 6-02, with the following exceptions: 1. The mixing shall be done at a batch plant. 2. The volume of concrete transported by truck shall not exceed 6-cubic yards per truck. 6-09.3(9)B Mixing Latex Modified Concrete The equipment used for mixing the concrete shall be operated with strict adherence to the procedures set forth by its manufacturer. A minimum of two mixers will be required at the overlay site for each concrete placement when the total volume of concrete to be placed during the concrete placement exceeds the material storage capacity of a single mixer. Additional mixers may be required if conditions require that material be stockpiled away from the jobsite. The Contractor shall have sufficient mixers on hand to ensure a consistent and continuous delivery and placement of concrete throughout the concrete placement. Charging the mobile mixer shall be done in the presence of the Engineer. Mixing capabilities shall be such that the finishing operation can proceed at a steady pace. 6-09.3(10) Overlay Profile and Screed Rails 6-09.3(10)A Survey of Existing Bridge Deck Prior to Scarification Prior to beginning the scarifying concrete surface finish work specified under Section 6-09.3(5), the Contractor shall complete a survey of the existing bridge deck(s) specified to receive modified concrete overlay for use in establishing the existing cross section and grade profile elevations. The Contracting Agency will provide the Contractor with primary survey control information consisting of descriptions of two primary control points used for the horizontal and vertical control. Primary control points will be described by reference to the bridge or project-specific stationing and elevation datum. The Contracting Agency will also provide horizontal coordinates for the beginning and ending points and for 2020 Standard Specifications M 41-10 Page 6-253 Modified Concrete Overlays 6-09 each Point of Intersection (PI) on each centerline alignment included in the project. The Contractor shall provide the Engineer 21 calendar days notice in advance of scheduled concrete surface scarification work to allow the Contracting Agency time to provide the primary survey control information. The Contractor shall verify the primary survey control information furnished by the Contracting Agency and shall expand the survey control information to include secondary horizontal and vertical control points as needed for the project. The Contractor’s survey records shall include descriptions of all survey control points, including coordinates and elevations of all secondary control points. The Contractor shall maintain detailed survey records, including a description of the work performed on each shift, the methods utilized to conduct the survey, and the control points used. The record shall be of sufficient detail to allow the survey to be reproduced. A Type 1 Working Drawing of each day’s survey record shall be provided to the Engineer within 3 working days after the end of the shift. The Contractor shall compile the survey information in an electronic file format acceptable to the Contracting Agency (Excel spreadsheet format is preferred). Survey information collected shall include station, offset, and elevation for each lane line and curb line. Survey information shall be collected at even 20-foot station intervals and also at the centerline of each bridge expansion joint. The Contractor shall ensure a surveying accuracy to within ± 0.01 feet for vertical control and ± 0.2 feet for horizontal control. The survey shall extend 100 feet beyond the bridge back of pavement seat. Except for the primary survey control information furnished by the Contracting Agency, the Contractor shall be responsible for all calculations, surveying, and measuring required for setting, maintaining, and resetting equipment and materials necessary for the construction of the overlay to the final grade profile. The Contracting Agency may post- check the Contractor’s surveying, but these post-checks shall not relieve the Contractor of responsibility for internal survey quality control. The Contracting Agency will establish the final grade profile based on the Contractor’s survey, and will provide the final grade profile to the Contractor within three working days after receiving the Contractor’s survey information. The Contractor shall not begin scarifying concrete surface work specified under Section 6-09.3(5) until receiving the final grade profile from the Engineer. 6-09.3(10)B Establishing Finish Overlay Profile The finish grade profile shall be + ¼ inch/- ⅛ inch from the Engineer’s final grade profile. The final grade profile shall be verified prior to the placement of modified concrete overlay with the screed rails in place. The finishing machine shall be passed over the entire surface to be overlaid and the final screed rail adjustments shall be made. If the resultant overlay thickness is not compatible with the finish grade profile generated by the Contractor’s screed rail setup, the Contractor shall make profile adjustments as specified by the Engineer. After the finish overlay profile has been verified, changes in the finishing machine elevation controls will not be allowed. The Contractor shall be Page 6-254 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays responsible for setting screed control to obtain the specified finish grade overlay profile as well as the finished surface smoothness requirements specified in Section 6-02.3(10). Screed rails upon which the finishing machine travels shall be placed outside the area to be overlaid, in accordance with item 7 of Section 6-09.3(2). Interlocking rail sections or other approved methods of providing rail continuity are required. Hold-down devices shot into the concrete are not permitted unless the concrete is to be subsequently overlaid. Hold-down devices of other types leaving holes in the exposed area will be allowed provided the holes are subsequently filled with mortar conforming to Section 9-20.4(2) mixed at a 1:2 cement/aggregate ratio. Hold-down devices shall not penetrate the existing deck by more than ¾ inch. Screed rails may be removed at any time after the concrete has taken an initial set. Adequate precautions shall be taken during the removal of the finishing machine and rails to protect the edges of the new surfaces. 6-09.3(11) Placing Concrete Overlay Five to ten working days prior to modified concrete overlay placement, a preoverlay conference shall be held to discuss equipment, construction procedures, personnel, and previous results. Inspection procedures shall also be reviewed to ensure coordination. Those attending representing the Contractor shall include the superintendent and all foremen in charge of placing and finishing the modified concrete overlay. If the project includes more than one bridge deck, an additional conference shall be held just before placing modified concrete overlay for each subsequent bridge deck. The Contractor shall not place modified concrete overlay until the Engineer agrees that: 1. Modified concrete overlay producing and placement rates will be high enough to meet placing and finishing deadlines, 2. Finishers with enough experience have been employed, and 3. Adequate finishing tools and equipment are at the site. Concrete placement shall be made in accordance with Section 6-02 and the following requirements: 1. After the lane or strip to be overlaid has been prepared and immediately before placing the concrete, it shall be thoroughly soaked and kept continuously wet with water for a minimum period of 6 hours prior to placement of the concrete. All freestanding water shall be removed prior to concrete placement. During concrete placement, the lane or strip shall be kept moist. The concrete shall then be promptly and continuously delivered and deposited on the placement side of the finishing machine. 2020 Standard Specifications M 41-10 Page 6-255 Modified Concrete Overlays 6-09 If latex modified concrete is used, the concrete shall be thoroughly brushed into the surface and then brought up to final grade. If either microsilica modified concrete or fly ash modified concrete are used, a slurry of the concrete, excluding aggregate, shall be thoroughly brushed into the surface prior to the overlay placement. Care shall be exercised to ensure that the surface receives a thorough, even coating and that the rate of progress is limited so that the brushed concrete does not become dry before it is covered with additional concrete as required for the final grade. All aggregate which is segregated from the mix during the brushing operation shall be removed from the deck and disposed of by the Contractor. If either microsilica modified concrete or fly ash modified concrete are used, the Contractor shall ensure that a sufficient number of trucks are used for concrete delivery to obtain a consistent and continuous delivery and placement of concrete throughout the concrete placement operation. When concrete is to be placed against the concrete in a previously placed transverse joint, lane, or strip, the previously placed concrete shall be sawed back 6 inches to straight and vertical edges and shall be sandblasted or water blasted before new concrete is placed. The Engineer may decrease the 6 inch saw back requirement to 2 inches minimum, if a bulkhead was used during previous concrete placement and the concrete was hand vibrated along the bulkhead. 2. Concrete placement shall not begin if rain is expected. Adequate precautions shall be taken to protect freshly placed concrete in the event that rain begins during placement. Concrete that is damaged by rain shall be removed and replaced by the Contractor at no additional expense to the Contracting Agency, and to the satisfaction of the Engineer. 3. Concrete shall not be placed when the temperature of the concrete surface is less than 45ºF or greater than 75ºF, and wind velocityone foot above the bridge deck is in excess of 10 mph. If the Contractor elects to Work at night to meet these criteria, adequate lighting shall be provided at no additional expense to the Contracting Agency. 4. If concrete placement is stopped for a period of ½ hour or more, the Contractor shall install a bulkhead transverse to the direction of placement at a position where the overlay can be finished full width up to the bulkhead. The bulkhead shall be full depth of the overlay and shall be installed to grade. The concrete shall be finished and cured in accordance with these Specifications. Further placement is permitted only after a period of 12 hours unless a gap is left in the lane or strip. The gap shall be of sufficient width for the finishing machine to clear the transverse bulkhead installed where concrete placement was stopped. The previously placed concrete shall be sawed back from the bulkhead, to a point designated by the Engineer, to straight and vertical edges and shall be sandblasted or water blasted before new concrete is placed. 5. Concrete shall not be placed against the edge of an adjacent lane or strip that is less than 36 hours old. Page 6-256 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays 6-09.3(12) Finishing Concrete Overlay Finishing shall be accomplished in accordance with the applicable portions of Section 6-02.3(10) and as follows. Concrete shall be placed and struck-off approximately ½ inch above final grade and then consolidated and finished to final grade with a single pass (the Engineer may require additional passes) of the finishing machine. Hand finishing may be necessary to close up or seal off the surface. The final product shall be a dense uniform surface. Latex shall not be sprayed on a freshly placed latex modified concrete surface; however, a light fog spray of water is permitted if required for finishing, as determined by the Engineer. Construction dams shall be separated from the newly placed concrete by passing a pointing trowel along the inside surfaces of the dams. Care shall be exercised to ensure that this trowel cut is made for the entire depth and length of the dams after the concrete has stiffened sufficiently that it does not flow back. 6-09.3(13) Curing Concrete Overlay As the finishing operation progresses, the concrete shall be immediately covered with a single layer of clean, new or used, wet burlap. The burlap shall have a maximum width of 6 feet. The Engineer will determine the suitability of the burlap for reuse, based on the cleanliness and absorption ability of the burlap. Care shall be exercised to ensure that the burlap is well drained and laid flat with no wrinkles on the deck surface. Adjacent strips of burlap shall have a minimum overlap of 6 inches. Once in place the burlap shall be lightly fog sprayed with water. A separate layer of white, reflective type polyethylene sheeting shall immediately be placed over the wet burlap. As an alternative to the application of burlap and fog spraying described above, the Contractor may propose a curing system using proprietary curing blankets specifically manufactured for bridge deck curing. The Contractor shall submit a Type 2 Working Drawing consisting of details of the proprietary curing blanket system, including product literature and details of how the system is to be installed and maintained. The wet curing regimen as described shall remain in place for a minimum of 42-hours. 6-09.3(14) Checking for Bond After the requirements for curing have been met, the entire overlaid surface shall be sounded by the Contractor in accordance with ASTM D4580, in a manner accepted by and in the presence of the Engineer, to ensure total bond of the concrete to the bridge deck. Concrete in unbonded areas shall be removed and replaced by the Contractor at no additional expense to the Contracting Agency, in accordance with Section 6-09.3(6) except as modified here. Saw cut the edges around the repair area with an edge perpendicular to the concrete surface. The depth of the saw cut shall be ¾ inch, but shall be reduced if necessary to avoid damaging any reinforcement. The geometry of the repair perimeter shall be 2020 Standard Specifications M 41-10 Page 6-257 Modified Concrete Overlays 6-09 rectangular, avoiding reentrant corners. All concrete in the removal area shall be removed by chipping, or other approved mechanical means to the depth necessary to remove all loose or unsound concrete. All removal shall maintain square edges at the boundaries of the repair area. Concrete for patching shall be the same modified concrete as used in the overlay. The repair area shall be wet cured for 42 hours in accordance with Section 6-09.3(13). After curing requirements have been met, all repaired areas shall be sounded by the Contractor in accordance with this section. 6-09.3(15) Sealing and Texturing Concrete Overlay After the requirements for checking for bond have been met, all joints and visible cracks shall be filled and sealed with a high molecular weight methacrylate resin (HMWM). Cracks 1/16 inch and greater in width shall receive two applications of HMWM. Immediately following the application of HMWM, the wetted surface shall be coated with sand for abrasive finish. After all cracks have been filled and sealed and the HMWM resin has cured, the concrete overlay surface shall receive a longitudinally sawn texture in accordance with Section 6-02.3(10)D5. Traffic shall not be permitted on the finished concrete until it has reached a minimum compressive strength of 3,000 psi as verified by rebound number determined in accordance with ASTM C805 and the longitudinally sawn texture is completed. 6-09.4 Measurement Scarifying concrete surface will be measured by the square yard of surface actually scarified. Modified concrete overlay will be measured by the cubic foot of material placed. For latex modified concrete overlay, the volume will be determined by the theoretical yield of the design mix and documented by the counts of the cement meter less waste. For both microsilica modified concrete overlay and fly ash modified concrete overlay, the volume will be determined from the concrete supplier’s Certificate of Compliance for each batch delivered less waste. Waste is defined as the following: 1. Material not placed. 2. Material placed in excess of 6 inches outside a longitudinal joint or transverse joint. Finishing and curing modified concrete overlay will be measured by the square yard of overlay surface actually finished and cured. Further deck preparation for Type 1 deck repair and for Type 2 deck repair will be measured by the square foot of surface area of deck concrete removed in accordance with Section 6-09.3(6). Page 6-258 2020 Standard Specifications M 41-10 6-09 Modified Concrete Overlays 6-09.5 Payment Payment will be made for each of the following Bid items that are included in the Bid Proposal: “Scarifying Conc. Surface”, per square yard. The unit Contract price per square yard for “Scarifying Conc. Surface” shall be full pay for performing the Work as specified, including testing and calibration of the machines and tools used, containment, collection, and disposal of all water and abrasives used and debris created by the scarifying operation, measures taken to protect adjacent traffic from flying debris, and final cleanup following the scarifying operation. “Modified Conc. Overlay”, per cubic foot. The unit contract price per cubic foot for “Modified Conc. Overlay” shall be full pay for furnishing the modified concrete overlay, including the overlay material placed into Type 1 deck repairs in accordance with Section 6-09.3(6)C. “Finishing and Curing Modified Conc. Overlay”, per square yard. The unit Contract price per square yard for “Finishing and Curing Modified Conc. Overlay” shall be full pay for performing the Work as specified, including placing, finishing, and curing the modified concrete overlay, checking for bond, and sealing all cracks. “Further Deck Preparation for Type 1 Deck Repair”, per square foot. “Further Deck Preparation for Type 2 Deck Repair”, per square foot. “Structure Surveying”, lump sum. The lump sum contract price for “Structure Surveying” shall be full pay to perform the work as specified, including establishing secondary survey control points, performing survey quality control, and recording, compiling, and submitting the survey records to the Engineer. 2020 Standard Specifications M 41-10 Page 6-259 Concrete Barrier 6-10 6-10 Concrete Barrier 6-10.1 Description This section applies to building precast or cast-in-place cement concrete barriers as required by the Plans, these Specifications, or the Engineer. This Work may also include the removal, storage and resetting of permanent barrier at the locations shown in the Plans or as specified by the Engineer. 6-10.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates 9-03 Premolded Joint Fillers 9-04.1 Reinforcing Steel 9-07 Grout 9-20.3 Wire rope shall be Class 6 × 19, made of improved plow steel that has been galvanized and preformed. Galvanizing shall meet ASTM A603. The wire rope shall have right regular lay and a fiber core. It shall be ⅝ inch in diameter and have a minimum breaking strength of 15 tons. All hardware (connecting pins, drift pins, nuts, washers, etc.) shall be galvanized in keeping with AASHTO M 232. Connecting pins, drift pins and steel pins for type 3 anchors shall conform to Section 9-06.5(4) and be galvanized in accordance with AASHTO M232. All other hardware shall conform to Section 9-06.5(1) and be galvanized in accordance with AASHTO M232. Grout for permanent installations of precast single slope barrier shall conform to Section 9-20.3(3) and shall be placed in accordance with Section 6-02.3(20). 6-10.3 Construction Requirements Single slope barrier shall be cast-in-place or slipformed, except when precast single slope barrier is specified in the Plans or specified by the Engineer. Concrete barrier installed in conjunction with light standard foundations and sign bridge foundations, regardless of the barrier shape, shall be cast-in-place using stationary forms. Concrete barrier transition Type 2 to bridge f-shape shall be precast. Steel welded wire reinforcement deformed, conforming to Section 9-07.7, may be substituted in concrete barrier in place of deformed steel bars conforming to Section 9-07.2, subject to the following conditions: 1. Steel welded wire reinforcement spacing shall be the same as the deformed steel bar spacing shown in the Standard Plans. Page 6-260 2020 Standard Specifications M 41-10 6-10 Concrete Barrier 2. The minimum cross sectional area for steel welded wire reinforcement shall be no less than 86 percent of the cross sectional area for the deformed steel bars being substituted. 3. Development lengths and splice lengths shall conform to requirements specified in the AASHTO LRFD Bridge Design Specifications, current edition. 6-10.3(1) Precast Concrete Barrier The fabrication plant for precast concrete barriers shall be approved by Contracting Agency prior to the use of barrier and the plant shall perform quality control testing and inspection on all barrier used by the Contracting Agency. The Contractor shall advise the Engineer of the production schedule for the fabrication of barrier. Test results from the fabricators QC testing shall demonstrate compliance with Sections 6-02.3(4)C consistency, 6-02.3(4)D temperature and time of placement, 6-02.3(2)A air content, and compressive strength. All tests will be conducted in accordance with Section 6-02.3(5)D. The fabricators QC tester conducting the sampling and testing shall be qualified by ACI, Grade I to perform this Work. The equipment used shall be calibrated/certified annually. All test results and certifications shall be kept at the fabricator’s facility for review by the Contracting Agency. The Contracting Agency intends to perform Quality Assurance Inspection. This inspection is for the qualification of the plant QC process. This inspection shall not relieve the Contractor of any responsibility for identifying and replacing defective material and workmanship. The concrete in precast barrier shall be Class 5000 for Type F and Class 4000 for all other precast barriers, and comply with the provisions of Section 6-02.3. If Self-Consolidating Concrete is used, the concrete shall conform to Sections 6-02.3(27)B and 6-02.3(27)C. No concrete barrier shall be shipped until test cylinders made of the same concrete and cured under the same conditions show the concrete has reached the specified 28 day compressive strength. The Contractor may use Type III portland cement, but shall bear any added cost. Precast barrier shall be cast in steel forms. After release, the barrier shall be finished to an even, smooth, dense surface, free from any rock pockets or holes larger than ¼ inch across. Troweling shall remove all projecting concrete from the bearing surface. If heat curing methods are used, precast concrete barrier shall be cured in accordance with Section 6-02.3(25)D except that the barrier shall be cured in the forms until a rebound number test, or test cylinders which have been cured under the same conditions as the barrier, indicate the concrete has reached a compressive strength of a least 70% of the specified 28 day compressive strength. No additional curing is required once the barrier is removed from the forms. 2020 Standard Specifications M 41-10 Page 6-261 Concrete Barrier 6-10 The barrier shall be precast in sections as the Standard Plans require. All barrier in the same project (except end sections and variable length units needed for closure) shall be the same length. All barrier shall be new and unused. It shall be true to Plan dimensions. The manufacturer shall be responsible for any damage or distortion that results from manufacturing. Only one section less than 20 feet long for single slope barrier and 10 feet long for all other barriers may be used in any single run of precast barrier, and it shall be at least 8 feet long. It may be precast or cast-in-place. Hardware identical to that used with other sections shall interlock such a section with adjacent precast sections. Barrier connection voids for permanent installations of precast single slope barrier shall be filled with grout. 6-10.3(2) Cast-In-Place Concrete Barrier Forms for cast-in-place concrete barrier, including traffic barrier, traffic-pedestrian barrier, and pedestrian barrier on bridges and related Structures, shall be made of steel or exterior plywood coated with plastic. The Contractor may construct the barrier by the slip-form method. The barrier shall be made of Class 4000 concrete that meets the requirements of Section 6-02, except that the fine aggregate gradation used for slip-form barrier may be either Class 1 or 2. The Contractor may use portland cement Type III at no additional expense to the Contracting Agency. In addition to the steel reinforcing bar tying and bracing requirements specified in Section 6-02.3(24) C, the Contractor may also place small amounts of concrete to aid in holding the steel reinforcing bars in place. These small amounts of concrete shall be not more than 2-cubic feet in volume, and shall be spaced at a minimum of 10-foot intervals within the steel reinforcement cage. These small amounts of concrete shall be consolidated and shall provide 2 inches minimum clearance to the steel reinforcing bars on the outside face of the barrier. All spattered and excess mortar and concrete shall be removed from the steel reinforcing bars prior to slip-form casting. Barrier expansion joints shall be spaced at 96-foot intervals, and dummy joints shall be spaced at 12-foot intervals unless otherwise specified in the Contract. Immediately after removing the forms, the Contractor shall complete any finishing Work needed to produce a uniformly smooth, dense surface. The surface shall have no rock pockets and no holes larger than ¼ inch across. The barrier shall be cured and finished in accordance with Section 6-02.3(11)A. The maximum allowable deviation from a 10-foot straightedge held longitudinally on all surfaces shall be ¼ inch. For single sloped barrier the maximum allowable deviation from a straightedge held along the vertical sloped face of the barrier shall be ¼ inch. At final acceptance of the project, the barrier shall be free from stains, smears, and any discoloration. Page 6-262 2020 Standard Specifications M 41-10 6-10 Concrete Barrier 6-10.3(3) Removing and Resetting Permanent Concrete Barrier The Contractor shall reset concrete barrier if the Plans or the Engineer require. If resetting is impossible immediately after removal, the Contractor shall store the barrier at Engineer- approved locations. 6-10.3(4) Joining Precast Concrete Barrier to Cast-In-Place Barrier The Contractor may join segments of cast-in-place barrier to precast barrier where transitions, split barriers, or gaps shorter than 10 feet require it. At each joint of this type, the cast-in-place segment shall include hardware that ties both its ends to abutting precast sections. 6-10.3(5) Temporary Barrier For temporary barrier, the Contractor may use precast concrete barrier or temporary steel barrier. If temporary steel barrier is selected, the Contractor shall verify the lateral deflection distance meets or is less than what is shown in the Contract Plans. Temporary concrete barrier shall comply with Standard Plan requirements and cross- sectional dimensions, except that: (1) it may be made in other lengths than those shown in the Standard Plan, and (2) it may have permanent lifting holes no larger than 4 inches in diameter or lifting loops. Temporary steel barrier shall be certified that it meets the requirements of NCHRP 350 or MASH Test Level 3 or 4 and shall be installed in accordance with the manufacturer’s recommendations. If the Contract calls for the removal and resetting of permanent barrier, and the permanent barrier is not required to remain in place until reset, the permanent barrier may be substituted for temporary concrete barrier. Any of the permanent barrier damaged during its use as temporary barrier will become the property of the Contractor and be replaced with permanent barrier when the permanent barrier is reset to its permanent location. All barrier shall be in good condition, without cracks, chips, spalls, dirt, or traffic marks. If any barrier segment is damaged during or after placement, the Contractor shall immediately repair it to the Engineer’s satisfaction or replace it with an undamaged section. Delineators shall be placed on the traffic face of the barrier 6 inches from the top and spaced a maximum of 40 feet on tangents and 20 feet through curves. The reflector color shall be white on the right side of traffic and yellow on the left side of traffic. The Contractor shall maintain, replace and clean the delineators when ordered by the Engineer. As soon as the temporary barrier is no longer needed, the Contractor shall remove it from the project. Contracting Agency furnished barrier shall remain Contracting Agency property, and the Contractor shall deliver it to a stockpile site noted in the Contract or to locations as approved by the Engineer. Contractor furnished barrier shall remain the property of the Contractor. 2020 Standard Specifications M 41-10 Page 6-263 Concrete Barrier 6-10 6-10.3(6) Placing Concrete Barrier Precast concrete barrier Type F, Types 2 and 4, precast single slope barrier, and transitions shall rest on a paved foundation shaped to a uniform grade and section. The foundation surface for precast concrete barrier Type F, Types 2 and 4, precast single slope barrier, and transitions shall meet this test for uniformity: When a 10-foot straightedge is placed on the surface parallel to the centerline for the barrier, the surface shall not vary more than ¼ inch from the lower edge of the straightedge. If deviations exceed ¼ inch, the Contractor shall correct them as required in Section 5-04.3(13). The Contractor shall align the joints of all precast segments so that they offset no more than ¼ inch transversely and no more than ¾ inch vertically. Grouting is not permitted, except as previously stated for single slope barrier. If foundation grade and section are acceptable, the Engineer may permit the Contractor to obtain vertical alignment of the barrier by shimming. Shimming shall be done with a polystyrene, foam pad (12 by 24 inches) under the end 12 inches of bearing surface. Precast barrier shall be handled and placed with equipment that will not damage or disfigure it. 6-10.4 Measurement Precast concrete barrier will be measured by the linear foot along its completed line and slope. Temporary barrier will be measured by the linear foot along the completed line and slope of the barrier, one time only for each setup of barrier protected area. Any intermediate moving or resetting will not be measured. Cast-in-place concrete barrier will be measured by the linear foot along its completed line unless the Contract specifies that it be measured per cubic yard for concrete Class 4000 and per pound for steel reinforcing bar (as required in Section 6-02.4). Cast-in-place concrete barrier light standard section will be measured by the unit for each light standard section installed. Removing and resetting existing permanent barrier will be measured by the linear foot and will be measured one time only for removing, storage, and resetting. No measure will be made for barrier that has been removed and reset for the convenience of the Contractor. Concrete barrier transition Type 2 to bridge F-shape will be measured by the linear foot installed. Single slope concrete barrier light standard foundation will be measured by the unit for each light standard foundation installed. Traffic barrier, traffic pedestrian barrier, and pedestrian barrier will be measured as specified for cast-in-place concrete barrier. Page 6-264 2020 Standard Specifications M 41-10 6-10 Concrete Barrier 6-10.5 Payment Payment will be made for each of the following Bid items that are included in the Proposal: “Precast Conc. Barrier Type ____”, per linear foot. “Cast-In-Place Conc. Barrier”, per linear foot. “Conc. Class 4000 _____”, per cubic yard. “St. Reinf. Bar _____”, per pound. “Removing and Resetting Existing Permanent Barrier”, per linear foot. The unit Contract price per linear foot for “Cast-In-Place Conc. Barrier” shall be full pay for excavation, forms, placement, special construction features, and all other materials, tools, equipment, and labor necessary to complete the Work as specified; except that when the Contract specifies, the unit Contract price per cubic yard for “Conc. Class 4000 _____” and the per pound for “St. Reinf. Bar _____”, shall be full pay for excavation, forms, placement, special construction features, and all other materials, tools, equipment, and labor necessary to complete the Work as specified. “Traffic Barrier”, per linear foot. “Traffic Pedestrian Barrier”, per linear foot. “Pedestrian Barrier” per linear foot. The unit Contract price per linear foot for “Traffic Barrier”, “Traffic Pedestrian Barrier”, and “Pedestrian Barrier” shall be full pay for constructing the barrier on top of the bridge deck, and associated bridge approach slabs, curtain walls and wingwalls, excluding the steel reinforcing bars that extend from the bridge deck, bridge approach slab, curtain walls, and wingwalls. “Single Slope Concrete Barrier”, per linear foot. The unit Contract price per linear foot for “Single Slope Concrete Barrier” shall be full pay for either cast-in-place or precast single slope concrete barrier. “Conc. Barrier Transition Type 2 to Bridge F-Shape”, per linear foot. The unit Contract price per linear foot for “Conc. Barrier Transition Type 2 to Bridge F-Shape” shall be full pay for performing the Work as specified, excluding bridge traffic barrier modifications necessary for this installation. “Single Slope Conc. Barrier Light Standard Foundation”, per each. “Cast-In-Place Conc. Barrier Light Standard Section”, per each. “Temporary Barrier”, per linear foot. The unit Contract price per linear foot for “Temporary Barrier” shall be full pay for all costs, including furnishing, installing, connecting, anchoring, maintaining, temporary storage, and final removal of the temporary barrier. Payment for transition sections between different types of barrier shall be made at the unit Contract price for the type of barrier indicated in the Plans for each transition section. 2020 Standard Specifications M 41-10 Page 6-265 Reinforced Concrete Walls 6-11 6-11 Reinforced Concrete Walls 6-11.1 Description This Work consists of constructing reinforced concrete retaining walls, including those shown in the Standard Plans, L walls, and counterfort walls. 6-11.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Concrete 9-03.1 Gravel Backfill 9-03.12 Premolded Joint Filler 9-04.1(2) Steel Reinforcing Bar 9-07.2 Epoxy-Coated Steel Reinforcing Bar 9-07.3 Concrete Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Water 9-25 Other materials required shall be as specified in the Special Provisions. 6-11.3 Construction Requirements 6-11.3(1) Submittals The Contractor shall submit Type 2E Working Drawings consisting of excavation shoring plans in accordance with Section 2-09.3(3)D. The Contractor shall submit Type 2E Working Drawings of falsework and formwork plans in accordance with Sections 6-02.3(16) and 6-02.3(17). If the Contractor elects to fabricate and erect precast concrete wall stem panels, Type 2E Working Drawings of the following information shall be submitted in accordance with Section 6-02.3(28)A: 1. Working drawings for fabrication of the wall stem panels, showing dimensions, steel reinforcing bars, joint and joint filler details, surface finish details, lifting devices with the manufacturer’s recommended safe working capacity, and material Specifications. 2. Working drawings and design calculations for the erection of the wall stem panels showing dimensions, support points, support footing sizes, erection blockouts, member sizes, connections, and material Specifications. 3. Design calculations for the precast wall stem panels, the connection between the precast panels and the cast-in-place footing, and all modifications to the cast-in- place footing details as shown in the Plans or Standard Plans. Page 6-266 2020 Standard Specifications M 41-10 6-11 Reinforced Concrete Walls 6-11.3(2) Excavation and Foundation Preparation Excavation shall conform to Section 2-09.3(3), and to the limits and construction stages shown in the Plans. Foundation soils found to be unsuitable shall be removed and replaced in accordance with Section 2-09.3(1)C. 6-11.3(3) Precast Concrete Wall Stem Panels The Contractor may fabricate precast concrete wall stem panels for construction of Standard Plan Retaining Walls. Precast concrete wall stem panels may be used for construction of non-Standard Plan retaining walls if allowed by the Plans or Special Provisions. Precast concrete wall stem panels shall conform to Section 6-02.3(28), and shall be cast with Class 4000 concrete. If Self-Consolidating Concrete is used, the concrete shall conform to Sections 6-02.3(27)B and 6-02.3(27)C. The precast concrete wall stem panels shall be designed in accordance with the following codes: 1. For all loads except as otherwise noted – AASHTO LRFD Bridge Design Specifications, latest edition and current interims. The seismic design shall use the acceleration coefficient and soil profile type as specified in the Plans. 2. For all wind loads – AASHTO Guide Specifications for Structural Design of Sound Barriers, latest edition and current interims. The precast concrete wall stem panels shall be fabricated in accordance with the dimensions and details shown in the Plans, except as modified in the shop drawings. The precast concrete wall stem panels shall be fabricated full height, and shall be fabricated in widths of 8, 16, and 24 feet. The construction tolerances for the precast concrete wall stem panels shall be as follows: Height ±¼ inch Width ±¼ inch Thickness +¼ inch -⅛ inch Concrete cover for steel reinforcing bar +⅜ inch -⅛ inch Width of precast concrete wall stem panel joints ±¼ inch Offset of precast concrete wall stem panels ±¼ inch (Deviation from a straight line extending 5 feet on each side of the panel joint) The precast concrete wall stem panels shall be constructed with a mating shear key between adjacent panels. The shear key shall have beveled corners and shall be 1½ inches in thickness. The width of the shear key shall be 3½ inches minimum and 5½ inches maximum. The shear key shall be continuous and shall be of uniform width over the entire height of the wall stem. 2020 Standard Specifications M 41-10 Page 6-267 Reinforced Concrete Walls 6-11 The Contractor shall provide the specified surface finish as noted, and to the limits shown, in the Plans to the exterior concrete surfaces. Special surface finishes achieved with form liners shall conform to Sections 6-02.2 and 6-02.3(14) as supplemented in the Special Provisions. Rolled on textured finished shall not be used. Precast concrete wall stem panels shall be cast in a vertical position if the Plans call for a form liner texture on both sides of the wall stem panel. The precast concrete wall stem panel shall be rigidly held in place during placement and curing of the footing concrete. The precast concrete wall stem panels shall be placed a minimum of 1 inch into the footing to provide a shear key. The base of the precast concrete wall stem panel shall be sloped ½ inch per foot to facilitate proper concrete placement. To ensure an even flow of concrete under and against the base of the wall panel, a form shall be placed parallel to the precast concrete wall stem panel, above the footing, to allow a minimum 1-foot head to develop in the concrete during concrete placement. The steel reinforcing bars shall be shifted to clear the erection blockouts in the precast concrete wall stem panel by 1½ inches minimum. All precast concrete wall stem panel joints shall be constructed with joint filler installed on the rear (backfill) side of the wall. The joint filler material shall extend from 2 feet below the final ground level in front of the wall to the top of the wall. The joint filler shall be a nonorganic flexible material and shall be installed to create a waterproof seal at panel joints. The soil bearing pressure beneath the falsework supports for the precast concrete wall stem panels shall not exceed the maximum design soil pressure shown in the Plans for the retaining wall. 6-11.3(4) Cast-In-Place Concrete Construction Cast-in-place concrete for concrete retaining walls shall be formed, reinforced, cast, cured, and finished in accordance with Section 6-02, and the details shown in the Plans and Standard Plans. All cast-in-place concrete shall be Class 4000. Cast-in-place footings shall have a longitudinal slope no steeper than 1V: 6H, unless otherwise shown in the Plans or Standard Plans. The Contractor shall provide the specified surface finish as noted, and to the limits shown, in the Plans to the exterior concrete surfaces. Special surface finishes achieved with formliners shall conform to Sections 6-02.2 and 6-02.3(14) as supplemented in the Special Provisions. Cast-in-place concrete for adjacent wall stem sections (between vertical expansion joints) shall be formed and placed separately, with a minimum 12-hour time period between concrete placement operations. Premolded joint filler, ½ inch thick, shall be placed full height of all vertical wall stem expansion joints in accordance with Section 6-01.14. Page 6-268 2020 Standard Specifications M 41-10 6-11 Reinforced Concrete Walls 6-11.3(5) Backfill, Weepholes, and Gutters Unless the Plans specify otherwise, backfill and weepholes shall be placed in accordance with the Standard Plans and Section 6-02.3(22). Gravel backfill for drain shall be compacted in accordance with Section 2-09.3(1)E. Backfill within the zone defined as Bridge Approach Embankment in Section 1-01.3 shall be compacted in accordance with Method C of Section 2-03.3(14)C. All other backfill shall be compacted in accordance with Method B of Section 2-03.3(14)C, unless otherwise specified. Cement concrete gutter shall be constructed as shown in the Standard Plans. 6-11.3(6) Traffic Barrier and Pedestrian Barrier When shown in the Plans, traffic barrier and pedestrian barrier shall be constructed in accordance with Sections 6-02.3(11)A and 6-10.3(2), and the details shown in the Plans and Standard Plans. 6-11.4 Measurement Concrete Class 4000 for retaining wall will be measured as specified in Section 6-02.4. Steel reinforcing bar for retaining wall and epoxy-coated steel reinforcing bar for retaining wall will be measured as specified in Section 6-02.4. Traffic barrier and pedestrian barrier will be measured as specified in Section 6-10.4 for cast-in-place concrete barrier. 6-11.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Conc. Class 4000 For Retaining Wall”, per cubic yard. All costs in connection with furnishing and installing weep holes and premolded joint filler shall be included in the unit Contract price per cubic yard for “Conc. Class 4000 for Retaining Wall”. “St. Reinf. Bar For Retaining Wall”, per pound. “Epoxy-Coated St. Reinf. Bar For Retaining Wall”, per pound. “Traffic Barrier”, per linear foot. “Pedestrian Barrier”, per linear foot. The unit Contract price per linear foot for “___ Barrier” shall be full pay for constructing the barrier on top of the retaining wall, except that when these Bid items are not included in the Proposal, all costs in connection with performing the Work as specified shall be included in the unit Contract price per cubic yard for “Conc. Class 4000 For Retaining Wall”, and the unit Contract price per pound for “___ Bar For Retaining Wall”. 2020 Standard Specifications M 41-10 Page 6-269 Noise Barrier Walls 6-12 6-12 Noise Barrier Walls 6-12.1 Description This Work consists of constructing cast-in-place concrete, precast concrete, masonry, and timber noise barrier walls, including those shown in the Standard Plans. 6-12.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Concrete 9-03.1 Gravel Backfill 9-03.12 Premolded Joint Filler 9-04.1(2) Bolts, Nuts, and Washers 9-06.5(1) Noise Barrier Wall Access Door 9-06.17 Steel Reinforcing Bar 9-07.2 Epoxy-Coated Steel Reinforcing Bar 9-07.3 Paints 9-08 Grout 9-20.3 Concrete Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Water 9-25 Other materials required shall be as specified in the Special Provisions. 6-12.3 Construction Requirements 6-12.3(1) Submittals All noise barrier walls not constructed immediately adjacent to the Roadway, and that require construction of access for Work activities, shall have a noise barrier wall access plan. The Contractor shall submit a Type 2 Working Drawing consisting of the noise barrier wall access plan. The noise barrier wall access plan shall include, but not be limited to, the locations of access to the noise barrier wall construction sites, and the method, materials, and equipment used to construct the access, remove the access, and recontour and reseed the disturbed ground. For construction of all noise barrier walls with shafts, the Contractor shall submit a Type 2 Working Drawing consisting of the shaft construction plan, including at a minimum the following information: 1. List and description of equipment to be used to excavate and construct the shafts, including description of how the equipment is appropriate for use in the expected subsurface conditions. 2. The construction sequence and order of shaft construction. Page 6-270 2020 Standard Specifications M 41-10 6-12 Noise Barrier Walls 3. Details of shaft excavation methods, including methods to clean the shaft excavation. 4. Details and dimensions of the shaft, and casing if used. 5. The method used to prevent ground caving (temporary casing, slurry, or other means). 6. Details of concrete placement including procedures for deposit through a conduit, tremie, or pump. 7. Method and equipment used to install and support the steel reinforcing bar cage. For construction of precast concrete noise barrier walls, the Contractor shall submit Type 2 Working Drawings consisting of shop drawings for the precast concrete panels in accordance with Section 6-02.3(28)A. In addition to the items listed in Section 6-02.3(28)A, the precast concrete panel shop drawings shall include the following: 1. Construction sequence and method of forming the panels. 2. Details of additional reinforcement provided at lifting and support locations. 3. Method and equipment used to support the panels during storage, transporting, and erection. 4. Erection sequence, including the method of lifting the panels, placing and adjusting the panels to proper alignment and grade, and supporting the panels during bolting, grouting, and backfilling operations. The Contractor shall not begin noise barrier wall construction activities, including access construction and precast concrete panel fabrication, until receiving the Engineer’s approval of all appropriate and applicable submittals. 6-12.3(2) Work Access and Site Preparation The Contractor shall construct Work access in accordance with the Work access plan. The construction access roads shall minimize disturbance to the existing vegetation, especially trees. Only trees and shrubs in direct conflict with the approved construction access road alignment shall be removed. Only one access road into the noise barrier wall from the main Roadway and one access road from the noise barrier wall to the main Roadway shall be constructed at each noise barrier wall. Existing vegetation that has been identified by the Engineer shall be protected in accordance with Sections 1-07.16 and 2-01, and the Special Provisions. 6-12.3(3) Shaft Construction The Contractor shall excavate and construct the shafts in accordance with the shaft construction plan. The shafts shall be excavated to the required depth as shown in the Plans. The excavation shall be completed in a continuous operation using equipment capable of excavating through the type of material expected to be encountered. 2020 Standard Specifications M 41-10 Page 6-271 Noise Barrier Walls 6-12 If the shaft excavation is stopped, the Contractor shall secure the shaft by installing a safety cover over the opening. The Contractor shall ensure the safety of the shaft and surrounding soil and the stability of the side walls. A temporary casing, slurry, or other methods acceptable to the Engineer shall be used as necessary to ensure such safety and stability. When caving conditions are encountered, the Contractor shall stop further excavation until implementing the method to prevent ground caving as specified in the shaft construction plan. When obstructions are encountered, the Contractor shall notify the Engineer promptly. An obstruction is defined as a specific object (including, but not limited to, boulders, logs, and man made objects) encountered during the shaft excavation operation, which prevents or hinders the advance of the shaft excavation. When efforts to advance past the obstruction to the design shaft tip elevation result in the rate of advance of the shaft drilling equipment being significantly reduced relative to the rate of advance for the rest of the shaft excavation, then the Contractor shall remove the obstruction under the provisions of Section 6-12.5. The method of removal of such obstructions, and the continuation of excavation shall be as proposed by the Contractor and accepted by the Engineer. The Contractor shall use appropriate means to clean the bottom of the excavation of all shafts. No more than 2 inches of loose or disturbed material shall be present at the bottom of the shaft just prior to beginning concrete placement. The Contractor shall not begin placing steel reinforcing bars and concrete in the shaft until receiving the Engineer’s acceptance of the shaft excavation. The steel reinforcing bar cage shall be rigidly braced to retain its configuration during handling and construction. The Contractor shall not place individual or loose bars. The Contractor shall install the steel reinforcing bar cage as specified in the shaft construction plan. The Contractor shall maintain the minimum concrete cover shown in the Plans. If casings are used, the Contractor shall remove the casing during concrete placement. A minimum 5-feet head of concrete shall be maintained to balance soil and water pressure at the bottom of the casing. The casing shall be smooth. Where the top of the shaft is above the existing ground, the Contractor shall case the top of the hole prior to placing the concrete. Concrete for shafts shall conform to Class 4000P. The Contractor shall place concrete in the shaft immediately after completing the shaft excavation and receiving the Engineer’s acceptance of the excavation. The Contractor shall place the concrete in one continuous operation to the elevation shown in the Plans, using a method to prevent segregation of aggregates. The Contractor shall place the concrete as specified in the shaft construction plan. If water is present, concrete shall be placed in accordance with Section 6-02.3(6)B. Page 6-272 2020 Standard Specifications M 41-10 6-12 Noise Barrier Walls 6-12.3(4) Trench, Grade Beam, or Spread Footing Construction Where the noise barrier wall foundations exist below the existing ground line, excavation shall conform to Section 2-09.3(4), and to the limits and construction stages shown in the Plans. Foundation soils found to be unsuitable shall be removed and replaced in accordance with Section 2-09.3(1)C. Where the noise barrier wall foundations exist above the existing ground line, the Contractor shall place and compact backfill material in accordance with Section 2-03.3(14)C. Concrete for trench, grade beam, or spread footing foundations shall conform to Class 4000. Cast-in-place concrete shall be formed, placed, and cured in accordance with Section 6-02, except that concrete for trench foundations shall be placed against undisturbed soil. Cast-in-place footings shall have a longitudinal slope no steeper than 1V: 6H, unless otherwise shown in the Plans or Standard Plans. The excavation shall be backfilled in accordance with item 1 of the Compaction Subsection of Section 2-09.3(1)E. The steel reinforcing bar cage and the noise barrier wall anchor bolts shall be installed and rigidly braced prior to grade beam and spread footing concrete placement to retain their configuration during concrete placement. The Contractor shall not place individual or loose steel reinforcing bars and anchor bolts, and shall not install anchor bolts during or after concrete placement. 6-12.3(5) Cast-In-Place Concrete Panel Construction Construction of cast-in-place concrete panels for noise barrier walls shall conform to Section 6-11.3(4). For noise barrier walls with traffic barrier, the construction of the traffic barrier shall also conform to Section 6-10.3(2). The top of the cast-in-place concrete panels shall conform to the top of wall profile shown in the Plans. Where a vertical step is constructed to provide elevation change between adjacent panels, the dimension of the step shall be 2 feet. Each horizontal run between steps shall be a minimum of 48 feet. 6-12.3(6) Precast Concrete Panel Fabrication and Erection The Contractor shall fabricate and erect the precast concrete panels in accordance with Section 6-02.3(28), and the following requirements: 1. Concrete shall conform to Class 4000. If Self-Consolidating Concrete is used, the concrete shall conform to Sections 6-02.3(27)B and 6-02.3(27)C. 2. Except as otherwise noted in the Plans and Special Provisions, all concrete surfaces shall receive a Class 2 finish in accordance with Section 6-02.3(14)B. 2020 Standard Specifications M 41-10 Page 6-273 Noise Barrier Walls 6-12 3. The precast concrete panels shall be cast in accordance with Section 6-02.3(28)B. The Contractor shall fully support the precast concrete panel to avoid bowing and sagging surfaces. After receiving the Engineer’s review of the shop drawings, the Contractor shall cast one precast concrete panel to be used as the sample panel. The Contractor shall construct the sample panel in accordance with the procedure and details specified in the shop drawings. The Contractor shall make the sample panel available to the Engineer for acceptance. Upon receiving the Engineer’s acceptance of the sample panel, the Contractor shall continue production of precast concrete panels for the noise barrier wall. All precast concrete panels will be evaluated against the sample panel for the quality of workmanship exhibited. The sample panel shall be retained at the fabrication site until all precast concrete panels have been fabricated and accepted. After completing precast concrete panel fabrication, the Contractor may utilize the sample panel as a production noise barrier wall panel. 4. In addition to the fabrication tolerance requirements of Section 6-02.3(28)F, the precast concrete panels for noise barrier walls shall not exceed the following scalar tolerances: Length and Width: ± ⅛ inch per 5 feet, not to exceed ¼ inch total. Thickness: ± ¼ inch. The difference obtained by comparing the measurement of the diagonal of the face of the panels shall not be greater than ½ inch. Dimension tolerances for the traffic barrier portion of precast concrete panels formed with traffic barrier shapes shall conform to Section 6-10.3(2). 5. Precast concrete panels shall not be erected until the foundations for the panels have attained a minimum compressive strength of 3,400 psi. 6. The bolts connecting the precast concrete panels to their foundation shall be tightened to “snug tight” as defined in Section 6-03.3(32). 7. After erection, the precast concrete panels shall not exceed the joint space tolerances shown in the Plans. The panels shall not exceed ⅜ inch out of plumb in any direction. The Contractor shall seal the joints between precast concrete panels with a backer rod and sealant system as specified. The Contractor shall seal both sides of the joint full length. The top of precast concrete panels shall conform to the top of wall profile shown in the Plans. Where a vertical step is constructed to provide elevation change between adjacent panels, the dimension of the step shall be 2 feet. Each horizontal run between steps shall be a minimum of 48 feet. Page 6-274 2020 Standard Specifications M 41-10 6-12 Noise Barrier Walls 6-12.3(7) Masonry Wall Construction Construction requirements for masonry noise barrier wall panels shall be as specified in the Special Provisions. 6-12.3(8) Fabricating and Erecting Timber Noise Barrier Wall Panels Construction requirements for timber noise barrier wall panels shall be as specified in the Special Provisions. 6-12.3(9) Access Doors and Concrete Landing Pads The Contractor shall install access doors and door frames as shown in the Plans and Standard Plans. The Contractor shall install the access doors to open toward the Roadway side. The door frames shall be set in place with grout conforming to either Section 9-20.3(2) or 9-20.3(4) and placed in accordance with Section 6-02.3(20), with the grout completely filling the void between the door frame and the noise barrier wall panel. All frame and door surfaces, except stainless steel surfaces, shall be painted in accordance with Section 6-07.3(9). Primer shall be applied to all non-stainless steel surfaces. All primer coated exposed metal surfaces shall be field painted with the remaining Section 6-07.3(9)A paint system coats. The top coat, when dry, shall match the color specified in the Plans or Special Provisions. The Contractor shall construct concrete landing pads for each access door location as shown in the Plans. The concrete shall conform to Section 6-02.3(2)B. Access door deadbolt locks shall be capable of accepting a Best CX series core. The Contractor shall furnish and install a spring-loaded construction core lock with each lock. The Engineer will furnish the permanent Best CX series core for the Contractor to install at the conclusion of the project. 6-12.3(10) Finish Ground Line Dressing The Contractor shall contour and dress the ground line on both sides of the noise barrier wall, providing the minimum cover over the foundation as shown in the Plans. The Contractor shall contour the ground adjacent to the barrier to ensure good drainage away from the barrier. After the access roads are no longer needed for noise barrier wall construction activities, the Contractor shall restore the area to the original condition. The Contractor shall recontour the access roads to match into the surrounding ground and shall reseed all disturbed areas in accordance with the Section 8-01 and the Special Provisions, and the noise barrier wall access plan. 2020 Standard Specifications M 41-10 Page 6-275 Noise Barrier Walls 6-12 6-12.4 Measurement Noise barrier wall will be measured by the square foot area of one face of the completed wall panel in place. Except as otherwise noted, the bottom limit for measurement will be the top of the trench footing, spread footing, or shaft cap. For Noise Barrier Type 5, the bottom measurement limit will be the optional construction joint at the base of the traffic barrier. For Noise Barrier Type 7, the bottom measurement limit will be base of the traffic barrier. For Noise Barrier Types 8, 11, 12, 14, 15, and 20, the bottom measurement limit will be the base of the wall panel. Noise barrier wall access door will be measured once for each access door assembly with concrete landing pad furnished and installed. 6-12.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Noise Barrier Wall Type __”, per square foot. The unit Contract price per square foot for “Noise Barrier Wall Type __” shall be full pay for constructing the noise barrier walls as specified, including constructing and removing access roads, excavating and constructing foundations and grade beams, constructing cast-in-place concrete, and masonry wall panels, fabricating and erecting precast concrete, and timber wall panels, applying sealer, and contouring the finish ground line adjacent to the noise barrier walls. “Noise Barrier Wall Access Door”, per each. The unit Contract price per each for “Noise Barrier Wall Access Door” shall be full pay for furnishing and installing the access door assembly as specified, including painting the installed access door assembly and constructing the concrete landing pads. “Removing Noise Barrier Wall Shaft Obstructions”, estimated. Payment for removing obstructions, as defined in Section 6-12.3(3), will be made for the changes in shaft construction methods necessary to remove the obstruction. The Contractor and the Engineer shall evaluate the effort made and reach agreement on the equipment and employees utilized, and the number of hours involved for each. Once these cost items and their duration have been agreed upon, the payment amount will be determined using the rate and markup methods specified in Section 1-09.6. For the purpose of providing a common proposal for all bidders, the Contracting Agency has entered an amount for the item “Removing Noise Barrier Wall Shaft Obstructions” in the bid proposal to become a part of the total bid by the Contractor. Page 6-276 2020 Standard Specifications M 41-10 6-12 Noise Barrier Walls If the shaft construction equipment is idled as a result of the obstruction removal work and cannot be reasonably reassigned within the project, then standby payment for the idled equipment will be added to the payment calculations. If labor is idled as a result of the obstruction removal work and cannot be reasonably reassigned within the project, then all labor costs resulting from Contractor labor agreements and established Contractor policies will be added to the payment calculations. The Contractor shall perform the amount of obstruction work estimated by the Contracting Agency within the original time of the contract. The Engineer will consider a time adjustment and additional compensation for costs related to the extended duration of the shaft construction operations, provided: 1. The dollar amount estimated by the Contracting Agency has been exceeded, and; 2. The Contractor shows that the obstruction removal work represents a delay to the completion of the project based on the current progress schedule provided in accordance with Section 1-08.3. 2020 Standard Specifications M 41-10 Page 6-277 Structural Earth Walls 6-13 6-13 Structural Earth Walls 6-13.1 Description This Work consists of constructing structural earth walls (SEW). 6-13.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Concrete 9-03.1 Gravel Borrow for Structural Earth Walls 9-03.14(4) Premolded Joint Filler 9-04.1(2) Steel Reinforcing Bar 9-07.2 Epoxy-Coated Steel Reinforcing Bar 9-07.3 Mortar 9-20.4 Concrete Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Water 9-25 Other materials required shall be as specified in the Special Provisions. 6-13.3 Construction Requirements Proprietary structural earth wall systems shall be as specified in the Special Provisions. 6-13.3(1) Quality Assurance The structural earth wall manufacturer shall provide a qualified and experienced representative to resolve wall construction problems. The structural earth wall manufacturer’s representative shall be present at the beginning of wall construction activities, and at other times as needed throughout construction. Recommendations made by the structural earth wall manufacturer’s representative shall be followed by the Contractor. The completed wall shall meet the following tolerances: 1. Deviation from the design batter and horizontal alignment, when measured along a 10-foot straightedge, shall not exceed the following: a. Welded wire faced structural earth wall: 2 inches b. Precast concrete panel and concrete block faced structural earth wall: ¾ inch 2. Deviation from the overall design batter of the wall shall not exceed the following per 10 feet of wall height: a. Welded wire faced structural earth wall: 1½ inches b. Precast concrete panel and concrete block faced structural earth wall: ½ inch Page 6-278 2020 Standard Specifications M 41-10 6-13 Structural Earth Walls 3. The maximum outward bulge of the face between welded wire faced structural earth wall reinforcement layers shall not exceed 2 inches. The maximum allowable offset in any precast concrete facing panel joint shall be ¾ inch. The maximum allowable offset in any concrete block joint shall be ¾ inch. 4. The base of the structural earth wall excavation shall be within 3 inches of the staked elevations, unless otherwise accepted or specified by the Engineer. 5. The external structural earth wall dimensions shall be placed within 2 inches of that staked on the ground. 6. The backfill reinforcement layers shall be located horizontally and vertically within 1 inch of the locations shown in the structural earth wall Working Drawings. At least 5 working days prior to the Contractor beginning any structural earth wall Work at the site, a structural earth wall preconstruction conference shall be held to discuss construction procedures, personnel, and equipment to be used, and other elements of structural earth wall construction. Those attending shall include: 1. (representing the Contractor) The superintendent, on site supervisors, and all foremen in charge of excavation, leveling pad placement, concrete block and soil reinforcement placement, and structural earth wall backfill placement and compaction. 2. (representing the Structural Earth Wall Manufacturer) The qualified and experienced representative of the structural earth wall manufacturer as specified at the beginning of this section. 3. (representing the Contracting Agency) The Engineer, key inspection personnel, and representatives from the WSDOT Construction Office and Materials Laboratory Geotechnical Services Branch. 6-13.3(2) Submittals The Contractor, or the supplier as the Contractor’s agent, shall furnish a Manufacturer’s Certificate of Compliance certifying that the structural earth wall materials conform to the specified material requirements. This includes providing a Manufacturer’s Certificate of Compliance for all concrete admixtures, cement, fly ash, steel reinforcing bars, reinforcing strips, reinforcing mesh, tie strips, fasteners, welded wire mats, backing mats, construction geotextile for wall facing, drainage geosynthetic fabric, block connectors, and joint materials. The Manufacturer’s Certificate of Compliance for geogrid reinforcement shall include the information specified in Section 9-33.4(4) for each geogrid roll, and shall specify the geogrid polymer types for each geogrid roll. A Type 1 Working Drawing of all test results performed by the Contractor or the Contractor’s supplier, which are necessary to ensure compliance with the specifications, shall be submitted along with each Manufacturer’s Certificate of Compliance. Before fabrication, the Contractor shall submit a Type 1 Working Drawing consisting of the field construction manual for the structural earth walls, prepared by the wall manufacturer. This manual shall provide step-by-step directions for construction of the wall system. 2020 Standard Specifications M 41-10 Page 6-279 Structural Earth Walls 6-13 The Contractor, through the license/patent holder for the structural earth wall system, shall submit Type 2E Working Drawings consisting of detailed design calculations and details. If not prepared by the license/patent holder for the structural earth system, the design calculation and working drawing submittal shall include documentation that the design calculation and working drawing submittal has been reviewed by, and received the concurrence of, the headquarters organization of the structural earth wall manufacturer as identified in the Special Provisions. Review and concurrence by a sales representative office is not acceptable. 6-13.3(2)A Design Calculation Content Requirements The design calculation submittal shall include detailed design calculations based on the wall geometry and design parameters specified in the Plans and Special Provisions. The calculations shall include detailed explanations of any symbols, design input, materials property values, and computer programs used in the design of the walls. All computer output submitted shall be accompanied by supporting hand calculations detailing the calculation process. If MSEW 3.0, or a later version, is used for the wall design, hand calculations supporting MSEW are not required. The design calculations shall be based on the current AASHTO LRFD Bridge Design Specifications, including current interims, the current WSDOT Bridge Design Manual LRFD (BDM), and the WSDOT Geotechnical Design Manual (GDM), and also based on the following: 1. The wall design calculations shall address all aspects of wall internal stability for the service, strength, and extreme event limit states. 2. The wall surcharge conditions (backfill slope) shown in the Plans. 3. If a highway is adjacent to and on top of the wall, a 2-foot surcharge shall be used in the design. 4. If the Plans detail an SEW traffic barrier or SEW pedestrian barrier on top of the wall, the barrier shall be designed for a minimum TL-4 impact load, unless otherwise specified in the Plans or Special Provisions. 5. If the Plans detail an SEW traffic barrier or SEW pedestrian barrier on top of the wall, the wall shall be designed for the impact load transferred from the barrier to the wall. 6. The geotechnical design parameters for the wall shall be as specified in the Special Provisions. 7. The soil reinforcement length shall be as shown in the Plans. If the Plans do not show a length, the length shall be either 6 feet or 0.7 times the wall design height H, whichever is greater. If there are differences in design requirements between the AASHTO LRFD Bridge Design Specifications and the BDM or GDM, the BDM and GDM requirements shall govern. Page 6-280 2020 Standard Specifications M 41-10 6-13 Structural Earth Walls 6-13.3(2)B Working Drawing Content Requirements All design details shown in the working drawings shall be selected from the design details and products specified for the specific structural earth wall manufacturer in the Preapproved Wall Appendix in the current WSDOT Geotechnical Design Manual (GDM). Geosynthetic reinforcement shown in the working drawings shall be selected from the products listed in the current WSDOT Qualified Products List (QPL). Substitution of design details and products not listed in the current WSDOT GDM or QPL will not be allowed. The working drawing submittal shall include all details, dimensions, quantities, and cross sections necessary to construct the wall based on the wall geometry and design parameters specified in the Plans and Special Provisions, and shall include, but not be limited to, the following items: 1. A plan and elevation sheet or sheets for each wall, containing the following: a. An elevation view of the wall that includes the following: i. The elevation at the top of the wall, at all horizontal and vertical break points, and at least every 50 feet along the wall; ii. Elevations at the base of welded wire mats or the top of leveling pads and foundations, and the distance along the face of the wall to all steps in the welded wire mats, foundations, and leveling pads; iii. The designation as to the type of panel, block, or module; iv. The length, size, and number of geogrids or mesh or strips, and the distance along the face of the wall to where changes in length of the geogrids or mesh or strips occur; or v. The length, size, and wire sizes and spacing of the welded wire mats and backing mats, and the distance along the face of the wall to where changes in length, size, and wire sizes and spacing of the welded wire mats and backing mats occur; and vi. The location of the original and final ground line. b. A plan view of the wall that indicates the offset from the construction centerline to the face of the wall at all changes in horizontal alignment; the limit of the widest module, geogrid, mesh, strip, or welded wire mat, and the centerline of any drainage structure or drainage pipe that is behind or passes under or through the wall. c. General notes, if any, required for design and construction of the wall. d. All horizontal and vertical curve data affecting wall construction. e. A listing of the summary of quantities provided on the elevation sheet of each wall for all items, including incidental items. 2020 Standard Specifications M 41-10 Page 6-281 Structural Earth Walls 6-13 f. A cross section showing limits of construction. In fill sections, the cross section shall show the limits and extent of select granular backfill material placed above original ground. g. Limits and extent of reinforced soil volume. 2. All details, including steel reinforcing bar bending details. Bar bending details shall be in accordance with Section 9-07.1. 3. All details for foundations and leveling pads, including details for steps in the foundations or leveling pads. 4. All modules and facing elements shall be detailed. The details shall show all dimensions necessary to construct the element, all steel reinforcing bars in the element, and the location of reinforcement element attachment devices embedded in the precast concrete facing panel or concrete block. 5. All details for construction of the wall around drainage facilities, sign, signal, luminaire, and noise barrier wall foundations, and structural abutment and foundation elements shall be clearly shown. 6. All details for connections to SEW traffic or pedestrian barriers, coping, parapets, noise barrier walls, and attached lighting shall be shown. 7. All details for the SEW traffic or pedestrian barrier attached to the top of the wall (if shown in the Plans), including interaction with bridge approach slabs. 6-13.3(3) Excavation and Foundation Preparation Excavation shall conform to Section 2-09.3(3). Foundation soils found to be unsuitable shall be removed and replaced in accordance with Section 2-09.3(1)C. The foundation for the Structure shall be graded level for a width equal to or exceeding the length of reinforcing as shown in the structural earth wall Working Drawings and, for walls with geogrid reinforcing, in accordance with Section 2-12.3. Prior to wall construction, the foundation, if not in rock, shall be compacted as accepted by the Engineer. At the foundation level of the bottom course of precast concrete facing panels and concrete blocks, an unreinforced concrete leveling pad shall be provided as shown in the Plans. The leveling pad shall be cured a minimum of 12 hours and have a minimum compressive strength of 1,500 psi before placement of the precast concrete facing panels or concrete blocks. Page 6-282 2020 Standard Specifications M 41-10 6-13 Structural Earth Walls 6-13.3(4) Precast Concrete Facing Panel and Concrete Block Fabrication Concrete for precast concrete facing panels shall meet the following requirements: 1. Have a minimum 28-day compressive strength of 4,000 pounds per square inch, unless otherwise specified in the Special Provisions for specific proprietary wall systems. If Self-Consolidating Concrete is used, the concrete shall conform to Sections 6-02.3(27)B and 6-02.3(27)C. 2. Contain a water-reducing admixture meeting AASHTO M194 Type A, D, F, or G. 3. Be air-entrained, 6 percent ± 1½ percent. 4. Have a maximum slump of 4 inches, or 6 inches if a Type F or G water reducer is used. Concrete for dry cast concrete blocks shall meet the following requirements: 1. Have a minimum 28-day compressive strength of 4,000 psi. 2. Conform to ASTM C1372, except as otherwise specified. 3. The lot of blocks produced for use in this project shall conform to the following freeze-thaw test requirements when tested in accordance with ASTM C1262. Minimum acceptable performance shall be defined as weight loss at the conclusion of 150 freeze-thaw cycles not exceeding 1 percent of the block’s initial weight for a minimum of four of the five block specimens tested. 4. The concrete blocks shall have a maximum water absorption of 1 percent above the water absorption content of the lot of blocks produced and successfully tested for the freeze-thaw test specified in item 3 above. Precast concrete facing panels and concrete blocks will be accepted based on successful compressive strength tests, WSDOT “Approved for Shipment” stamp or tag, and visual inspection at the jobsite. The precast concrete facing panels and concrete blocks shall be considered acceptable regardless of curing age when compressive test results indicate that the compressive strength conforms to the 28-day requirements and when the visual inspection is satisfactorily completed. Fabrication of precast concrete facing panels and blocks shall conform to Section 6-02.3(28). Testing of dry cast concrete blocks shall conform to ASTM C140. All precast concrete facing panels shall be 5 feet square, except: 1. for partial panels at the top, bottom, and ends of the wall; and 2. as otherwise shown in the Plans. 2020 Standard Specifications M 41-10 Page 6-283 Structural Earth Walls 6-13 All precast concrete facing panels shall be manufactured within the following tolerances: 1. All dimensions ± 3/16 inch. 2. Squareness, as determined by the difference between the two diagonals, shall not exceed ½ inch. 3. Surface defects on smooth formed surfaces measured on a length of 5 feet shall not exceed ⅛ inch. Surface defects on textured-finished surfaces measured on a length of 5 feet shall not exceed 5/16 inch. All concrete blocks shall be manufactured within the following tolerances: 1. Vertical dimensions shall be ± 1/16 inch of the Plan dimension, and the rear height shall not exceed the front height. 2. The dimensions of the grooves in the top and bottom faces of the concrete blocks shall be formed within the tolerances specified by the proprietary wall manufacturer, for the fit required for the block connectors. 3. All other dimensions shall be ± ¼ inch of the Plan dimension. Tie attachment devices, except for geosynthetic reinforcement, shall be set in place to the dimensions and tolerances shown in the Plans prior to casting. The forms forming precast concrete facing panels, including the forms for loop pockets and access pockets, and the forms forming the concrete blocks, shall be removed in accordance with the recommendations of the wall manufacturer, without damaging the concrete. The concrete surface for the precast concrete facing panel shall have the finish shown in the Plans for the front face and an unformed finish for the rear face. The rear face of the precast concrete facing panel shall be roughly screeded to eliminate open pockets of aggregate and surface distortions in excess of ¼ inch. The concrete surface for the front face of the concrete block shall be flat, and shall be a conventional “split face” finish in accordance with the wall manufacturer’s Specifications.The concrete surface of all other faces shall be Class 2 in accordance with Section 6-02.3(14)B. The finish and appearance of the concrete blocks shall also conform to ASTM C1372. The color of the concrete block shall be concrete gray, unless otherwise shown in the Plans. The date of manufacture, production lot number, and the piece-mark, shall be clearly marked on the rear face of each precast concrete facing panel, and marked or tagged on each pallet of concrete blocks. All precast concrete facing panels and concrete blocks shall be handled, stored, and shipped in accordance with Sections 6-02.3(28)G and 6-02.3(28)H to prevent chipping, cracks, fractures, and excessive bending stresses. Precast concrete facing panels in storage shall be supported on firm blocking located immediately adjacent to tie strips to avoid bending the tie strips. Page 6-284 2020 Standard Specifications M 41-10 6-13 Structural Earth Walls 6-13.3(5) Precast Concrete Facing Panel and Concrete Block Erection The precast concrete facing panels shall be placed vertically. During erection, precast concrete facing panels shall be handled by means of a lifting device set into the upper edge of the panels. Concrete blocks shall be erected in a running bond fashion in accordance with the wall manufacturer’s field construction manual, and may be placed by hand. The top surface of each course of concrete blocks, including all pockets and recesses, shall be cleaned of backfill and all extraneous materials prior to connecting the reinforcing strips or geosynthetic reinforcing, and placing the next course of concrete blocks. Concrete blocks receiving geosynthetic reinforcement shall be connected as specified in the Special Provisions. Cap block top courses shall be bonded to the lower course of concrete blocks as specified below. All other concrete blocks shall be connected with block connectors or pins placed into the connector slots. Precast concrete facing panels and concrete blocks shall be placed in successive horizontal lifts as backfill placement proceeds in the sequence shown in the structural earth wall Working Drawings as approved by the Engineer. External bracing is required for the initial lift for precast concrete facing panels. As backfill material is placed behind the precast concrete facing 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. Reinforcing shall be placed normal to the face of the wall, unless otherwise shown in the Plans or directed by the Engineer. Prior to placement of the reinforcing, backfill shall be compacted. Geosynthetic reinforcing shall be placed in accordance with Section 2-12.3 and as follows: 1. The Contractor shall stretch out the geosynthetic in the direction perpendicular to the wall face to remove all slack and wrinkles, and shall hold the geosynthetic in place with soil piles or other methods as recommended by the geosynthetic manufacturer, before placing backfill material over the geosynthetic to the specified cover. 2. The geosynthetic reinforcement shall be continuous in the direction perpendicular to the wall face from the back face of the concrete panel to the end of the geosynthetic or to the last geogrid node at the end of the specified reinforcement length. Geosynthetic splices parallel to the wall face will not be allowed. At the completion of each course of concrete blocks and prior to installing any block connectors or geosynthetic reinforcement at this level, the Contractor shall check the blocks for level placement in all directions, and shall adjust the blocks by grinding or rear face shimming, or other method as recommended by the structural earth wall manufacturer’s representative and as approved by the Engineer, to bring the blocks into a level plane. 2020 Standard Specifications M 41-10 Page 6-285 Structural Earth Walls 6-13 For concrete block wall systems receiving a cap block top course, the cap blocks shall be bonded to the lower course either with mortar conforming to Section 9-20.4(3), or with an adhesive capable of bonding the concrete block courses together. 6-13.3(6) Welded Wire Faced Structural Earth Wall Erection The Contractor shall erect the welded wire wall reinforcement in accordance with the wall manufacturer’s field construction manual. Construction geotextile for wall facing shall be placed between the backfill material within the reinforced zone and the coarse granular material immediately behind the welded wire wall facing, as shown in the Plans and the structural earth wall Working Drawings. Geosynthetic reinforcing, when used, shall be placed in accordance with Sections 2-12.3 and 6-13.3(5). 6-13.3(7) Backfill Backfill placement shall closely follow erection of each course of welded wire mats and backing mats, precast concrete facing panels, or concrete blocks. Backfill shall be placed in such a manner as to avoid any damage or disturbance to the wall materials or misalignment of the welded wire mats and backing mats, precast concrete facing panels, or concrete blocks. Backfill shall be placed in a manner that segregation does not occur. Construction equipment shall not operate directly on the wall reinforcement. A minimum backfill thickness of 6 inches over the reinforcement shall be required prior to operation of vehicles or equipment. The Contractor shall place wall backfill over geosynthetic reinforcement, or construction geotextile for wall facing, in accordance with Section 2-12.3. Misalignment or distortion of the precast concrete facing panels or concrete blocks due to placement of backfill outside the limits of this Specification shall be corrected in a manner acceptable to the Engineer. The moisture content of the backfill material prior to and during compaction shall be uniformly distributed throughout each layer of material. The moisture content of all backfill material shall conform to Sections 2-03.3(14)C and 2-03.3(14)D. Backfill shall be compacted in accordance with Method C of Section 2-03.3(14)C, except as follows: 1. The maximum lift thickness after compaction shall not exceed 10 inches. 2. The Contractor shall decrease this lift thickness, if necessary, to obtain the specified density. 3. The Contractor shall not use sheepsfoot rollers or rollers with protrusions for compacting backfill reinforced with geosynthetic layers, or for compacting the first lift of backfill above the construction geosynthetic for wall facing for each layer of welded wire mats. Rollers shall have sufficient capacity to achieve compaction without causing distortion to the face of the wall in accordance with the tolerances specified in Section 6-13.3(1). Page 6-286 2020 Standard Specifications M 41-10 6-13 Structural Earth Walls 4. The Contractor shall compact the zone within 3 feet of the back of the wall facing panels without causing damage to or distortion of the wall facing elements (welded wire mats, backing mats, construction geotextile for wall facing, precast concrete facing panels, and concrete blocks) by using a plate compactor. No soil density tests will be taken within this area. 5. For wall systems with geosynthetic reinforcement, the minimum compacted backfill lift thickness of the first lift above each geosynthetic reinforcement layer shall be 6 inches. At the end of each day’s operation, the Contractor shall shape the last level of backfill to permit runoff of rainwater away from the wall face. In addition, the Contractor shall not allow surface runoff from adjacent areas to enter the wall construction site. 6-13.3(8) Guardrail Placement Where guardrail posts are required, the Contractor shall not begin installing guardrail posts until completing the structural earth wall to the top of wall elevation shown in the Plans. The Contractor shall install the posts in a manner that prevents movement of the precast concrete facing panels or concrete blocks, and prevents ripping, tearing, or pulling of the wall reinforcement. The Contractor may cut welded wire reinforcement of welded wire faced structural earth walls to facilitate placing the guardrail posts, but only in the top two welded wire reinforcement layers and only with the permission of the Engineer in a manner that prevents bulging of the wall face and prevents ripping or pulling of the welded wire reinforcement. Holes through the welded wire reinforcement shall be the minimum size necessary for the post. The Contractor shall demonstrate to the Engineer prior to beginning guardrail post installation that the installation method will not rip, tear, or pull the wall reinforcement. The Contractor shall place guardrail posts between the reinforcing strips, reinforcing mesh, and tie strips of the non-geosynthetic reinforced precast concrete panel or concrete block faced structural earth walls. Holes through the reinforcement of geosynthetic reinforced walls, if necessary, shall be the minimum size necessary for the guardrail post. 6-13.3(9) SEW Traffic Barrier and SEW Pedestrian Barrier The Contractor, in conjunction with the structural earth wall manufacturer, shall design and detail the SEW traffic barrier and SEW pedestrian barrier in accordance with Section 6-13.3(2) and the above ground geometry details shown in the Plans. The barrier Working Drawings and supporting calculations shall be Type 2E and shall include, at a minimum, the following: 1. Complete details of barrier cross section geometry, including the portion below ground, and accommodations necessary for bridge approach slabs, PCCP, drainage facilities, underground utilities, and sign support, luminaire pole, traffic signal standard, and other barrier attachments. 2020 Standard Specifications M 41-10 Page 6-287 Structural Earth Walls 6-13 2. Details of the steel reinforcement of the barrier, including a bar list and bending diagram in accordance with Section 6-02.3(24), and including additional reinforcement required at sign support, luminaire pole, traffic signal standard, and other barrier attachment locations. 3. Details of the interface of, and the interaction between, the barrier and the top layers of structural earth wall reinforcement and facing. 4. When the Plans specify placement of conduit pipes through the barrier, details of conduit pipe and junction box placement. SEW traffic barrier and SEW pedestrian barrier shall be constructed in accordance with Sections 6-02.3(11)A and 6-10.3(2), and the details in the Plans and in the structural earth wall Working Drawings as approved by the Engineer. The moment slab supporting the SEW traffic or pedestrian barrier shall be continuously wet cured for 3 days in accordance with Section 6-02.3(11). 6-13.4 Measurement Structural earth wall will be measured by the square foot of completed wall in place. The bottom limits for vertical measurement will be the bottom of the bottom mat, for welded wire faced structural earth walls, or the top of the leveling pad (or bottom of wall if no leveling pad is present) for precast concrete panel or concrete block faced structural earth walls. The top limit for vertical measurement will be the top of wall as shown in the Plans. The horizontal limits for measurement are from the end of the wall to the end of the wall. Gravel borrow for structural earth wall including haul will be measured by the cubic yard in place determined by the limits shown in the Plans. SEW traffic barrier, and SEW pedestrian barrier will be measured as specified in Section 6-10.4 for cast-in-place concrete barrier. 6-13.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Structural Earth Wall”, per square foot. The unit Contract price per square foot for “Structural Earth Wall” shall be full payment for all costs to perform the Work in connection with constructing structural earth walls, including leveling pads and copings when specified. “Gravel Borrow for Structural Earth Wall incl. Haul”, per cubic yard. The unit Contract price per cubic yard for “Gravel Borrow for Structural Earth Wall incl. Haul” shall be full payment for all costs to perform the Work in connection with furnishing and placing backfill for structural earth wall, including hauling and compacting the backfill, and furnishing and placing the wall-facing backfill for welded wire-faced structural earth walls. “SEW Traffic Barrier”, per linear foot. Page 6-288 2020 Standard Specifications M 41-10 6-13 Structural Earth Walls “SEW Pedestrian Barrier”, per linear foot. The unit Contract price per linear foot for “SEW ___ Barrier” shall be full pay for constructing the barrier on top of the structural earth wall, except that when these Bid items are not included in the Proposal, all costs in connection with performing the Work as specified shall be included in the unit Contract price per square foot for “Structural Earth Wall”. 2020 Standard Specifications M 41-10 Page 6-289 Geosynthetic Retaining Walls 6-14 6-14 Geosynthetic Retaining Walls 6-14.1 Description This Work consists of constructing geosynthetic retaining walls, including those shown in the Standard Plans. 6-14.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Concrete 9-03.1 Sand 9-03.13(1) Gravel Borrow for Structural Earth Wall 9-03.14(4) Polyurethane Sealant 9-04.2(3) Closed Cell Foam Backer Rod 9-04.2(3)A Anchor Rods and Associated Nuts, Washers, and Couplers 9-06.5(4) Reinforcing Steel 9-07 Welded Wire Reinforcement 9-07.7 Grout 9-20.3(4) Construction Geosynthetic 9-33 Anchor plate shall conform to ASTM A36, ASTM A572 Grade 50, or ASTM A588. The requirements specified in Section 2-12.2 for geotextile shall also apply to geosynthetic and geogrid materials used for permanent and temporary geosynthetic retaining walls. Other materials required shall be as specified in the Special Provisions. 6-14.3 Construction Requirements Temporary geosynthetic retaining walls are defined as those walls and wall components constructed and removed or abandoned before the Physical Completion Date of the project or as shown in the Plans. All other geosynthetic retaining walls shall be considered as permanent. 6-14.3(1) Quality Assurance The Contractor shall complete the base of the retaining wall excavation to within plus or minus 3 inches of the staked elevations unless otherwise directed by the Engineer. The Contractor shall place the external wall dimensions to within plus or minus 2 inches of that staked on the ground. The Contractor shall space the reinforcement layers vertically and place the overlaps to within plus or minus 1 inch of that shown in the Plans. Page 6-290 2020 Standard Specifications M 41-10 6-14 Geosynthetic Retaining Walls The completed wall(s) shall meet the following tolerances: Permanent Wall Temporary Wall Deviation from the design batter and horizontal alignment for the face when measured along a 10-foot straightedge at the midpoint of each wall layer shall not exceed: 3 inches 5 inches Deviation from the overall design batter per 10 feet of wall height shall not exceed: 2 inches 3 inches Maximum outward bulge of the face between backfill reinforcement layers shall not exceed: 4 inches 6 inches 6-14.3(2) Submittals The Contractor shall submit Type 2E Working Drawings consisting of detailed plans for each wall. The Working Drawing submittal shall include all details, dimensions, and cross sections necessary to construct the wall based on the wall geometry and design parameters specified in the Plans, including at a minimum, the following: 1. Detailed wall plans, with plan and elevation views for each wall, showing the actual lengths proposed for the geosynthetic reinforcing layers and the locations of each geosynthetic product proposed for use in each of the geosynthetic reinforcing layers. 2. Detailed cross sections showing the geosynthetic reinforcing layers, fascia connection dowels or anchor rods, and fascia formwork connection or support details located within or adjacent to the wall backfill. 3. The Contractor’s proposed wall construction method, including proposed forming systems, types of equipment to be used, proposed erection sequence and details of how the backfill will be retained during each stage of construction. 4. Manufacturer’s Certificate of Compliance, samples of the retaining wall geosynthetic and sewn seams for the purpose of acceptance as specified. 5. Details of geosynthetic retaining wall corner construction, including details of the positive connection between the wall sections on both sides of the corner. 6. Details of terminating a top layer of retaining wall geosynthetic and backfill due to a changing retaining wall profile. Acceptance of the Contractor’s proposed wall construction details and methods shall not relieve the Contractor of their responsibility to construct the walls in accordance with the requirements of these Specifications. 6-14.3(3) Excavation and Foundation Preparation Excavation shall conform to Section 2-09.3(3). Foundations soils found to be unsuitable shall be removed and replaced in accordance with Section 2-09.3(1)C. The Contractor shall direct all surface runoff from adjacent areas away from the retaining wall construction site. 2020 Standard Specifications M 41-10 Page 6-291 Geosynthetic Retaining Walls 6-14 6-14.3(4) Erection and Backfill The Contractor shall begin wall construction at the lowest portion of the excavation and shall place each layer horizontally as shown in the Plans. The Contractor shall complete each layer entirely before beginning the next layer. Geotextile splices shall consist of a sewn seam or a minimum 1-foot overlap. Geogrid splices shall consist of adjacent geogrid strips butted together and fastened using hog rings, or other methods acceptable to the Engineer, in such a manner to prevent the splices from separating during geogrid installation and backfilling. Splices exposed at the wall face shall prevent loss of backfill material through the face. The splicing material exposed at the wall face shall be as durable and strong as the material to which the splices are tied. The Contractor shall offset geosynthetic splices in one layer from those in the other layers such that the splices shall not line up vertically. Splices parallel to the wall face will not be allowed, as shown in the Plans. The Contractor shall stretch out the geosynthetic in the direction perpendicular to the wall face to ensure that no slack or wrinkles exist in the geosynthetic prior to backfilling. For geogrids, the length of the reinforcement required as shown in the Plans shall be defined as the distance between the geosynthetic wrapped face and the last geogrid node at the end of the reinforcement in the wall backfill. The Contractor shall place fill material on the geosynthetic in lifts such that 6 inches minimum of fill material is between the vehicle or equipment tires or tracks and the geosynthetic at all times. The Contractor shall remove all particles within the backfill material greater than 3 inches in size. Turning of vehicles on the first lift above the geosynthetic will not be permitted. The Contractor shall not end dump fill material directly on the geosynthetic without the prior permission of the Engineer. The Contractor shall use a temporary form system to prevent sagging of the geosynthetic facing elements during construction. A typical example of a temporary form system and sequence of wall construction required when using this form are detailed in the Plans. Soil piles or the geosynthetic manufacturer’s recommended method, in combination with the forming system shall be used to hold the geosynthetic in place until the specified cover material is placed. The Contractor shall place and compact the wall backfill in accordance with the wall construction sequence detailed in the Plans and Method C of Section 2-03.3(14)C, except as follows: 1. The maximum lift thickness after compaction shall not exceed 10 inches 2. The Contractor shall decrease this lift thickness, if necessary, to obtain the specified density. 3. Rollers shall have sufficient capacity to achieve compaction without causing distortion to the face of the wall in accordance with Section 6-14.3(1). 4. The Contractor shall not use sheepsfoot rollers or rollers with protrusions. Page 6-292 2020 Standard Specifications M 41-10 6-14 Geosynthetic Retaining Walls 5. The Contractor shall compact the zone within 3 feet of the back of the wall facing panels without causing damage to or distortion of the wall facing elements (welded wire mats, backing mats, construction geotextile for wall facing, precast concrete facing panels, and concrete blocks) by using a plate compactor. No soil density tests will be taken within this area. 6. For wall systems with geosynthetic reinforcement, the minimum compacted backfill lift thickness of the first lift above each geosynthetic reinforcement layer shall be 6 inches. The Contractor shall construct wall corners at the locations shown in the Plans, and in accordance with the wall corner construction sequence and method in the Working Drawing submittal. Wall angle points with an interior angle of less than 150 degrees shall be considered to be a wall corner. The wall corner shall provide a positive connection between the sections of the wall on each side of the corner such that the wall backfill material cannot spill out through the corner at any time during the design life of the wall. The Contractor shall construct the wall corner such that the wall sections on both sides of the corner attain the full geosynthetic layer embedment lengths shown in the Plans. Where required by retaining wall profile grade, the Contractor shall terminate top layers of retaining wall geosynthetic and backfill in accordance with the method in the Working Drawing submittal. The end of each layer at the top of the wall shall be constructed in a manner that prevents wall backfill material from spilling out the face of the wall throughout the life of the wall. If the profile of the top of the wall changes at a rate of 1:1 or steeper, this change in top of wall profile shall be considered to be a corner. 6-14.3(5) Guardrail Placement The Contractor shall install guardrail posts as shown in the Plans after completing the wall, but before the permanent facing is installed. The Contractor shall install the posts in a manner that prevents bulging of the wall face and prevents ripping, tearing, or pulling of the geosynthetic reinforcement. Holes through the geosynthetic reinforcement shall be the minimum size necessary for the post. The Contractor shall demonstrate to the Engineer prior to beginning guardrail post installation that the installation method will not rip, tear, or pull the geosynthetic reinforcement. 6-14.3(6) Permanent Facing The Contractor shall apply a permanent facing to the surface of all permanent geosynthetic retaining walls as shown in the Plans. Shotcrete facing, if shown in the Plans, shall conform to Section 6-18. Concrete fascia panel, if shown in the Plans, shall conform to Section 6-15.3(9), if cast-in-place, and shall conform to Section 6-02.3(28), if precast. 2020 Standard Specifications M 41-10 Page 6-293 Geosynthetic Retaining Walls 6-14 6-14.3(7) Geosynthetic Retaining Wall Traffic Barrier and Geosynthetic Retaining Wall Pedestrian Barrier Geosynthetic wall traffic barrier (single slope and f-shape) and geosynthetic retaining wall pedestrian barrier shall be constructed in accordance with Sections 6-02.3(11)A and 6-10.3(2), and the details in the Plans. The moment slab supporting the geosynthetic wall traffic barrier and geosynthetic wall pedestrian barrier shall be continuously wet cured for 3 days in accordance with Section 6-02.3(11). 6-14.4 Measurement Permanent geosynthetic retaining wall and temporary geosynthetic retaining wall will be measured by the square foot of face of completed wall. Corner wrap area and extensions of the geosynthetic wall beyond the area of wall face shown in the Plans or staked by the Engineer are considered incidental to the wall construction and will not be included in the measurement of the square foot of face of completed geosynthetic retaining wall. Gravel borrow for structural earth wall will be measured as specified in Section 2-03.4. Shotcrete facing and concrete fascia panel will be measured by the square foot surface area of the completed facing or fascia panel, measured to the neat lines of the facing or panel as shown in the Plans. When a footing is required, the measurement of the fascia panel area will include the footing. Geosynthetic wall single slope traffic barrier, geosynthetic wall f-shape traffic barrier, and geosynthetic retaining wall pedestrian barrier will be measured as specified in Section 6-10.4 for cast-in-place concrete barrier. 6-14.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Geosynthetic Retaining Wall”, per square foot. “Temporary Geosynthetic Retaining Wall”, per square foot. All costs in connection with constructing the temporary or permanent geosynthetic retaining wall as specified shall be included in the unit Contract price per square foot for “Geosynthetic Retaining Wall” and “Temporary Geosynthetic Retaining Wall”, including compaction of the backfill material and furnishing and installing the temporary forming system. “Gravel Borrow for Structural Earth Wall Incl. Haul”, per ton or per cubic yard. All costs in connection with furnishing and placing backfill material for temporary or permanent geosynthetic retaining walls as specified shall be included in the unit Contract price per ton or per cubic yard for “Gravel Borrow for Structural Earth Wall Incl. Haul”. “Concrete Fascia Panel For Geosynthetic Wall”, per square foot. Page 6-294 2020 Standard Specifications M 41-10 6-14 Geosynthetic Retaining Walls All costs in connection with constructing the concrete fascia panels as specified shall be included in the unit Contract price per square foot for “Concrete Fascia Panel For Geosynthetic Wall”, including all steel reinforcing bars, premolded joint filler, polyethylene bond breaker strip, joint sealant, PVC pipe for weep holes, exterior surface finish, and pigmented sealer (when specified), constructing and placing the concrete footing, edge beam, anchor beam, anchor rod assembly, and backfill. Shotcrete facing will be paid for in accordance with Section 6-18.5. “Geosynthetic Wall Single Slope Traffic Barrier”, per linear foot. “Geosynthetic Wall F-Shape Traffic Barrier”, per linear foot. “Geosynthetic Retaining Wall Pedestrian Barrier”, per linear foot. The unit Contract price per linear foot for “Geosynthetic Wall Single Slope Traffic Barrier”, “Geosynthetic Wall F-Shape Traffic Barrier”, and “Geosynthetic Retaining Wall Pedestrian Barrier” shall be full pay for constructing the barrier on top of the geosynthetic retaining wall. 2020 Standard Specifications M 41-10 Page 6-295 Soil Nail Walls 6-15 6-15 Soil Nail Walls 6-15.1 Description This Work consists of constructing soil nail walls. 6-15.2 Materials Materials shall meet the requirements of the following sections: Grout 9-20.3(4) Prefabricated Drainage Mat 9-33.2(3) Other materials required, including materials for soil nails, shall be as specified in the Special Provisions. 6-15.3 Construction Requirements 6-15.3(1) General Description Soil nailing shall consist of excavating to the layer limits shown in the Plans, drilling holes at the specified angle into the native material, placing and grouting epoxy coated or encapsulated steel reinforcing bars (soil nails) in the drilled holes, placing prefabricated drainage material and steel reinforcement, and applying a shotcrete facing over the steel reinforcement. After completing the wall to full height, the Contractor shall construct the concrete fascia panels as shown in the Plans. All proprietary items used in the soil nailed Structure shall be installed in accordance with the manufacturer’s recommendations. In the event of a conflict between the manufacturer’s recommendations and these Specifications, these Specifications shall prevail. 6-15.3(2) Contractor’s Experience Requirements The Contractor or Subcontractor performing this Work shall have completed at least five projects, within the last 5 years, involving construction of retaining walls using soil nails or ground anchors or shall have completed the construction of two or more projects totaling at least 15,000 square feet of retaining wall with a minimum total of 500 soil nails or ground anchors. The Contractor shall assign an engineer with at least 3 years of experience in the design and construction of permanently anchored or nailed Structures to supervise the Work. The Contractor shall not use consultants or manufacturer’s representatives in order to meet the requirements of this Section. Drill operators and on-site supervisors shall have a minimum of 1 year experience installing permanent soil nails or ground anchors. Contractors or Subcontractors that are specifically prequalified in Class 36 Work will be considered to have met the above experience requirements. Page 6-296 2020 Standard Specifications M 41-10 6-15 Soil Nail Walls 6-15.3(3) Submittals The Contractor shall submit Type 2 Working Drawings of the following information. 1. A brief description of each project satisfying the Contractors Experience Requirements with the Owner’s name and current phone number (this item is not required if the Contractor or Subcontractor is prequalified in Class 36). 2. A list identifying the following personnel assigned to this project and their experience with permanently anchored or nailed Structures: a. Supervising Engineer. b. Drill Operators. c. On-site Supervisors who will be assigned to the project. 3. The proposed detailed construction procedure that includes: a. Proposed method(s) of excavation of the soil and/or rock. b. A plan for the removal and control of groundwater encountered during excavation, drilling, and other earth moving activities. Include a list of the equipment used to remove and control groundwater. c Proposed drilling methods and equipment. d. Proposed hole diameter(s). e. Proposed method of soil nail installation. f. Mix design and procedures for placing the grout. g. Shotcrete mix design with compressive strength test results. h. Procedures for placing the shotcrete (include placement in conditions when ground water is encountered). i. Encapsulation system for additional corrosion protection selected for the soil nails and anchorages requiring encapsulation. 4. Detailed Working Drawings of the method proposed for the soil nail testing that includes: a. All necessary drawings and details to clearly describe the proposed system of jacking support, framing, and bracing to be used during testing. b. Calibration data for each load cell, test jack, pressure gauge, stroke counter on the grout pump, and master gauge to be used. The calibration tests shall have been performed by an independent testing Laboratory, and tests shall have been performed within 60 calendar days of the date submitted. Testing or Work shall not commence until the Engineer has approved the load cell, jack, pressure gage, and master pressure gauge calibrations. 5. Certified mill test results and typical stress-strain curves along with samples from each heat, properly marked, for the soil nail steel. The typical stress-strain curve shall be obtained by approved standard practices. The guaranteed ultimate strength, yield strength, elongation, and composition shall be specified. 2020 Standard Specifications M 41-10 Page 6-297 Soil Nail Walls 6-15 6-15.3(4) Preconstruction Conference A soil nail preconstruction conference shall be held at least 5 working days prior to the Contractor beginning any permanent soil nail Work at the site to discuss construction procedures, personnel and equipment to be used. The list of materials specified on the Record of Materials Form (ROM) for this item of Work will also be discussed. Those attending shall include: 1. (representing the Contractor) The superintendent, on site supervisors, and all foremen in charge of excavating the soil face, drilling the soil nail hole, placing the soil nail and grout, placing the shotcrete facing, and tensioning and testing the soil nail. 2. (representing the Contracting Agency) The Engineer, key inspection personnel, and representatives from the WSDOT Construction Office and Materials Laboratory Geotechnical Services Branch. If the Contractor’s key personnel change, or if the Contractor proposes a significant revision of the approved permanent soil nail installation plan, an additional conference shall be held before any additional permanent soil nail operations are performed. 6-15.3(5) Earthwork The ground contour above the wall shall be established to its final configuration and slope as shown in the Plans prior to beginning excavation of the soil for the first row of soil nails. All excavation shall conform to Section 2-03. The excavation shall proceed from the top down in a horizontal lift sequence with the ground level excavated no more than 3 feet below the elevation of the row of nails to be installed in that lift. The excavated vertical wall face shall not be left unshored more than 24 hours for any reason. A lift shall not be excavated until the nail installation and reinforced shotcrete placement for the preceding lift has been completed and accepted. After a lift is excavated, the cut surface shall be cleaned of all loose materials, mud, rebound, and other foreign matter that could prevent or reduce shotcrete bond. The accuracy of the ground cut shall be such that the required thickness of shotcrete can be placed within a tolerance of plus or minus 2 inches from the defined face of the wall, and over excavation does not damage overlying shotcrete sections by undermining or other causes. The Contractor should review the geotechnical recommendations report prepared for this project for further information on the soil conditions at the location of each wall. Copies of the geotechnical recommendations report are available for review by prospective Bidders at the location identified in the Special Provisions. Page 6-298 2020 Standard Specifications M 41-10 6-15 Soil Nail Walls 6-15.3(6) Soil Nailing The Contractor shall not handle and transport the encapsulated soil nails until the encapsulation grout has reached sufficient strength to resist damage during handling. The Contractor shall handle the encapsulated soil nails in such a manner to prevent large deflections or distortions during handling. When handling or transporting encapsulated soil nails, the Contractor shall provide slings or other equipment necessary to prevent damage to the soil nails and the corrosion protection. The Engineer may reject any encapsulated nail which is damaged during transportation or handling. Damaged or defective encapsulation shall be repaired in accordance with the manufacturer’s recommendations. Soil nails shall be handled and sorted in such a manner as to avoid damage or corrosion. Prior to inserting a soil nail in the drilled hole, the Contractor and the Engineer will examine the soil nail for damage. If, in the opinion of the Engineer, the epoxy coating or bar has been damaged, the nail shall be repaired. If, in the opinion of the Engineer, the damage is beyond repair, the soil nail shall be rejected. If, in the opinion of the Engineer, the epoxy coating can be repaired, the Contractor shall patch the coating with an Engineer approved patching material. Nail holes shall be drilled at the locations shown in the Plans or as staked by the Engineer. The nails shall be positioned plus or minus 6 inches from the theoretical location shown in the Plans. The Contractor shall select the drilling method and the grouting pressure used for the installation of the soil nail. The drill hole shall be located so that the longitudinal axis of the drill hole and the longitudinal axis of the nail are parallel. At the point of entry the soil nail shall be installed within plus or minus 3 degrees of the inclination from horizontal shown in the Plans, and the nail shall be within plus or minus 3 degrees of a line drawn perpendicular to the face of the wall unless otherwise shown in the Plans. Water or other liquids shall not be used to flush cuttings during drilling, but air may be used. The nail shall be inserted into the drilled hole with centralizers to the desired depth in such a manner as to prevent damage to the drilled hole, sheathing or epoxy during installation. The centralizers shall provide a minimum of 0.5 inches of grout cover over the soil nail and shall be spaced no further than 8 feet apart. When the soil nail cannot be completely inserted into the drilled hole without difficulty, the Contractor shall remove the nail from the drilled hole and clean or redrill the hole to permit insertion. Partially inserted soil nails shall not be driven or forced into the hole. Subsidence, or any other detrimental impact from drilling shall be cause for immediate cessation of drilling and repair of all damages in a manner approved by the Engineer at no additional cost to the Contracting Agency. If caving conditions are encountered, no further drilling will be allowed until the Contractor selects a method to prevent ground movement. The Contractor may use temporary casing. The Contractor’s method to prevent ground movement shall be approved by the Engineer. The casings for the nail holes, if used, shall be removed as the grout is being placed. 2020 Standard Specifications M 41-10 Page 6-299 Soil Nail Walls 6-15 Where necessary for stability of the excavation face, a sealing layer of shotcrete may be placed before drilling is started, or the Contractor shall have the option of drilling and grouting of nails through a stabilizing berm of native soil at the face of the excavation. The stabilizing berm shall extend horizontally from the soil face and from the face of the shotcrete a minimum distance of 1 foot, and shall be cut down from that point at a safe slope, no steeper than 1H:1V unless approved by the Engineer. The berm shall be excavated to final grade after installation and full length grouting of the nails. Nails damaged during berm excavation shall be repaired or replaced by the Contractor, to the satisfaction of the Engineer, at no added cost to the Contracting Agency. If sections of the wall are constructed at different times than the adjacent soil nail sections, the Contractor shall use stabilizing berms, temporary slopes, or other measures acceptable to the Engineer, to prevent sloughing or failure of the adjacent soil nail sections. If cobbles and boulders are encountered at the soil face during excavation, the Contractor shall remove all cobbles and boulders that protrude from the soil face into the design wall section and fill the void with shotcrete. All shotcrete used to fill voids created by removal of cobbles and boulders shall be incidental to shotcrete facing. The grout equipment shall produce a grout free of lumps and undispersed cement. A positive displacement grout pump shall be used. The pump shall be equipped with a pressure gauge near the discharge end to monitor grout pressures. The pressure gauge shall be capable of measuring pressures of at least 150 psi or twice the actual grout pressures used by the Contractor, whichever is greater. The grouting equipment shall be sized to enable the grout to be pumped in one continuous operation. The mixer shall be capable of continuously agitating the grout. The grout shall be injected from the lowest point of the drilled hole. The quantity of the grout and the grout pressures shall be recorded. The grout pressures and grout takes shall be controlled to prevent excessive ground heave. The Contractor shall make and cure grout cubes once per day in accordance with WSDOT T 813. These samples shall be retained by the Contractor until all associated verification and proof testing of the soil nails has been successfully completed. If the Contractor elects to test the grout cubes for compressive strength, testing shall be conducted by an independent laboratory and shall be in accordance with the FOP for AASHTO T106. 6-15.3(7) Shotcrete Facing Prior to placing any shotcrete on an excavated layer, the Contractor shall vertically center prefabricated drainage mat between the columns of nails as shown in the Plans. The prefabricated drainage mat shall be installed in accordance with the manufacturer’s recommendations. The permeable drain side shall be placed against the exposed soil face. The prefabricated drainage mat shall be installed after each excavation lift and shall be hydraulically connected with the prefabricated drainage mat previously placed, such that the vertical flow of water is not impeded. The Contractor shall tape all joints in the prefabricated drainage mat to prevent shotcrete intrusion during shotcrete application. Page 6-300 2020 Standard Specifications M 41-10 6-15 Soil Nail Walls The Contractor shall place steel reinforcing bars and welded wire fabric, and apply the shotcrete facing in accordance with Section 6-18 and the details shown in the Plans. The shotcrete shall be constructed to the minimum thickness as shown in the Plans. Costs associated with additional thickness of shotcrete due to over excavation or irregularities in the cut face shall be borne by the Contractor. Each soil nail shall be secured at the shotcrete facing with a steel plate as shown in the Plans. The plate shall be seated on a wet grout pad of a pasty consistency similar to that of mortar for brick-laying. The nut shall then be sufficiently tightened to achieve full bearing surface behind the plate. After the shotcrete and grout have had time to gain the specified strength, the nut shall be tightened with at least 100 foot-pounds of torque. After final tightening of the nut, the threads of the soil nail shall at a minimum be flush with the end of the nut. 6-15.3(8) Soil Nail Testing and Acceptance Both verification and proof testing of the nails is required. The Contractor shall supply all materials, equipment, and labor to perform the tests. The Contractor shall submit Type 1 Working Drawings of all test data. Soil nails used for verification tests and proof tests shall not be production soil nails, but instead shall be separate sacrificial soil nails not otherwise incorporated into the Work. The testing equipment shall include a dial gauge or vernier scale capable of measuring to 0.001 inch of the ground anchor movement. A hydraulic jack and pump shall be used to apply the test load. The movement-measuring device shall have a minimum travel equal to the theoretical elastic elongation of the total nail length plus 1 inch. The dial gauge or vernier scale shall be aligned so that its axis is within 5 degrees from the axis of the nail and shall be monitored with a reference system that is independent of the jacking system and excavation face. The jack and pressure gauge shall be calibrated by an independent testing Laboratory as a unit. Each load cell, test jack and pressure gauge, grout pump stroke counter, and master gauge, shall be calibrated as specified in Section 6-15.3(3), item 4b. Additionally, the Contractor shall not use load cells, test jacks and pressure gauges, grout pump stroke counters, and master gauges, greater than 60 calendar days past their most recent calibration date, until such items are re-calibrated by an independent testing Laboratory. The pressure gauge shall be graduated in increments of either 100 psi or 2 percent of the maximum test load, whichever is less. The pressure gauge shall be selected to place the maximum test load within the middle ⅔ of the range of the gauge. The ram travel of the jack shall not be less than the theoretical elastic elongation of the total length at the maximum test load plus 1 inch. The jack shall be independently supported and centered over the nail so that the nail does not carry the weight of the jack. The Contractor shall have a second calibrated jack pressure gauge at the site. Calibration data shall provide a specific reference to the jack and the pressure gauge. 2020 Standard Specifications M 41-10 Page 6-301 Soil Nail Walls 6-15 The loads on the nails during the verification and proof tests shall be monitored to verify consistency of load – defined as maintaining the test load within 5 percent of the specified value. Verification and proof test loads less than 20,000 pounds or sustained for 5 minutes or less shall be monitored by the jack pressure gauge alone. Verification and proof test loads equal to or greater than 20,000 pounds and sustained for longer than 5 minutes shall be monitored with the assistance of an electric or hydraulic load cell. The Contractor shall provide the load cell, the readout device, and a calibration curve from the most recent calibration as specified in Section 6-15.3(3), item 4b. The load cell shall be selected to place the maximum test load within the middle ⅔ of the range of the load cell. The load cell shall be mounted between the jack and the anchor plate. The stressing equipment shall be placed over the nail in such a manner that the jack bearing plates, load cell and stressing anchorage are in alignment. Nails to be tested shall be initially grouted no closer to the excavation face than the dimension shown in the Plans. After placing the grout, the nail shall remain undisturbed until the grout has reached strength sufficient to provide resistance during testing. Test nails shall be left in the ground after testing, with the exposed portion of the test nail cut and removed to 2 feet behind the excavated face or inside face of shotcrete. The drill holes for test nails shall be completely backfilled with grout or nonstructural filler after testing on those test nails has been completed. Load testing shall be performed against a temporary reaction frame with bearing pads that bear directly against the existing soil or the shotcrete facing. Bearing pads shall be kept a minimum of 12 inches from the edges of the drilled hole and the load shall be distributed to prevent failure of the soil face or fracture of the shotcrete. The Contractor shall submit Type 2E Working Drawings of the reaction frame. The soil nail load monitoring procedure for verification and proof test load greater than 20,000 pounds and sustained for longer than 5 minutes shall be as follows: 1. For each increment of load, attainment of the load shall be initially established and confirmed by the reading taken from the jack gauge. 2. Once the soil nail anchor load has been stabilized, based on the jack gauge reading, the load cell readout device shall immediately be read and recorded to establish the load cell reading to be used at this load. The load cell reading is intended only as a confirmation of a stable soil nail load, and shall not be taken as the actual load on the soil nail. 3. During the time period that the load on the soil nail is held at this load increment, the Contractor shall monitor the load cell reading. The Contractor shall adjust the jack pressure as necessary to maintain the initial load cell reading. Jack pressure adjustment for any other reason will not be allowed. 4. Soil nail elongation measurements shall be taken at each load increment as specified in Sections 6-15.3(8)A and 6-15.3(8)B. 5. Steps 1 through 4 shall be repeated at each increment of load, in accordance with the load sequence specified in Sections 6-15.3(8)A and 6-15.3(8)B. Page 6-302 2020 Standard Specifications M 41-10 6-15 Soil Nail Walls 6-15.3(8)A Verification Testing Verification testing shall be performed on nails installed within the pattern of production nails to verify the Contractor’s procedures, hole diameter, and design assumptions. No drilling or installation of production nails will be permitted in any ground/rock unit unless successful verification testing of anchors in that unit has been completed and approved by the Engineer, using the same equipment, methods, nail inclination, nail length, and hole diameter as planned for the production nails. Changes in the drilling or installation method may require additional verification testing as determined by the Engineer and shall be done at no additional expense to the Contracting Agency. Verification tests may be performed prior to excavation for the soil nail wall. Successful verification tests are required within the limits as specified in the Special Provisions. Test nail locations within these limits shall be at locations selected by the Engineer. The Contractor shall submit Type 2E Working Drawings consisting of design details of the verification testing, including the system for distributing test load pressures to the excavation surface and appropriate nail bar size and reaction plate. The intent is to stress the bond between the grout and the surrounding soil/rock to at least twice the design load transfer. Prior to beginning verification testing, the Contractor shall measure and record the length of the nonbonded zone for each verification test soil nail. The bar shall be proportioned such that the maximum stress at 200 percent of the test load does not exceed 80 percent of the yield strength of the steel. The jack shall be positioned at the beginning of the test such that unloading and repositioning of the jack during the test will not be required. The verification tests shall be made by incrementally loading the nails in accordance with the following schedule of hold time: AL 1 minute 0.25TL 10 minutes 0.50TL 10 minutes 0.75TL 10 minutes 1.00TL 10 minutes 1.25TL 10 minutes 1.50TL 60 minutes 1.75TL 10 minutes 2.00TL 10 minutes AL = Nail Alignment Load TL = Nail Test Load The test load shall be determined by the following equation = Test Load (TL) = Bond Length (BL) × Design Load Transfer (DLT). The load shall be applied in increments of 25 percent of the test load. Each load increment shall be held for at least 10 minutes. Measurement of nail movement shall be obtained at each load increment. The load-hold period shall start as soon as the load is applied and the nail movement with respect to a fixed reference shall be measured and recorded at 1 minute, 2, 3, 4, 5, 6, 10, 20, 30, 40, 50, and 60 minutes. 2020 Standard Specifications M 41-10 Page 6-303 Soil Nail Walls 6-15 The Engineer will evaluate the results of each verification test and make a determination of the suitability of the test and of the Contractor’s proposed production nail design and installation system. Tests that fail to meet the design criteria will require additional verification testing or an approved revision to the Contractor’s proposed production nail design and installation system. If a nail fails in creep, retesting will not be allowed. A verification tested nail with a 60-minute load hold at 1.50TL is acceptable if: 1. The nail carries the test load with a creep rate that does not exceed 0.08 inch per log cycle of time and is at a linear or decreasing creep rate. 2. The total movement at the test load exceeds 80 percent of the theoretical elastic elongation of the non-bonded length. Furthermore, a pullout failure shall not occur for the verification test anchor at the 2.0TL maximum load. Pullout failure load is defined as the load at which attempts to increase the test load result only in continued pullout movement of the test nail without a sustainable increase in the test load. 6-15.3(8)B Proof Testing Proof tests shall be performed on proof test soil nails installed within the pattern of the production soil nails at the locations shown in the Plans. Proof test soil nails shall be installed using the same equipment, methods, nail inclination, nail length, and hole diameter as for adjacent production nails. The Contractor shall maintain the side-wall stability of the drill hole for the non-grouted portion during the test. The bond length shall be determined from the Nail Schedule and Test Nail Detail shown in the Plans. Prior to beginning proof testing, the Contractor shall measure and record the length of the nonbonded zone for each proof test soil nail. Proof tests shall be performed by incrementally loading the nail in accordance with the schedule below. The anchor movement shall be measured and recorded to the nearest 0.001 inch with respect to an independent fixed reference point in the same manner as for the verification tests at the alignment load and at each increment of load. The load shall be monitored in accordance with Section 6-15.3(8). The scheduling of hold times shall be as follows: AL 1 minute 0.25TL 5 minutes 0.50TL 5 minutes 0.75TL 5 minutes 1.00TL 5 minutes 1.25TL 5 minutes 1.50TL 10 minutes AL = Nail Alignment Load TL = Nail Test Load Page 6-304 2020 Standard Specifications M 41-10 6-15 Soil Nail Walls The maximum load in a proof test shall be held for 10 minutes. The load hold period shall start as soon as the maximum load is applied and the nail movement with respect to an independent fixed reference shall be measured and recorded at 1, 2, 3, 4, 5, 6, and 10 minutes. The nail movement between 1 and 10 minutes shall not exceed 0.04 inches. If the nail movement between 1 and 10 minutes exceeds 0.04 inches, the maximum load shall be held an additional 50 minutes. If the load hold is extended, the nail movement shall be recorded at 20, 30, 40, 50, and 60 minutes. If a nail fails in creep, retesting will not be allowed. A proof tested nail is acceptable if: 1. The nail carries the maximum load with less than 0.04 inches of movement between 1 and 10 minutes, unless the load hold extended to 60 minutes, in which case the nail would be acceptable if the creep rate does not exceed 0.08 inches per log cycle of time. 2. The total movement at the maximum load exceeded 80 percent of the theoretical elastic elongation of the non-bonded length. 3 The creep rate is not increasing with time during the load hold period. If a proof test fails, the Engineer may direct the Contractor to replace some or all of the installed production nails between the failed test and an adjacent proof test nail that has met the test criteria. The Engineer may also require additional proof testing. All additional proof tests, and all installation of additional or modified nails, shall be performed at no additional expense to the Contracting Agency. 6-15.3(9) Concrete Fascia Panels The Contractor shall construct the concrete fascia panels in accordance with Section 6-02 and the details in the Plans. The concrete fascia panels shall be cured in accordance with the Section 6-02.3(11) requirements specified for retaining walls. The Contractor shall provide the specified surface finish as noted, and to the limits shown, in the Plans to the exterior concrete surface. When noted in the Plans, the Contractor shall apply pigmented sealer to the limits shown in the Plans. Asphalt or cement concrete gutter shall be constructed as shown in the Plans and as specified in Section 8-04. 6-15.4 Measurement Prefabricated drainage mat will be measured by the square yard of material furnished and installed. Soil nails will be measured per each for each soil nail installed and accepted. Soil nail verification test and soil nail proof test will be measured per each for each successfully completed soil nail verification test and soil nail proof test at the locations specified in the Special Provisions and shown in the Plans. 2020 Standard Specifications M 41-10 Page 6-305 Soil Nail Walls 6-15 Shotcrete facing and concrete fascia panel will be measured by the square foot surface area of the completed facing or fascia panel, measured to the neat lines of the facing or panel as shown in the Plans. 6-15.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Soil Nail – Epoxy Coated”, per each. “Soil Nail – Encapsulated”, per each. All costs in connection with furnishing and installing the soil nails as specified shall be included in the unit Contract price per each for “Soil Nail - ___”, including all drilling, grouting, centralizers, bearing plates, welded shear connectors, nuts, and other Work required for installation of each soil nail. “Prefabricated Drainage Mat”, per square yard. “Soil Nail Verification Test and Soil Nail Proof Test”, per each. All costs in connection with successfully completing soil nail verification tests and soil nail proof tests as specified shall be included in the unit contract price per each for “Soil Nail Verification Test and Soil Nail Proof Test”, including removal of the exposed portion of the test nail and backfilling the drilled hole with grout or nonstructural filler. “Concrete Fascia Panel”, per square foot. All costs in connection with constructing the concrete fascia panels as specified shall be included in the unit Contract price per square foot for “Concrete Fascia Panel”, including all steel reinforcing bars, premolded joint filler, polyethylene bond breaker strip, joint sealant, PVC pipe for weep holes, exterior surface finish, and pigmented sealer (when specified). Shotcrete facing will be paid for in accordance with Section 6-18.5. Unless otherwise specified, all costs in connection with excavation in front of the back face of the shotcrete facing shall be included in the unit Contract price per cubic yard for “Roadway Excavation” or “Roadway Excavation Incl. Haul” as specified in Section 2-03.5. Page 6-306 2020 Standard Specifications M 41-10 6-16 Soldier Pile and Soldier Pile Tieback Walls 6-16 Soldier Pile and Soldier Pile Tieback Walls 6-16.1 Description This Work consists of constructing soldier pile walls and soldier pile tieback walls. 6-16.2 Materials Materials shall meet the requirements of the following sections: Controlled Density Fill 2-09.3(1)E Cement 9-01 Aggregates for Concrete 9-03.1 Gravel Backfill 9-03.12 Premolded Joint Filler 9-04.1(2) Welded Shear Studs 9-06.15 Steel Reinforcing Bar 9-07.2 Epoxy-Coated Steel Reinforcing Bar 9-07.3 Paints 9-08 Timber Lagging 9-09.2 Preservative Treatment for Timber Lagging 9-09.3(1) Soldier Piles 9-10.5 Concrete Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Water 9-25 Prefabricated Drainage Mat 9-33.2(3) Other materials required shall be as specified in the Special Provisions. 6-16.3 Construction Requirements 6-16.3(1) Quality Assurance The steel soldier piles shall be placed so that the centerline of the pile at the top is within 1 inch of the Plan location. The steel soldier pile shall be plumb, to within 0.5 percent of the length based on the total length of the pile. Welding, repair welding, and welding inspection shall conform to the Section 6-03.3(25) requirements for welding, repair welding, and welding inspection for all other steel fabrication. 6-16.3(2) Submittals The Contractor shall submit Type 2 Working Drawings consisting of shop plans as specified in Section 6-03.3(7) for all structural steel, including the steel soldier piles, and shall submit Type 2 Working Drawings consisting of shop plans and other details as specified in Section 6-17.3(3) for permanent ground anchors. The Contractor shall submit Type 1 Working Drawings consisting of the permanent ground anchor grout mix design and the procedures for placing the grout to the Engineer for approval. 2020 Standard Specifications M 41-10 Page 6-307 Soldier Pile and Soldier Pile Tieback Walls 6-16 The Contractor shall submit Type 2E Working Drawings consisting of forming plans for the concrete fascia panels, as specified in Sections 6-02.3(16) and 6-02.3(17). 1. Where the lateral pressure from concrete placement, as specified in Section 6-02.3(17)J, is less than or equal to the design earth pressure, the Contractor may tie forms directly to the soldier piles. 2. Where the lateral pressure from concrete placement, as specified in Section 6-02.3(17)J, is greater than the design earth pressure, the Contractor shall follow one of the following procedures: a. Tie the forms to strongbacks behind the lagging, or use some other system that confines the pressure from concrete placement between the lagging and the form panels, in addition to the ties to the soldier piles. b. Reduce the rate of placing concrete to reduce the pressure from concrete placement to less than or equal to the design earth pressure in addition to the ties to the soldier piles. c. Follow a procedure with a combination of a. and b. 3. The Contractor shall design the forms for an appropriate rate of placing concrete so that no cold joints occur, considering the wall thickness and height, and volume of concrete to be placed. The Contractor shall submit Type 2 Working Drawings consisting of a shaft installation plan. In preparing the submittal, the Contractor shall reference the available subsurface data provided in the Contract test hole boring logs and the geotechnical report(s) prepared for this project. This plan shall provide at least the following information: 1. An overall construction operation sequence and the sequence of shaft construction. 2. List, description, and capacities of proposed equipment including but not limited to cranes, drills, augers, bailing buckets, final cleaning equipment, and drilling units. The narrative shall describe why the equipment was selected, and describe equipment suitability to the anticipated site and subsurface conditions. The narrative shall include a project history of the drilling equipment demonstrating the successful use of the equipment on shafts of equal or greater size in similar soil/rock conditions. 3. Details of shaft excavation methods including proposed drilling methods, methods for cleanout of the shafts, disposal plan for excavated material and drilling slurry (if applicable), and a review of method suitability to the anticipated site and subsurface conditions. 4. Details of the method(s) to be used to ensure shaft stability (i.e., prevention of caving, bottom heave, etc. using temporary casing, slurry, or other means) during excavation and concrete placement. This shall include a review of method suitability to the anticipated site and subsurface conditions. If temporary casings are proposed, casing dimensions and detailed procedures for casing installation and removal shall be provided. If slurry is proposed, detailed procedures for mixing, using, maintaining, and disposing of the slurry shall be provided. A detailed mix design, and a discussion of its suitability to the anticipated subsurface conditions shall also be provided for the proposed slurry. Page 6-308 2020 Standard Specifications M 41-10 6-16 Soldier Pile and Soldier Pile Tieback Walls 5. Details of soldier pile placement including internal support bracing and centralization methods. 6. Details of concrete placement including proposed operational procedures for pumping and/or tremie methods. 7. Details of the device used to prevent unauthorized entry into a shaft excavation. 8. The method to be used to form the horizontal construction joint at the top elevation specified for concrete Class 4000P in the shaft. 6-16.3(3) Shaft Excavation Shafts shall be excavated to the required depth as shown in the Plans. The minimum diameter of the shaft shall be as shown in the Plans. The excavation shall be completed in a continuous operation using equipment capable of excavating through the type of material expected to be encountered. The Contractor may use temporary telescoping casing to construct the shafts. If the shaft excavation is stopped the shaft shall be secured by installation of a safety cover. It shall be the Contractor’s responsibility to ensure the safety of the shaft and surrounding soil and the stability of the sidewalls. A temporary casing, slurry, or other methods specified in the shaft installation plan shall be used if necessary to ensure such safety and stability. Where caving in conditions are encountered, no further excavation will be allowed until the Contractor has implemented the method to prevent ground caving as submitted in accordance with item 4 of the Shaft Installation Plan. No more than 2 inches of loose or disturbed material, for soldier piles with permanent ground anchors, nor more than 12 inches of loose or disturbed material, for soldier piles without permanent ground anchors, shall be present at the bottom of the shaft just prior to beginning concrete placement. The excavated shaft shall be inspected and receive acceptance by the Engineer prior to proceeding with construction. When obstructions are encountered, the Contractor shall notify the Engineer promptly. An obstruction is defined as a specific object (including, but not limited to, boulders, logs, and man made objects) encountered during the shaft excavation operation that prevents or hinders the advance of the shaft excavation. When efforts to advance past the obstruction to the design shaft tip elevation result in the rate of advance of the shaft drilling equipment being significantly reduced relative to the rate of advance for the rest of the shaft excavation, then the Contractor shall remove the obstruction under the provisions of Section 6-16.5. The method of removal of such obstructions, and the continuation of excavation shall be as proposed by the Contractor and approved by the Engineer. 2020 Standard Specifications M 41-10 Page 6-309 Soldier Pile and Soldier Pile Tieback Walls 6-16 Excavation of shafts shall not commence until a minimum of 12 hours after the shaft backfill for the adjacent shafts has been placed. The temporary casings for the shafts shall be removed. A minimum 5-foot head of concrete shall be maintained to balance the soil and water pressure at the bottom of the casing. The casing shall be smooth. 6-16.3(4) Installing Soldier Piles Soldier piles, if spliced, shall conform to all requirements of Section 6-05.3(6). The prefabricated steel soldier piles shall be lowered into the drilled shafts and secured in position. Concrete cover over the soldier pile shall be 3 inches minimum, except that the cover over the soldier pile flange plate reinforcing at permanent ground anchor locations shall be 1½ inches minimum. The steel soldier piles and attachments shall be shop painted after fabrication to the limits shown in the Plans with one coat of inorganic zinc primer. Application of the one coat of primer shall be in accordance with Section 6-07. The welded shear studs may be attached before or after painting. Paint damaged by welding shear studs in place does not require repair. 6-16.3(5) Backfilling Shaft The excavated shaft shall be backfilled with either controlled density fill (CDF), or pumpable lean concrete, as shown in the Plans and subject to the following requirements: 1. Dry shaft excavations shall be backfilled with CDF. 2. Wet shaft excavations shall be backfilled with pumpable lean concrete. 3. Pumpable lean concrete shall be a Contractor designed mix providing a minimum 28-day compressive strength of 100 psi. Acceptance of pumpable lean concrete will conform to the acceptance requirements specified in Section 2-09.3(1) for CDF. 4. A wet shaft is defined as a shaft where water is entering the excavation and remains present to a depth of 6 inches or more. 5. When the Plans or test hole boring logs identify the presence of a water table at or above the elevation of the bottom of soldier pile shaft, the excavation shall be considered as wet, except as otherwise noted. Such a shaft may be considered a dry shaft provided the Contractor furnishes and installs casing that is sufficiently sealed into competent soils such that water cannot enter the excavation. Placement of the shaft backfill shall commence immediately after completing the shaft excavation and receiving the Engineer’s approval of the excavation. CDF or pumpable lean concrete shall be placed in one continuous operation to the top of the shaft. Vibration of shaft backfill is not required. If water is not present, the shaft backfill shall be deposited by a method that prevents segregation of aggregates. The shaft backfill shall be placed such that the free-fall is vertical down the shaft without hitting the sides of the soldier pile or the excavated Page 6-310 2020 Standard Specifications M 41-10 6-16 Soldier Pile and Soldier Pile Tieback Walls shaft. The Contractor’s method for depositing the shaft backfill shall have approval of the Engineer prior to the placement of the shaft backfill. If water is present, the shaft backfill shall be deposited in accordance with Section 6-02.3(6)B. 6-16.3(6) Designing and Installing Lagging and Installing Permanent Ground Anchors Lagging for soldier pile walls shall conform to one of the following two categories: 1. Temporary lagging is defined as lagging that is in service as a structural member for a maximum of 36 months before a permanent load-carrying fascia is in place, except for the following exception: Lagging for soldier pile walls in site soils conforming to an excluded soil type as defined under Section 6-16.3(6)A will be classified as permanent lagging conforming to Section 6-16.3(6)C, in which case this requirement will be specified in the Plans along with design details for such lagging. 2. Permanent lagging is defined as all lagging not conforming to the definition of temporary lagging as specified in category 1, above. 6-16.3(6)A Soil Classification For the purposes of designing lagging for soldier pile walls, soils shall be categorized in the classifications defined below. Soil Type 1 The following shall be considered Type 1 soils: 1. Cohesive fine-grained soils either CL or CH of medium consistency with γH/Su < 5. 2. Cohesive fine-grained soils either CL or CH that are stiff to very stiff and nonfissured. 3. Fine-grained soils either ML or SM-ML that are above the water table. 4. Coarse-grained soils either GW, GP, GM, GC, SW, SP, or SM that are medium dense to dense. Soil Type 2 The following shall be considered Type 2 soils: 1. Cohesive fine-grained soils either CL or CH that are heavily overconsolidated and fissured. 2. Fine-grained ML soils or coarse-grained SM-ML soils that are below the water table. 3. Coarse-grained SC soil that is medium dense to dense and is below the water table. 4. Coarse-grained soils either SW, SP, or SM that are loose. 2020 Standard Specifications M 41-10 Page 6-311 Soldier Pile and Soldier Pile Tieback Walls 6-16 Soil Type 3 The following shall be considered Type 3 soils: 1. Cohesive fine-grained soils either CL or CH that are soft with γH/Su > 5. 2. Fine-grained slightly plastic ML soil that is below the water table. 3. Coarse-grained SC soil that is loose and below the water table. Exclusions Regardless of whether site soils conform to one of the soil types defined above, site soils under the following conditions are excluded from the Type 1, Type 2, and Type 3 soil classifications: 1. Disturbed soils such as those in landslides or known unstable areas. 2. Layered soils dipping into the excavation steeper than 4H:1V. Lagging for soldier pile walls located in site soils excluded from the Type 1, Type 2, and Type 3 soil classifications shall be designed in accordance with the latest AASHTO LRFD Bridge Design Specifications with current interim specifications. Use of the table in Section 6-16.3(6)B for timber lagging in these situations will not be allowed. 6-16.3(6)B Temporary Lagging The Contractor shall design temporary lagging for all soldier pile walls. The temporary lagging design shall be based on the following: 1. The AASHTO LRFD Bridge Design Specifications, latest edition with current interim specifications, except that timber members used for temporary lagging may be selected based on the table below. 2. The soil type as specified in the Plans or as determined from the geotechnical report prepared for the project. 3. The soil pressure diagram, either as shown in the Plans or as included in the geotechnical report prepared for the project, including the surcharge for temporary construction load when shown in the Plans. The Contractor shall submit Type 2E Working Drawings consisting of the soldier pile wall lagging design details and supporting design calculations. The submittal shall include, at a minimum, the following: 1. Description of the material used for the lagging, including identification of applicable material specifications. 2. Installation method and sequence. 3. If the lagging material is to be removed during or after installation of the permanent fascia, a description of how the lagging is removed without disturbing or damaging the fascia, soldier piles, and retained soil, and a description of how, and with what material, the void left by the removal of lagging is to be filled. Page 6-312 2020 Standard Specifications M 41-10 6-16 Soldier Pile and Soldier Pile Tieback Walls 4. For all cases, except with timber for temporary lagging, a description with appropriate details of how subsurface drainage is to be accommodated, either in accordance with Section 6-16.3(7) for timber lagging, Section 6-15.3(7) for shotcrete facing, or other means appropriate for the geotechnical site conditions and acceptable to the Engineer for other lagging materials. Lagging materials and lagging installation methods that cause the buildup of, and prevent the relief of, pore water pressure will not be allowed. Free-draining materials are defined as those materials that exhibit a greater permeability than the material being retained. Temporary lagging may be untreated timber conforming to the Section 9-09.2 requirements specified under Structures for timber lagging or another material selected by the Contractor. Timber for temporary lagging shall conform to the minimum actual thickness specified in the table below for the soil type, exposed wall height, and lagging clear span as shown in the Plans. Notwithstanding the requirements of Section 1-06.1, steel materials used by the Contractor as temporary lagging may be salvaged steel provided that the use of such salvaged steel materials shall be subject to visual inspection and acceptance by the Engineer. For salvaged steel materials where the grade of steel cannot be positively identified, the design stresses for the steel shall conform to the Section 6-02.3(17)B requirements for salvaged steel, regardless of whether rivets are present or not. Minimum Actual Thickness of Timber Used as Temporary Lagging Soil Type1 1 1 2 2 3 3 3 Exposed Wall Height (feet) 25 and under Over 25 to 60 25 and under Over 25 to 60 15 and under Over 15 to 25 Over 25 Clear Span of Lagging (feet)Minimum Actual Thickness of Rough Cut Timber Lagging (inches)3 5 2 3 3 3 3 3 4 6 3 3 3 3 3 4 5 7 3 3 3 4 4 5 6 8 3 4 4 4 5 6 See Note2 9 4 4 4 5 See Note2 See Note2 See Note2 10 4 5 5 5 See Note2 See Note2 See Note2 1Soil Type as defined in Section 6-16.3(6)A. 2For exposed wall heights exceeding the limits in the table above, or where minimum rough cut lagging thickness is not provided, the Contractor shall design the lagging in accordance with the latest AASHTO LRFD Bridge Design Specifications with current interim specifications. 3Table modified from FHWA document “Lateral Support Systems and Underpinning” (Report No. FHWA- RD-75-130). 2020 Standard Specifications M 41-10 Page 6-313 Soldier Pile and Soldier Pile Tieback Walls 6-16 6-16.3(6)C Permanent Lagging Permanent lagging, including timber, shall be as shown in the Plans. The use of the table in Section 6-16.3(6)B for the design of timber lagging for permanent lagging will not be allowed. 6-16.3(6)D Installing Lagging and Permanent Ground Anchors The excavation and removal of CDF and pumpable lean concrete for the lagging installation shall proceed in advance of the lagging and shall not begin until the CDF and pumpable lean concrete are of sufficient strength that the material remains in place during excavation and lagging installation. If the CDF or pumpable lean concrete separates from the soldier pile, or caves or spalls from around the soldier pile, the Contractor shall discontinue excavation and lagging installation operations until the CDF and pumpable lean concrete is completely set. The bottom of the excavation in front of the wall shall be level. Excavation shall conform to Section 2-03. For walls without permanent ground anchors, the bottom of excavation shall not be more than 3 feet below the bottom level of the lagging already installed, but in no case shall the depth of excavation beneath the bottom level of installed lagging be such to cause instability of the excavated face. For walls with permanent ground anchors, the bottom of excavation shall be not more than 3 feet below the permanent ground anchor level until all permanent ground anchors at that level are installed and stressed, but in no case shall the depth of excavation beneath the permanent ground anchor level be such to cause instability of the excavated face. Any caving that occurs during excavation shall be backfilled with free-draining material. Installing, stressing, and testing the permanent ground anchors shall be in accordance with Section 6-17 and the construction sequence specified in the Plans. The lagging shall be installed from the top of the soldier pile proceeding downward. The lagging shall make direct contact with the soil. When and where lagging is not in full contact with the soil being retained, either the lagging shall be wedged back to create contact or the void shall be filled with a free-draining material. When utilizing lagging in fill situations, the backfill layers shall be placed in accordance with Section 2-03.3(14) except that all layers shall be compacted to 90 percent of maximum density. 6-16.3(7) Prefabricated Drainage Mat For walls with concrete fascia panels, a 4-foot-wide strip of prefabricated drainage mat shall be installed full height of the concrete fascia panel, centered between soldier pile flanges, unless otherwise shown in the Plans. The prefabricated drainage mat shall be attached to the lagging in accordance with the manufacturer’s recommendations. The fabric side shall face the lagging. Splicing of the prefabricated drainage mat shall be in accordance with the manufacturer’s recommendations. Page 6-314 2020 Standard Specifications M 41-10 6-16 Soldier Pile and Soldier Pile Tieback Walls The Contractor shall ensure the hydraulic connection of the prefabricated drainage mat to the previously installed material so that the vertical flow of water is not impeded. The Contractor shall tape all joints in the prefabricated drainage mat to prevent concrete intrusion during concrete fascia panel construction. 6-16.3(8) Concrete Fascia Panel The Contractor shall construct the concrete fascia panels as shown in the Plans, and in accordance with the forming plan. The concrete fascia panels shall be cured in accordance with the Section 6-02.3(11) requirements specified for retaining walls. The Contractor shall provide the specified surface finish as noted, and to the limits shown, in the Plans to the exterior concrete surface. When noted in the Plans, the Contractor shall apply pigmented sealer to the limits shown in the Plans. Asphalt or cement concrete gutter shall be constructed as shown in the Plans. 6-16.4 Measurement Soldier pile shaft construction will be measured by the linear foot of shaft excavated below the top of ground line for the shaft, defined as the highest existing ground point within the shaft diameter. Furnishing soldier pile will be measured by the linear foot of pile assembly specified in the Proposal, including adjustments to the Plan quantity made in accordance with Section 1-04.4. Lagging will be measured by the square foot area of lagging installed. The quantity will be computed based on the vertical dimension from the highest lagging elevation to the lowest lagging elevation between each pair of adjacent soldier piles as the height dimension and the center-to-center spacing of the soldier piles as the length dimension. Prefabricated drainage mat will be measured by the square yard of material furnished and installed. Concrete fascia panel will be measured by the square foot surface area of the completed fascia panel, measured to the neat lines of the panel as shown in the Plans. 6-16.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Shaft - ___ Diameter”, per linear foot. All costs in connection with constructing soldier pile shafts shall be included in the unit Contract price per linear foot for “Shaft - ___ Diameter”, including shaft excavation, temporary casing if used, CDF, lean concrete, concrete Class 4000P, and installing the soldier pile assembly. “Furnishing Soldier Pile - ___”, per linear foot. 2020 Standard Specifications M 41-10 Page 6-315 Soldier Pile and Soldier Pile Tieback Walls 6-16 All costs in connection with furnishing soldier pile assemblies shall be included in the unit Contract price per linear foot for “Furnishing Soldier Pile - ___”, including fabricating and painting the pile assemblies, and field splicing and field trimming the soldier piles. Payment will be made based on the quantity specified in the Proposal unless changes are made to this quantity in accordance with Section 1-04.4, in which case the quantity specified in the Proposal will be adjusted by the amount of the change and will be paid for in accordance with Section 1-04.4. “Lagging”, per square foot. All costs in connection with furnishing and installing lagging shall be included in the unit contract price per square foot for “Lagging”, including design of temporary lagging and filling voids behind the lagging with a free-draining material as approved by the Engineer. “Prefabricated Drainage Mat”, per square yard. “Concrete Fascia Panel”, per square foot. All costs in connection with constructing the concrete fascia panels as specified shall be included in the unit Contract price per square foot for “Concrete Fascia Panel”, including all steel reinforcing bars, premolded joint filler, polyethylene bond breaker strip, joint sealant, PVC pipe for weep holes, exterior surface finish, and pigmented sealer (when specified). Unless otherwise specified, all costs in connection with non-shaft excavation, including all excavation required for placement of timber lagging, shall be included in the unit Contract price per cubic yard for “Roadway Excavation” or “Roadway Excavation Incl. Haul” as specified in Section 2-03.5. “Removing Soldier Pile Shaft Obstructions”, estimated. Payment for removing obstructions, as defined in Section 6-16.3(3), will be made for the changes in shaft construction methods necessary to remove the obstruction. The Contractor and the Engineer shall evaluate the effort made and reach agreement on the equipment and employees utilized, and the number of hours involved for each. Once these cost items and their duration have been agreed upon, the payment amount will be determined using the rate and markup methods specified in Section 1-09.6. For the purpose of providing a common proposal for all bidders, the Contracting Agency has entered an amount for the item “Removing Soldier Pile Shaft Obstructions” in the bid proposal to become a part of the total bid by the Contractor. If the shaft construction equipment is idled as a result of the obstruction removal work and cannot be reasonably reassigned within the project, then standby payment for the idled equipment will be added to the payment calculations. If labor is idled as a result of the obstruction removal work and cannot be reasonably reassigned within the project, then all labor costs resulting from Contractor labor agreements and established Contractor policies will be added to the payment calculations. Page 6-316 2020 Standard Specifications M 41-10 6-16 Soldier Pile and Soldier Pile Tieback Walls The Contractor shall perform the amount of obstruction work estimated by the Contracting Agency within the original time of the contract. The Engineer will consider a time adjustment and additional compensation for costs related to the extended duration of the shaft construction operations, provided: 1. The dollar amount estimated by the Contracting Agency has been exceeded, and; 2. The Contractor shows that the obstruction removal work represents a delay to the completion of the project based on the current progress schedule provided in accordance with Section 1-08.3. 2020 Standard Specifications M 41-10 Page 6-317 Permanent Ground Anchors 6-17 6-17 Permanent Ground Anchors 6-17.1 Description This Work consists of constructing permanent ground anchors. 6-17.2 Materials Materials required, including materials for permanent ground anchors, shall be as specified in the Special Provisions. 6-17.3 Construction Requirements The Contractor shall select the ground anchor type and the installation method, and determine the bond length and anchor diameter. The Contractor shall install ground anchors that will develop the load indicated in the Plans and verified by tests specified in Sections 6-17.3(8)A, 6-17.3(8)B, and 6-17.3(8)C. 6-17.3(1) Definitions Anchor Devices: The anchor head wedges or nuts that grip the prestressing steel. Bearing Plate: The steel plate that evenly distributes the ground anchor force to the Structure. Bond Length: The length of the ground anchor that is bonded to the ground and transmits the tensile force to the soil or rock. Ground Anchor: A system, referred to as a tieback or as an anchor, used to transfer tensile loads to soil or rock. A ground anchor includes all prestressing steel, anchorage devices, grout, coatings, sheathings, and couplers if used. Maintaining Consistency of Load: Maintaining the test load within 5 percent of the specified value. Minimum Guaranteed Ultimate Tensile Strength (MUTS): The minimum guaranteed breaking load of the prestressing steel as defined by the specified standard. Tendon Bond Length: The length of the tendon that is bonded to the anchor grout. Tendon Unbonded Length: The length of the tendon that is not bonded to the anchor grout. Total Anchor Length: The unbonded length plus the tendon bond length. Page 6-318 2020 Standard Specifications M 41-10 6-17 Permanent Ground Anchors 6-17.3(2) Contractor Experience Requirements The Contractor or Subcontractor performing this Work shall have installed permanent ground anchors for a minimum of 3 years. Prior to the beginning of construction, the Contractor shall submit a list containing at least five projects on which the Contractor has installed permanent ground anchors. A brief description of each project and a reference shall be included for each project listed. As a minimum, the reference shall include an individual’s name and current phone number. The Contractor shall assign an engineer to supervise the Work with at least 3 years of experience in the design and construction of permanently anchored Structures. The Contractor shall not use consultants or manufacturer’s representatives in order to meet the requirements of this Section. Drill operators and on-site supervisors shall have a minimum of 1 year experience installing permanent ground anchors. Contractors or Subcontractors that are specifically prequalified in Class 36 Work will be considered to have met the above experience requirements. The Contractor shall allow up to 15 calendar days for the Engineer’s review of the qualifications and staff as noted above. Work shall not be started on any anchored wall system nor materials ordered until approval of the Contractor’s qualifications are given. 6-17.3(3) Submittals The Contractor shall submit Type 2E Working Drawings consisting of details and structural design calculations for the ground anchor system or systems intended for use. The Contractor shall submit a Type 1 Working Drawing consisting of a detailed description of the construction procedure proposed for use. The Contractor shall submit a Type 2 Working Drawing consisting of ground anchor schedule giving: 1. Ground anchor number 2. Ground anchor factored design load 3. Type and size of tendon 4. Minimum total bond length 5. Minimum anchor length 6. Minimum tendon bond length 7. Minimum unbonded length The Contractor shall submit a Type 2 Working Drawing detailing the ground anchor tendon and the corrosion protection system. Include details of the following: 1. Spacers and their location 2. Centralizers and their location 2020 Standard Specifications M 41-10 Page 6-319 Permanent Ground Anchors 6-17 3. Unbonded length corrosion protection system, including the permanent rubber seal between the trumpet and the tendon unbonded length corrosion protection and the transition between the tendon bond length and the unbonded tendon length corrosion protection. 4. Bond length corrosion protection system 5. Anchorage and trumpet 6. Anchorage corrosion protection system 7. Anchors using non-restressable anchorage devices The Contractor shall submit Type 2 Working Drawings consisting of shop plans as specified in Section 6-03.3(7) for all structural steel, including the permanent ground anchors. The Contractor shall submit Type 1 Working Drawings consisting of the mix design for the grout conforming to Section 9-20.3(4) and the procedures for placing the grout. The Contractor shall also submit the methods and materials used in filling the annulus over the unbonded length of the anchor. The Contractor shall submit Type 2 Working Drawings consisting of the method proposed to be followed for the permanent ground anchor testing. This shall include all necessary drawings and details to clearly describe the method proposed. The Contractor shall submit Type 2 Working Drawings consisting of calibration data for each load cell, test jack, pressure gauge and master pressure gauge to be used. The calibration tests shall have been performed by an independent testing Laboratory and tests shall have been performed within 60 calendar days of the date submitted. 6-17.3(4) Preconstruction Conference A permanent ground anchor preconstruction conference shall be held at least 5 working days prior to the Contractor beginning any permanent ground anchor Work at the site to discuss construction procedures, personnel, and equipment to be used. The list of materials specified on the Record of Materials Form (ROM) for this item of Work will also be discussed. Those attending shall include: 1. (representing the Contractor) The superintendent, on site supervisors, and all foremen in charge of drilling the ground anchor hole, placing the permanent ground anchor and grout, and tensioning and testing the permanent ground anchor. 2. (representing the Contracting Agency) The Engineer, key inspection personnel, and representatives from the WSDOT Construction Office and Materials Laboratory Geotechnical Services Branch. If the Contractor’s key personnel change, or if the Contractor proposes a significant revision of the approved permanent ground anchor installation plan, an additional conference shall be held before any additional permanent ground anchor operations are performed. Page 6-320 2020 Standard Specifications M 41-10 6-17 Permanent Ground Anchors 6-17.3(5) Tendon Fabrication The tendons can be either shop or field fabricated. The tendon shall be fabricated as shown in the shop plans. The Contractor shall select the type of tendon to be used. The tendon shall be sized so the factored design load does not exceed 80 percent of the minimum guaranteed ultimate tensile strength of the tendon. In addition, the tendon shall be sized so the maximum test load does not exceed 80 percent of the minimum guaranteed ultimate tensile strength of the tendon. The Contractor shall be responsible for determining the bond length and tendon bond length necessary to develop the factored design load indicated in the Plans in accordance with Sections 6-17.3(8)A, 6-17.3(8)B, and 6-17.3(8)C. The minimum bond length shall be 10 feet in rock and 15 feet in soil. When the Plans require the tendon bond length to be encapsulated, the tendon bond length portion of the tendon shall be corrosion protected by encapsulating the tendon in a grout-filled PE or PVC tube as specified in Section 6-17.2 as supplemented in the Special Provisions. The tendons can be grouted inside the encapsulation prior to inserting the tendon in the drill hole or after the tendon has been placed in the drill hole. Expansive admixtures can be mixed with the encapsulation grout if the tendon is grouted inside the encapsulation while outside the drill hole. The tendon shall be centralized within the bond length encapsulation with a minimum of 0.20 inches of grout cover. Spacers shall be used along the tendon bond length of multi-element tendons to separate the elements of the tendon so the prestressing steel will bond to the encapsulation grout. Centralizers shall be used to provide a minimum of 0.5 inches of grout cover over the tendon bond length encapsulation. Centralizers shall be securely attached to the encapsulation and the center-to-center spacing shall not exceed 10 feet. In addition, the upper centralizer shall be located a maximum of 5 feet from the top of the tendon bond length and the lower centralizer shall be located a maximum of 1 foot from the bottom of the tendon bond length. The centralizer shall be able to support the tendon in the drill hole and position the tendon so a minimum of 0.5 inches of grout cover is provided and shall permit free flow of grout. Centralizers are not required on encapsulated, pressure-injected ground anchor tendons if the ground anchor is installed in coarse grained soils (more than 50 percent of the soil larger than the number 200 sieve) using grouting pressures greater than 150 psi. Centralizers are not required on encapsulated, hollow-stem-augered ground anchor tendons if the ground anchor is grouted through and the hole is maintained full of a stiff grout (8-inch slump or less) during extraction of the auger. The minimum unbonded length of the tendon shall be the greater of 15 feet or that indicated in the Plans. 2020 Standard Specifications M 41-10 Page 6-321 Permanent Ground Anchors 6-17 Corrosion protection of the unbonded length shall be provided by a sheath completely filled with corrosion inhibiting grease or grout. If grease is used under the sheath, provisions shall be made to prevent the grease from escaping at the ends of the sheath. The grease shall completely coat the tendon and fill the voids between the tendon and the sheath. If the sheath is not fabricated from a smooth tube, a separate bond breaker shall be provided. The bond breaker shall prevent the tendon from bonding to the anchor grout surrounding the tendon unbonded length. The total anchor length shall not be less than that indicated in the Plans or the approved Working Drawing submittal. Anchorage devices shall be capable of developing 95 percent of the minimum guaranteed ultimate tensile strength of the prestressing steel tendon. The anchorage devices shall conform to the static strength requirements of Section 3.1 of the Post Tensioning Institute Specification for Unbonded Single Strand Tendons, First Edition – 1993. Non-restressable anchorage devices may be used except where indicated in the Plans. Restressable anchorages shall be provided on those ground anchors that require reloading. The post-tensioning supplier shall provide a restressable anchorage compatible with the post-tensioning system provided. The bearing plates shall be sized so the bending stresses in the plate do not exceed the yield strength of the steel when a load equal to 95 percent of the minimum guaranteed ultimate tensile strength of the tendon is applied, and the average bearing stress on the concrete does not exceed that recommended in Section 3.1.3 of the Post Tensioning Institute Specification for Unbonded Single Strand Tendons, First Edition – 1993. The trumpet shall have an inside diameter equal to or larger than the hole in the bearing plate. The trumpet shall be long enough to accommodate movements of the Structure during testing and stressing. For strand tendons with encapsulation over the unbonded length, the trumpet shall be long enough to enable the tendon to make a transition from the diameter or the tendon in the unbonded length to the diameter of the tendon at the anchor head without damaging the encapsulation. Trumpets filled with corrosion- inhibiting grease shall have a permanent rubber seal provided between the trumpet and the tendon unbonded length corrosion protection. Trumpets filled with grout shall have a temporary seal provided between the trumpet and the tendon unbonded length corrosion protection or the trumpet shall overlap the tendon unbonded length corrosion protection. Page 6-322 2020 Standard Specifications M 41-10 6-17 Permanent Ground Anchors 6-17.3(6) Tendon Storage and Handling Tendons shall be handled and stored in such a manner as to avoid damage or corrosion. Damage to the prestressing steel as a result of abrasions, cut, nicks, welds and weld splatter will be cause for rejection by the Engineer. The prestressing steel shall be protected if welding is to be performed in the vicinity. Grounding of welding leads to the prestressing steel is forbidden. Prestressing steel shall be protected from dirt, rust, and deleterious substances. A light coating of rust on the steel is acceptable. If heavy corrosion or pitting is noted, the Engineer will reject the affected tendons. The Contractor shall use care in handling and storing the tendons at the site. Prior to inserting a tendon in the drill hole, the Contractor and the Engineer will examine the tendon for damage to the encapsulation and the sheathing. If, in the opinion of the Engineer, the encapsulation is damaged, the Contractor shall repair the encapsulation in accordance with the tendon supplier’s recommendations and as approved by the Engineer. If, in the opinion of the Engineer, the smooth sheathing has been damaged, the Contractor shall repair it with ultra high molecular weight polyethylene (PE) tape. The tape shall be spiral wound around the tendon so as to completely seal the damaged area. The pitch of the spiral shall ensure a double thickness at all points. 6-17.3(7) Installing Permanent Ground Anchors The Contractor shall select the drilling method, the grouting procedure, and the grouting pressure used for the installation of the ground anchor. When caving conditions are encountered, no further drilling will be allowed until the Contractor selects a method to prevent ground movement. The Contractor may use a temporary casing. The Contractor’s method to prevent ground movement shall be submitted as a Type 2 Working Drawing. The casings for the anchor holes, if used, shall be removed. The drill hole shall be located so the longitudinal axis of the drill hole and the longitudinal axis of the tendon are parallel. The ground anchor shall not be drilled in a location that requires the tendon to be bent in order to enable the bearing plate to be connected to the supported Structure. At the point of entry the ground anchor shall be installed within plus or minus 3 degrees of the inclination from horizontal shown in the Plans or the Working Drawing submittal. The ground anchors shall not extend beyond the Right of Way limits. The tendon shall be inserted into the drill hole to the desired depth. When the tendon cannot be completely inserted without difficulty, the Contractor shall remove the tendon from the drill hole and clean or redrill the hole to permit insertion. Partially inserted tendons shall not be driven or forced into the hole. The Contractor shall use a grout conforming to Section 6-17.2 as supplemented in the Special Provisions. 2020 Standard Specifications M 41-10 Page 6-323 Permanent Ground Anchors 6-17 The grout equipment shall produce a grout free of lumps and undispersed cement. A positive displacement grout pump shall be used. The pump shall be equipped with a pressure gauge near the discharge end to monitor grout pressures. The pressure gauge shall be capable of measuring pressures of at least 150 psi or twice the actual grout pressures used by the Contractor, whichever is greater. The grouting equipment shall be sized to enable the grout to be pumped in one continuous operation. The mixer shall be capable of continuously agitating the grout. The grout shall be injected from the lowest point of the drill hole. The grout may be pumped through grout tubes, casing, or drill rods. The grout can be placed before or after insertion of the tendon. The quantity of the grout and the grout pressures shall be recorded. The grout pressures and grout takes shall be controlled to prevent excessive heave in soils or fracturing of rock formations. The Contractor shall make and cure grout cubes once per day in accordance with WSDOT T 813. These samples shall be retained by the Contractor until all associated verification, performance and proof testing of the permanent ground anchors has been successfully completed. If the Contractor elects to test the grout cubes for compressive strength, testing shall be conducted by an independent laboratory and shall be in accordance with the FOP for AASHTO T 106. After grouting, the tendon shall not be loaded for a minimum of 3 days. No grout shall be placed above the top of the bond length during the time the bond length grout is placed. The grout at the top of the drill hole shall not contact the back of the Structure or the bottom of the trumpet. Except as otherwise noted, only nonstructural filler shall be placed above the bond length grout prior to testing and acceptance of the anchor. The Contractor may place structural grout above the bond length grout prior to testing and acceptance of the anchor subject to the following conditions: 1. The anchor unbonded length shall be increased by 8 feet minimum. 2. The grout in the unbonded zone shall not be placed by pressure grouting methods. The corrosion protection surrounding the unbonded length of the tendon shall extend up beyond the bottom seal of the trumpet or 1 foot into the trumpet if no trumpet seal is provided. If the protection does not extend beyond the seal or sufficiently far enough into the trumpet, the Contractor shall extend the corrosion protection or lengthen the trumpet. The corrosion protection surrounding the no load zone length of the tendon shown in the Plans shall not contact the bearing plate or the anchor head during testing and stressing. If the protection is too long, the Contractor shall trim the corrosion protection to prevent contact. Page 6-324 2020 Standard Specifications M 41-10 6-17 Permanent Ground Anchors The bearing plate and anchor head shall be placed so the axis of the tendon and the drill hole are both perpendicular to the bearing plate within plus or minus 3 degrees and the axis of the tendon passes through the center of the bearing plate at the intersection of the trumpet and the bearing plate when fully seated with the alignment load. The trumpet shall be completely filled with corrosion inhibiting grease or grout. Trumpet grease can be placed anytime during construction. Trumpet grout shall be placed after the ground anchor has been tested. The Contractor shall demonstrate to the Engineer that the procedure selected by the Contractor for placement of either grease or grout produces a completely filled trumpet. All anchorages permanently exposed to the atmosphere shall be covered with a corrosion inhibiting grease-filled or grout-filled cover. The Contractor shall demonstrate to the Engineer that the procedures selected by the Contractor for placement of either grease or grout produces a completely filled cover. If the Plans require restressable anchorages, corrosion inhibiting grease shall be used to fill the anchorage cover and trumpet. 6-17.3(8) Testing and Stressing Each ground anchor shall be tested. The test load shall be simultaneously applied to the entire tendon. Stressing of single elements of multi-element tendons will not be permitted. The Engineer will record test data. The testing equipment shall consist of a dial gauge or vernier scale capable of measuring to 0.001 inch and shall be used to measure the ground anchor movement. The movement-measuring device shall have a minimum travel equal to the theoretical elastic elongation of the total anchor length plus 1 inch. The dial gauge or vernier scale shall be aligned so that its axis is within 5 degrees from the axis of the tieback. A hydraulic jack and pump shall be used to apply the test load. The jack and pressure gauge shall be calibrated by an independent testing Laboratory as a unit. Each load cell, test jack and pressure gauge, and master pressure gauge, shall be calibrated as specified in Section 6-17.3(3). Additionally, the Contractor shall not use load cells, test jacks and pressure gauges, and master pressure gauges, greater than 60 calendar days past their most recent calibration date, until such items are re-calibrated by an independent testing Laboratory. The pressure gauge shall be graduated in increments of either 100 psi or 2 percent of the maximum test load, whichever is less. The pressure gauge will be used to measure the applied load. The pressure gauge shall be selected to place the maximum test load within the middle ⅔ of the range of the gauge. The ram travel of the jack shall not be less than the theoretical elastic elongation of the total anchor length at the maximum test load plus 1 inch. The jack shall be independently supported and centered over the tendon so that the tendon does not carry the weight of the jack. The Contractor shall have a second calibrated jack pressure gauge at the site. Calibration data shall provide a specific reference to the jack and the pressure gauge. The loads on the tiebacks during the performance and verification tests shall be monitored to verify consistency of load as defined in Section 6-17.3(1). Performance test loads, and verification test loads when specified in the Special Provisions, sustained for 2020 Standard Specifications M 41-10 Page 6-325 Permanent Ground Anchors 6-17 5 minutes or less, and all proof test leads, shall be monitored by the jack pressure gauge alone. Performance test loads, and verification test loads when specified in the Special Provisions, sustained for longer than 5 minutes shall be monitored with the assistance of an electric or hydraulic load cell. The Contractor shall provide the load cell and a readout device. The load cell shall be mounted between the jack and the anchor plate. The load cell shall be selected to place the maximum test load within the middle ⅔ of the range of the load cell. The stressing equipment shall be placed over the ground anchor tendon in such a manner that the jack, bearing plates, load cell and stressing anchorage are in alignment. The permanent ground anchor load monitoring procedure for performance test loads, and verification test loads when specified in the Special Provisions, sustained for longer than 5 minutes shall be as follows: 1. For each increment of load, attainment of the load shall be initially established and confirmed by the reading taken from the jack gauge. 2. Once the permanent ground anchor load has been stabilized, based on the jack gauge reading, the load cell readout device shall immediately be read and recorded to establish the load cell reading to be used at this load. The load cell reading is intended only as a confirmation of a stable permanent ground anchor load, and shall not be taken as the actual load on the permanent ground anchor. 3. During the time period that the load on the permanent ground anchor is held at this load increment, the Contractor shall monitor the load cell reading. The Contractor shall adjust the jack pressure as necessary to maintain the initial load cell reading. Jack pressure adjustment for any other reason will not be allowed. 4. Permanent ground anchor elongation measurements shall be taken at each load increment as specified in Sections 6-17.3(8)A and 6-17.3(8)B. 5. Steps 1 through 4 shall be repeated at each increment of load, in accordance with the load sequence specified in Sections 6-17.3(8)A and 6-17.3(8)B. 6-17.3(8)A Verification Testing Verification tests will be required only when specified in the Special Provisions. 6-17.3(8)B Performance Testing Performance tests shall be done in accordance with the following procedures. Five percent of the ground anchors or a minimum of three ground anchors, whichever is greater, shall be performance tested. The Engineer shall select the ground anchors to be performance tested. The first production anchor shall be performance tested. The performance test shall be made by incrementally loading and unloading the ground anchor in accordance with the following schedule, consistent with the Load Resistance Factor Design (LRFD) design method. The load shall be raised from one increment to another immediately after a deflection reading. Page 6-326 2020 Standard Specifications M 41-10 6-17 Permanent Ground Anchors Performance Test Schedule Load AL 0.25FDL AL 0.25FDL 0.50FDL AL 0.25FDL 0.50FDL 0.75FDL AL 0.25FDL 0.50FDL 0.75FDL 1.00FDL AL Jack to lock-off load Where: AL is the alignment load FDL is the factored design load. The maximum test load in a performance test shall be held for 10 minutes. The load-hold period shall start as soon as the maximum test load is applied and the anchor movement, with respect to a fixed reference, shall be measured and recorded at 1, 2, 3, 4, 5, 6, and 10 minutes. If the anchor movement between 1 and 10 minutes exceeds 0.04 inches, the maximum test load shall be held for an additional 50 minutes. If the load-hold is extended, the anchor movement shall be recorded at 20, 30, 40, 50, and 60 minutes. If an anchor fails in creep, retesting will not be allowed. All anchors not performance tested shall be proof tested. 6-17.3(8)C Proof Testing Proof tests shall be performed by incrementally loading the ground anchor in accordance with the following schedule, consistent with the LRFD design method. The load shall be raised from one increment to another immediately after a deflection reading. The anchor movement shall be measured and recorded to the nearest 0.001 inches with respect to an independent fixed reference point at the alignment load and at each increment of load. The load shall be monitored with a pressure gauge. At load increments other than the maximum test load, the load shall be held just long enough to obtain the movement reading. 2020 Standard Specifications M 41-10 Page 6-327 Permanent Ground Anchors 6-17 Proof Test Schedule Load AL 0.25FDL 0.50FDL 0.75FDL 1.00FDL Jack to lock-off load Where: AL is the alignment load FDL is the factored design load The maximum test load in a proof test shall be held for 10 minutes. The load-hold period shall start as soon as the maximum test load is applied and the anchor movement with respect to a fixed reference shall be measured and recorded at 1, 2, 3, 4, 5, 6, and 10 minutes. If the anchor movement between 1 and 10 minutes exceeds 0.04 inches, the maximum test load shall be held of an additional 50 minutes. If the load-hold is extended, the anchor movements shall be recorded at 20, 30, 40, 50, and 60 minutes. If an anchor fails in creep, retesting will not be allowed. 6-17.3(9) Permanent Ground Anchor Acceptance Criteria A performance or proof tested ground anchor with a 10 minute load hold is acceptable if the: 1. Ground anchor carries the maximum test load with less than 0.04 inches of movement between 1 and 10 minutes; and 2. Total movement at the maximum test load exceeds 80 percent of the theoretical elastic elongation of the tendon unbonded length. A verification, performance or proof tested ground anchor with a 60-minute load hold is acceptable if the: 1. Ground anchor carries the maximum test load with a creep rate that does not exceed 0.08 inches/log cycle of time and is a linear or decreasing creep rate. 2. Total movement at the maximum test load exceeds 80 percent of the theoretical elastic elongation of the tendon unbonded length. If the total movement of the ground anchors at the maximum test load does not exceed 80 percent of the theoretical elastic elongation of the tendon unbonded length, the Contractor shall replace the ground anchor at no additional cost to the Contracting Agency. Retesting of a ground anchor will not be allowed. When a ground anchor fails, the Contractor shall modify the design, the construction procedures, or both. These modifications may include, but are not limited to, installing replacement ground anchors, modifying the installation methods, increasing the bond length or changing the ground anchor type. Any modification that requires changes to Page 6-328 2020 Standard Specifications M 41-10 6-17 Permanent Ground Anchors the Structure shall have prior approval of the Engineer. Any modifications of design or construction procedures shall be at the Contractor’s expense. Upon completion of the test, the load shall be adjusted to the lock-off load indicated in the Plans and transferred to the anchorage device. The ground anchor may be completely unloaded prior to lock-off. After transferring the load and prior to removing the jack a lift- off reading shall be made. The lift-off reading shall be within 10 percent of the specified lock-off load. If the load is not within 10 percent of the specified lock-off load, the anchorage shall be reset and another lift-off reading shall be made. This process shall be repeated until the desired lock-off load is obtained. 6-17.4 Measurement Permanent ground anchors will be measured per each for each permanent ground anchor installed and accepted. Permanent ground anchor performance tests will be measured per each for each anchor performance tested. The permanent ground anchor verification testing program will not be measured but will be paid for on a lump sum basis. 6-17.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Permanent Ground Anchor”, per each. All costs in connection with furnishing and installing permanent ground anchors shall be included in the unit Contract price per each for “Permanent Ground Anchor”, including proof testing of the installed anchor as specified “Permanent Ground Anchor Performance Test”, per each. “Permanent Ground Anchor Verification Test”, lump sum. 2020 Standard Specifications M 41-10 Page 6-329 Shotcrete Facing 6-18 6-18 Shotcrete Facing 6-18.1 Description This Work consists of constructing shotcrete facing as shown on the Plans. Shotcrete constructed as concrete slope protection shall be constructed in accordance with Section 8-16. 6-18.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Portland Cement Concrete 9-03.1 Premolded Joint Filler 9-04.1(2) Steel Reinforcing Bar 9-07.2 Epoxy-Coated Steel Reinforcing Bar 9-07.3 Concrete Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Ground Granulated Blast Furnace Slag 9-23.10 Microsilica Fume 9-23.11 Water 9-25 Other materials required, including materials for shotcrete, shall be as specified in the Special Provisions. 6-18.3 Construction Requirements 6-18.3(1) Submittals The Contractor shall submit Type 2 Working Drawings consisting of the following: 1. The shotcrete mix design with compressive strength test results. 2. Method and equipment used to apply, finish and cure the shotcrete facing. 3. Documentation of the experience of the nozzle operators in applying shotcrete. 6-18.3(2) Mix Design Shotcrete shall be proportioned to produce a 4,000 psi compressive strength at 28 days. Admixture shall be used only after receiving permission from the Engineer. If admixtures are used to entrain air, to reduce water-cement ratio, to retard or accelerate setting time, or to accelerate the development of strength, the admixtures shall be used at the rate specified by the manufacturer. Page 6-330 2020 Standard Specifications M 41-10 6-18 Shotcrete Facing 6-18.3(3) Testing The Contractor shall make shotcrete test panels for evaluation of shotcrete quality, strength, and aesthetics. Both preproduction and production test panels shall be prepared. The Contractor shall remove at least three cores from shotcrete test panels in accordance with ASTM C1604, except all cores obtained for the purpose of shotcrete strength testing shall meet the following: 1. The core diameter shall be at least 3.0 times the maximum aggregate size, but not less than 4 inches. 2. The core length shall be a minimum of 2.0 times the core diameter. 3. Cores shall be taken at a minimum distance of 1 inch from edge of core to edge of test panel and a minimum clear distance of 1 inch between them. 4. Test panels shall be sized to meet the core spacing specified above, but in no case shall be smaller than 12 by 12 inch. Cores removed from the panels shall be wiped off to remove surface drill water and immediately wrapped in wet burlap and sealed in a plastic bag. Cores shall be clearly marked to identify from where they were taken and whether they are for preproduction or production testing. If for production testing, the section of the wall represented by the cores shall be clearly marked on the cores. Cores shall be delivered to the Engineer within 2 hours of coring. The remainder of the panels shall remain the property of the Contractor. 6-18.3(3)A Preproduction Testing At least three cores for each mix design shall be prepared for evaluation and testing of the shotcrete quality and strength. One 48 by 48-inch qualification panel shall be prepared for evaluation and approval of the proposed method for shotcrete installation, finishing, and curing. Both the test panel and the 48-inch qualification panels shall be constructed using the same methods and initial curing proposed to construct the shotcrete facing, except that the test panel shall not include wire reinforcement. The test panel shall be constructed to the minimum thickness necessary to obtain the required core samples. The 48-inch qualification panel shall be constructed to the same thickness as proposed for the production facing. Production shotcrete Work shall not begin until satisfactory test results are obtained and the panels are accepted by the Engineer. 6-18.3(3)B Production Testing The Contractor shall provide three cores for each section of facing shot. The production panels shall be constructed using the same methods and initial curing used to construct the shotcrete wall, but without wire reinforcement. The panels shall be constructed to the minimum thickness necessary to obtain the required core samples. If the production shotcrete is found to be unsuitable based on the results of the test panels, the section(s) of the wall represented by the test panel(s) shall be repaired or replaced to the satisfaction of the Engineer at no additional cost to the Contracting Agency. Core acceptance testing for the 28-day compressive strength will be performed in accordance with ASTM C1604. 2020 Standard Specifications M 41-10 Page 6-331 Shotcrete Facing 6-18 6-18.3(4) Qualifications of Contractor’s Personnel All nozzle operators shall have had at least 1 year of experience in the application of shotcrete. Each nozzle operator will be qualified, by the Engineer, to place shotcrete, after successfully completing one test panel for each shooting position and surface type which will be encountered. Qualification will be based on a visual inspection of the shotcrete density, void structure, and finished appearance along with a minimum 7-day compressive strength of 2,500 psi determined from the average test results from two cores taken from each test panel. The 7-day core compressive strength shall be tested by the Contractor in accordance with ASTM C1604. The Contractor shall notify the Engineer not less than 2 days prior to the shooting of a qualification panel. The mix design for the shotcrete shall be the same as that slated for the wall being shot. Shotcrete shall be placed only by personnel qualified by the Engineer. If shotcrete finish Alternative B or C is specified, evidence shall be provided that all shotcrete crew members have completed at least three projects in the last 5 years where such finishing, or sculpturing and texturing of shotcrete was performed. 6-18.3(5) Placing Wire Reinforcement Reinforcement of the shotcrete shall be placed as shown in the Plans. The wire reinforcement shall be securely fastened to the steel reinforcing bars so that it will be 1 to 1.5 inches from the face of the shotcrete at all locations, unless otherwise shown in the Plans. Wire reinforcement shall be lapped 1.5 squares in all directions, unless otherwise shown in the Plans. 6-18.3(6) Alignment Control The Contractor shall install non-corroding alignment wires and thickness control pins to establish thickness and plane surface. The Contractor shall install alignment wires at corners and offsets not established by formwork. The Contractor shall ensure that the alignment wires are tight, true to line, and placed to allow further tightening. The Contractor shall remove the alignment wires after facing construction is complete. 6-18.3(7) Shotcrete Application A clean, dry supply of compressed air sufficient for maintaining adequate nozzle velocity for all parts for the Work and for simultaneous operation of a blow pipe for cleaning away rebound shall be maintained at all times. Thickness, method of support, air pressure, and rate of placement of shotcrete shall be controlled to prevent sagging or sloughing of freshly applied shotcrete. Page 6-332 2020 Standard Specifications M 41-10 6-18 Shotcrete Facing The shotcrete shall be applied from the lower part of the area upwards. Surfaces to be shot shall be damp, but free of standing water. The nozzles shall be held at an angle approximately perpendicular to the working face and at a distance that will keep rebound at a minimum and compaction will be maximized. Shotcrete shall emerge from the nozzle in a steady uninterrupted flow. If, for any reason, the flow becomes intermittent, the nozzle shall be diverted from the Work until a steady flow resumes. Surface defects shall be repaired as soon as possible after initial placement of the shotcrete. All shotcrete which lacks uniformity; which exhibits segregation, honeycombing, or lamination; or which contains any dry patches, slugs, voids, or sand pockets, shall be removed and replaced with fresh shotcrete by the Contractor, to the satisfaction of the Engineer at no cost to the Contracting Agency. Construction joints in the shotcrete shall be uniformly tapered over a minimum distance of twice the thickness of the shotcrete layer. The surface of the joints shall be cleaned and thoroughly wetted before adjacent shotcrete is placed. Shotcrete shall be placed in a manner that provides a finish with uniform texture and color across the construction joint. The shotcrete shall be cured by applying a clear curing compound in accordance with Section 9-23.2. The curing compound shall be applied immediately after final gunning. Two coats of curing compound shall be applied to the shotcrete surface immediately after finishing. When shotcrete is specified in the Plans as the final fascia finish, the curing requirements specified in Section 6-02.3(11) shall apply. If field inspection or testing, by the Engineer, indicates that any shotcrete produced, fails to meet the requirements, the Contractor shall immediately modify procedures, equipment, or system, as necessary to produce Specification Material. All substandard shotcrete already placed shall be repaired by the Contractor, to the satisfaction of the Engineer, at no additional cost to the Contracting Agency. Such repairs may include removal and replacement of all affected materials. 6-18.3(8) Shotcrete Finishing When the shotcrete facing is an interim coating to be covered by a subsequent shotcrete coating or a cast-in-place concrete fascia later under the same Contract, the Contractor shall strike off the surface of the shotcrete facing with a roughened surface as specified in Section 6-02.3(12). The grooves of the roughened surface shall be either vertical or horizontal. When the shotcrete facing provides the finished exposed final surface, the shotcrete face shall be finished using the alternative aesthetic treatment shown in the Plans. The alternatives are as follows: • Alternative A – After the surface has taken its initial set (crumbling slightly when cut), the surface shall be broom finished to secure a uniform surface texture. • Alternative B – Shotcrete shall be applied in a thickness a fraction beyond the alignment wires and forms. The shotcrete shall stiffen to the point where the surface does not pull or crack when screeded with a rod or trowel. Excess material shall be trimmed, sliced, or scraped to true lines and grade. Alignment wires shall be removed 2020 Standard Specifications M 41-10 Page 6-333 Shotcrete Facing 6-18 and the surface shall receive a steel trowel finish, leaving a smooth uniform texture and color. Once the shotcrete has cured, pigmented sealer shall be applied to the shotcrete face. The shotcrete surface shall be completed to within a tolerance of ½ inch of true line and grade. • Alternative C – Shotcrete shall be hand-sculptured, colored, and textured to simulate the relief, jointing, and texture of the natural backdrop surrounding the facing. The ends and base of the facing shall transition in appearance as appropriate to more nearly match the color and texture of the adjoining Roadway fill slopes. This may be achieved by broadcasting fine and coarse aggregates, rocks, and other native materials into the final surface of the shotcrete while it is still wet, allowing sufficient embedment into the shotcrete to become a permanent part of the surface. 6-18.4 Measurement Shotcrete facing will be measured by the square foot surface area of the completed facing measured to the neat lines of the facing as shown in the Plans. 6-18.5 Payment Payment will be made for each of the following Bid items when they are included in the Proposal: “Shotcrete Facing”, per square foot. All costs in connection with constructing shotcrete facing as specified shall be included in the unit Contract price per square foot for “Shotcrete Facing” including all steel reinforcing bars, premolded joint filler, polyethylene bond breaker strip, joint sealant, PVC pipe for weep holes, exterior surface finish, and pigmented sealer (when specified). Page 6-334 2020 Standard Specifications M 41-10 6-19 Shafts 6-19 Shafts 6-19.1 Description This work consists of constructing the shafts in accordance with the Plans, these Specifications, and as designated by the Engineer. 6-19.2 Materials Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Concrete 9-03.1 Steel Reinforcing Bar 9-07.2 Epoxy-Coated Steel Reinforcing Bar 9-07.3 Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Ground Granulated Blast Furnace Slag 9-23.10 Microsilica Fume 9-23.11 Water for Concrete 9-25.1 Permanent Casing 9-36.1(1) Temporary Casing 9-36.1(2) Mineral Slurry 9-36.2(1) Synthetic Slurry 9-36.2(2) Water Slurry 9-36.2(3) Steel Reinforcing Bar Centralizers 9-36.3 Access Tubes and Caps 9-36.4 Grout for Access Tubes 9-36.5 6-19.3 Construction Requirements 6-19.3(1) Quality Assurance 6-19.3(1)A Shaft Construction Tolerances Shafts shall be constructed so that the center at the top of the shaft is within the following horizontal tolerances: Shaft Diameter (feet)Tolerance (inches) Less than or equal to 2 3 Greater than 2 and less than 5 4 5 or larger 6 Shafts shall be within 1.5 percent of plumb. For rock excavation, allowable tolerance can be increased to 2 percent maximum. 2020 Standard Specifications M 41-10 Page 6-335 Shafts 6-19 During drilling or excavation of the shaft, the Contractor shall make frequent checks on the plumbness, alignment, and dimensions of the shaft. Any deviation exceeding the allowable tolerances shall be corrected with a procedure approved by the Engineer. Shaft steel reinforcing bar placement tolerances shall conform to Section 6-02.3(24)C. The elevation of the top of the reinforcing cage for drilled shafts shall be within +6 inches and -3 inches from the elevation shown in the Plans. 6-19.3(1)B Nondestructive Testing of Shafts 6-19.3(1)B1 Nondestructive Quality Assurance (QA) Testing of Shafts Unless otherwise specified in the Special Provisions, the Contractor shall perform nondestructive QA testing of shafts, except for those constructed completely in the dry. Either crosshole sonic log (CSL) testing in accordance with ASTM D 6760 or thermal integrity profiling (TIP) testing in accordance with ASTM D 7949 shall be used. 6-19.3(1)B2 Nondestructive Quality Verification (QV) Testing of Shafts The Contracting Agency may perform QV nondestructive testing of shafts that have been QA tested by the Contractor. The Contracting Agency may test up to ten percent of the shafts. The Engineer will identify the shafts selected for QV testing and the testing method the Contracting Agency will use. The Contractor shall accommodate the Contracting Agency’s nondestructive testing. 6-19.3(1)C Shaft Preconstruction Conference A shaft preconstruction conference shall be held at least 5 working days prior to the Contractor beginning any shaft construction work at the site to discuss construction procedures, personnel, and equipment to be used, and other elements of the approved shaft installation narrative as specified in Section 6-19.3(2)B. Those attending shall include: 1. (Representing the Contractor) – The superintendent, on site supervisors, and all foremen in charge of excavating the shaft, placing the casing and slurry as applicable, placing the steel reinforcing bars, and placing the concrete. If synthetic slurry is used to construct the shafts, the slurry manufacturer’s representative or approved Contractor’s employees trained in the use of the synthetic slurry shall also attend. 2. (Representing the Contracting Agency) – The Engineer, key inspection personnel, and representatives from the WSDOT Construction Office and Materials Laboratory, Geotechnical Division. If the Contractor proposes a significant revision of the approved shaft installation narrative, as determined by the Engineer, an additional conference shall be held before any additional shaft construction operations are performed. Page 6-336 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(2) Shaft Construction Submittal The shaft construction submittal shall be comprised of the following four components: construction experience; shaft installation narrative; shaft slurry technical assistance; and nondestructive QA testing personnel. The submittals shall be Type 2 Working Drawings, except the shaft slurry technical assistance and nondestructive QA testing personnel submittals shall be Type 1. 6-19.3(2)A Construction Experience The Contractor shall submit a project reference list to the Engineer for approval verifying the successful completion by the Contractor of at least three separate foundation projects with shafts of diameters and depths similar to or larger than those shown in the Plans, and ground conditions similar to those identified in the Contract. A brief description of each listed project shall be provided along with the name and current phone number of the project owner or the owner’s Contractor. The Contractor shall submit a list identifying the on-site supervisors and drill rig operators potentially assigned to the project to the Engineer. The list shall contain a brief description of each individual’s experience in shaft excavation operations and placement of assembled steel reinforcing bar cages and concrete in shafts. The individual experience lists shall be limited to a single page for each supervisor or operator. 1. On-site supervisors shall have a minimum 2 years experience in supervising construction of shaft foundations of similar size (diameter and depth) and scope to those shown in the Plans, and similar geotechnical conditions to those described in the boring logs and summary of geotechnical conditions. Work experience shall be direct supervisory responsibility for the on-site shaft construction operations. Project management level positions indirectly supervising on-site shaft construction operations is not acceptable for this experience requirement. 2. Drill rig operators shall have a minimum of 1 year experience in construction of shaft foundations. The Engineer may suspend the shaft construction if the Contractor substitutes unapproved personnel. The Contractor shall be fully liable for the additional costs resulting from the suspension of work, and no adjustments in contract time resulting from the suspension of work will be allowed. 6-19.3(2)B Shaft Installation Narrative The Contractor shall submit a shaft installation narrative to the Engineer. In preparing the narrative, the Contractor shall reference the available subsurface data provided in the contract test hole boring logs, the Summary of Geotechnical Conditions provided in the Appendix to the Special Provisions, and the geotechnical report(s) prepared for this project. This narrative shall provide at least the following information: 1. Proposed overall construction operation sequence. 2. Description, size, and capacities of proposed equipment, including but not limited to, cranes, drills, auger, bailing buckets, final cleaning equipment, and drilling unit. The 2020 Standard Specifications M 41-10 Page 6-337 Shafts 6-19 narrative shall describe why the equipment was selected, and describe equipment suitability to the anticipated site conditions and work methods. The narrative shall include a project history of the drilling equipment demonstrating the successful use of the equipment on shafts of equal or greater size in similar soil/rock conditions. The narrative shall also include details of shaft excavation and cleanout methods. 3. Details of the method(s) to be used to ensure shaft stability (i.e., prevention of caving, bottom heave, using temporary casing, slurry, or other means) during excavation (including pauses and stoppages during excavation) and concrete placement. If permanent casings are required, casing dimensions and detailed procedures for installation shall be provided. 4. A slurry mix design, including all additives and their specific purpose in the slurry mix, with a discussion of its suitability to the anticipated subsurface conditions, shall be submitted and include the procedures for mixing, using, and maintaining the slurry. A detailed plan for quality control of the selected slurry, including tests to be performed, test methods to be used, and minimum and/or maximum property requirements which must be met to ensure the slurry functions as intended, considering the anticipated subsurface conditions and shaft construction methods, in accordance with the slurry manufacturer’s recommendations and these Special Provisions shall be included. As a minimum, the slurry quality control plan shall include the following tests: Property Test Method Density Mud Weight (Density), API 13B-1, Section 1 Viscosity Marsh Funnel and Cup, API 13B-1, Section 2.2 PH Glass Electrode, pH Meter, or pH Paper Sand Content Sand, API 13B-1, Section 5 5. Description of the method used to fill or eliminate all voids below the top of shaft between the plan shaft diameter and excavated shaft diameter, when permanent casing is specified. 6. Details of concrete placement, including proposed operational procedures for pumping methods, and a sample uniform yield form to be used by the Contractor for plotting the approximate volume of concrete placed versus the depth of shaft for all shaft concrete placement (except concrete placement in the dry). 7. When shafts are constructed in water, the submittal shall include seal thickness calculations, seal placement procedure, and descriptions of provisions for casing shoring dewatering and flooding. 8. Description and details of the storage and disposal plan for excavated material and drilling slurry (if applicable). Page 6-338 2020 Standard Specifications M 41-10 6-19 Shafts 9. Reinforcing steel shop drawings with details of reinforcement placement, including bracing, centering, and lifting methods, and the method to ensure the reinforcing cage position is maintained during construction, including use of bar boots and/or rebar cage base plates, and including placement of rock backfill below the bottom of shaft elevation, provided the conditions of Section 6-19.3(5)D are satisfied. The reinforcing steel shop drawings and shaft installation narrative shall include, at a minimum: a. Procedure and sequence of steel reinforcing bar cage assembly. b. The tie pattern, tie types, and tie wire gages for all ties on permanent reinforcing and temporary bracing. c. Number and location of primary handling steel reinforcing bars used during lifting operations. d. Type and location of all steel reinforcing bar splices. e. Details and orientation of all internal cross-bracing, including a description of connections to the steel reinforcing bar cage. f. Description of how temporary bracing is to be removed. g. Location of support points during transportation. h. Cage weight and location of the center of gravity. i. Number and location of pick points used for lifting for installation and for transport (if assembled off-site). j. Crane charts and a description and/or catalog cuts for all spreaders, blocks, sheaves, and chockers used to equalize or control lifting loads. k. The sequence and minimum inclination angle at which intermediate belly rigging lines (if used) are released. l. Pick point loads at 0, 45, 60, and 90 degrees and at all intermediate stages of inclination where rigging lines are engaged or slackened. m. Methods and temporary supports required for cage splicing. n. For picks involving multiple cranes, the relative locations of the boom tips at various stages of lifting, along with corresponding net horizontal forces imposed on each crane. The Engineer will evaluate the shaft installation narrative for conformance with the Plans, Specifications, and Special Provisions, within the review time specified. If deemed necessary by the Engineer, a Shaft Installation Narrative Submittal Teleconference Meeting will be scheduled by the Contracting Agency following review of the Contractor’s initial submittal of the narrative and prior to Contracting Agency’s formal response to the initial submittal. Teleconference participants shall include the following: 2020 Standard Specifications M 41-10 Page 6-339 Shafts 6-19 1. (Representing the Contractor) – The superintendent, on-site supervisors, and other Contractor personnel involved in the preparation of the shaft installation narrative. 2. (Representing the Contracting Agency) – The Engineer, key inspection personnel, and representatives from the Materials Laboratory, Geotechnical Division, and the WSDOT Construction Office. 6-19.3(2)C Shaft Slurry Technical Assistance If slurry other than water slurry is used to construct the shafts, the Contractor shall provide or arrange for technical assistance in the use of the slurry as specified in Section 6-19.3(4)A. The Contractor shall submit the following to the Engineer: 1. The name and current phone number of the slurry manufacturer’s technical representative assigned to the project, and the frequency of scheduled visits to the project site by the synthetic slurry manufacturer’s representative. 2. The name(s) of the Contractor’s personnel assigned to the project and trained by the slurry manufacturer in the proper use of the slurry. The submittal shall include a signed training certification letter from the slurry manufacturer for each trained Contractor’s employee listed, including the date of the training. 6-19.3(2)D Nondestructive QA Testing Organization and Personnel The Contractor shall submit the names of the testing organizations, and the names of the personnel who will conduct nondestructive QA testing of shafts. The submittal shall include documentation that the qualifications specified below are satisfied. For TIP testing, the testing organization is the group that performs the data analysis and produces the final report. The testing organizations and the testing personnel shall meet the following minimum qualifications: 1. The testing organization shall have performed nondestructive tests on a minimum of three deep foundation projects in the last two years. 2. Personnel conducting the tests for the testing organization shall have a minimum of one year experience in nondestructive testing and interpretation. 3. The experience requirements for the organization and personnel shall be consistent with the testing methods the Contractor has selected for nondestructive testing of shafts. 4. Personnel preparing test reports shall be a Professional Engineer, licensed under Title 18 RCW, State of Washington, and shall seal the report in accordance with WAC 196-23-020. Page 6-340 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(3) Shaft Excavation Shafts shall be excavated to the required depth as shown in the Plans. Shaft excavation operations shall conform to this section and the shaft installation narrative. Shaft excavation shall not be started until the Contractor has received the Engineer’s acceptance for the reinforcing steel centralizers required when the casing is to be pulled during concrete placement. Except as otherwise noted, the Contractor shall not commence subsequent shaft excavations until receiving the Engineer’s acceptance of the first shaft, based on the results and analysis of the nondestructive testing for the first shaft. The Contractor may commence subsequent shaft excavations prior to receiving the Engineer’s acceptance of the first shaft, provided the following condition is satisfied: The Engineer permits continuing with shaft construction based on the Engineer’s observations of the construction of the first shaft, including, but not limited to, conformance to the shaft installation narrative in accordance with Section 6-19.3(2)B, and the Engineer’s review of Contractor’s daily reports and Inspector’s daily logs concerning excavation, steel reinforcing bar placement, and concrete placement. 6-19.3(3)A Conduct of Shaft Excavation Operations Once the excavation operation has been started, the excavation shall be conducted in a continuous operation until the excavation of the shaft is completed, except for pauses and stops as noted, using approved equipment capable of excavating through the type of material expected. Pauses during this excavation operation, except for casing splicing, tooling changes, slurry maintenance, and removal of obstructions, are not allowed. Pauses, defined as momentary interruptions of the excavation operation, will be allowed only for casing splicing, tooling changes, slurry maintenance, and removal of obstructions. Shaft excavation operation interruptions not conforming to this definition shall be considered stops. Stops for uncased excavations (including partially cased excavations) shall not exceed 16 hours duration. Stops for fully cased excavations, excavations in rock, and excavations with casing seated into rock, shall not exceed 65 hours duration. For stops exceeding the time durations specified above, the Contractor shall stabilize the excavation using one or both of the following methods: 1. For an uncased excavation, before the end of the work day, install casing in the hole to the depth of the excavation. The outside diameter of the casing shall not be smaller than 6 inches less than either the plan diameter of the shaft or the actual excavated diameter of the hole, whichever is greater. Prior to removing the casing and resumption of shaft excavation, the annular space between the casing and the excavation shall be sounded. If the sounding operation indicates that caving has occurred, the casing shall not be removed and shaft excavation shall not resume until the Contractor has stabilized the excavation in accordance with the shaft installation narrative conforming to Section 6-19.3(2)B, item 3. 2020 Standard Specifications M 41-10 Page 6-341 Shafts 6-19 2. For both a cased and uncased excavation, backfill the hole with either CDF or granular material. The Contractor shall backfill the hole to the ground surface, if the excavation is not cased, or to a minimum of 5 feet above the bottom of casing (temporary or permanent), if the excavation is cased. Backfilling of shafts with casing fully seated into rock, as determined by the Engineer, will not be required. During stops, the Contractor shall stabilize the shaft excavation to prevent bottom heave, caving, head loss, and loss of ground. The Contractor bears full responsibility for selection and execution of the method(s) of stabilizing and maintaining the shaft excavation, in accordance with Section 1-07.13. Shaft stabilization shall conform to the shaft installation narrative in accordance with Section 6-19.3(2)B, item 3. If slurry is present in the shaft excavation, the Contractor shall conform to the requirements of Section 6-19.3(4)B of this Special Provision regarding the maintenance of the slurry and the minimum level of drilling slurry throughout the stoppage of the shaft excavation operation, and shall recondition the slurry to the required slurry properties in accordance with Section 9-36.2 prior to recommencing shaft excavation operations. 6-19.3(3)B Temporary and Permanent Shaft Casing The Contractor shall furnish and install required temporary and permanent shaft casings as shown in the Plans and as specified in the Special Provisions. 6-19.3(3)B1 General Shaft Casing Requirements Shaft casing shall be watertight and clean prior to placement in the excavation. The outside diameter of the casing shall not be less than the specified diameter of the shaft. The inside diameter of the casing shall not be greater than the specified diameter of the shaft plus 6 inches, except as otherwise noted for shafts 5 feet or less in diameter, and as otherwise noted in Section 6-19.3(3)B4 for temporary telescoping casing. The inside diameter of casings for shafts 5 feet or less in diameter shall not be greater than the specified diameter of the shaft plus 1 foot. 6-19.3(3)B2 Permanent Shaft Casing Permanent casing is defined as casing designed as part of the shaft structure and installed to remain in place after construction is complete. All permanent casing shall be of ample strength to resist damage and deformation from transportation and handling, installation stresses, and all pressures and forces acting on the casing. Where the minimum thickness of permanent casing is specified in the Plans, it is specified to satisfy structural design requirements only. The Contractor shall increase the casing thickness as necessary to satisfy the requirements of this section. Page 6-342 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(3)B3 Temporary Shaft Casing Temporary casing is defined as casing installed to facilitate shaft construction only, which is not designed as part of the shaft structure, and which shall be completely removed after shaft construction is complete unless otherwise shown in the Plans. All temporary casing shall be of ample strength to resist damage and deformation from transportation and handling, installation and extraction stresses, and all pressures and forces acting on the casing. The casing shall be capable of being removed without deforming and causing damage to the completed shaft and without disturbing the surrounding soil. To maintain stable excavations and to facilitate construction, the Contractor may furnish and install temporary casing in addition to the required casing specified in the Special Provisions. The Contractor shall provide temporary casing at the site in sufficient quantities to meet the needs of the anticipated construction method. 6-19.3(3)B4 Temporary Telescoping Shaft Casing Where the acceleration coefficient used for seismic design of the structure, as specified in the General Notes of the Structure Plans, is less than or equal to 0.16, the Contractor may use temporary telescoping casing for the shafts at any bridge intermediate or interior pier, subject to the following conditions: 1. The Contractor shall submit the request to use temporary telescoping casing as a Type 2 Working Drawing. The request shall specify the diameters of the temporary telescoping casing, and shall specify the shafts where use is requested. The Contractor shall not proceed with the use of temporary telescoping casing until receiving the Engineer’s approval. 2. The minimum diameter of the shaft shall be as shown in the Plans. 3. The temporary telescoping casing shall conform to Sections 6-19.3(3)B1, 6-19.3(3) B3, and 9-36.1(2). The Contractor may use temporary telescoping casing for the shafts of any bridge end pier, regardless of the acceleration coefficient used for the seismic design of the structure, subject to conditions 2 and 3 specified above and the following two additional conditions: 4. A maximum of two telescoping casing diameter changes will be allowed. 5. The maximum diameter change at each casing diameter transition shall be 12 inches. 6-19.3(3)B5 Permanent Slip Casing Permanent slip casing is defined as casing installed vertically inside the temporary casing within the limits of the column-shaft splice zone, and wet-set into the shaft concrete no more than 3 feet below the column-shaft construction joint, allowing subsequent removal of the temporary casing. The casing diameter requirements of Section 6-19.3(3)B1 do not apply to permanent slip casing, but the inside diameter of the permanent slip casing shall provide the steel reinforcing bar clearance specified in Section 6-19.3(5)C. 2020 Standard Specifications M 41-10 Page 6-343 Shafts 6-19 6-19.3(3)C Conduct of Shaft Casing Installation and Removal and Shaft Excavation Operations The Contractor shall conduct casing installation and removal operations and shaft excavation operations such that the adjacent soil outside the casing and shaft excavation for the full height of the shaft is not disturbed. Disturbed soil is defined as soil whose geotechnical properties have been changed from those of the original in situ soil, and whose altered condition adversely affects the structural integrity of the shaft foundation. In no case shall shaft excavation and casing placement extend below the bottom of shaft excavation as shown in the Plans. 6-19.3(3)D Bottom of Shaft Excavation The Contractor shall use appropriate means such as a cleanout bucket or air lift to clean the bottom of the excavation of all shafts. No more than 2 inches of loose or disturbed material shall be present at the bottom of the shaft just prior to placing concrete. The excavated shaft shall be inspected and accepted by the Engineer prior to proceeding with construction. The bottom of the excavated shaft shall be sounded with an airlift pipe, a tape with a heavy weight attached to the end of the tape, or other means acceptable to the Engineer to determine that the shaft bottom meets the requirements in the Contract. 6-19.3(3)E Shaft Obstructions When obstructions are encountered, the Contractor shall notify the Engineer promptly. An obstruction is defined as a specific object (including, but not limited to, boulders, logs, and man made objects) encountered during the shaft excavation operation which prevents or hinders the advance of the shaft excavation. When efforts to advance past the obstruction to the design shaft tip elevation result in the rate of advance of the shaft drilling equipment being significantly reduced relative to the rate of advance for the portion of the shaft excavation in the geological unit that contains the obstruction, then the Contractor shall remove, break up, or push aside the obstruction under the provisions of Section 6-19.5. The method of dealing with such obstructions, and the continuation of excavation shall be as proposed by the Contractor and accepted by the Engineer. 6-19.3(3)F Voids Between Permanent Casing and Shaft Excavation When permanent casing is specified, excavation shall conform to the specified outside diameter of the shaft. After the casing has been filled with concrete, all void space occurring between the casing and shaft excavation shall be filled with a material which approximates the geotechnical properties of the in situ soils, in accordance with the shaft installation narrative specified in Section 6-19.3(2)B, item 5. 6-19.3(3)G Operating Shaft Excavation Equipment From an Existing Bridge Drilling equipment shall not be operated from an existing bridge, except as otherwise noted. If necessary and safe to do so, and if the Contractor submits a Type 2 Working Drawing consisting of a written request in accordance with Section 6-01.6, the Engineer may permit operation of drilling equipment on a bridge. Page 6-344 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(3)H Seals for Shaft Excavation in Water When shafts are constructed in water and the Plans show a seal between the casing shoring and the upper portion of the permanent casing of the shaft, the Contractor shall construct a seal in accordance with the shaft installation narrative specified in Section 6-19.3(2)B, item 7. Concrete for the casing shoring seal shall be Class 4000W conforming to Section 6-02. The seal thickness shown in the Plans is designed to resist the hydrostatic uplift force with the corresponding seal weight and adhesion of the seal to the permanent casing and the casing shoring of 20 psi, based on the casing shoring dimension and the seal vent water surface elevation specified in the Plans. If the Contractor uses a casing shoring diameter other than that specified in the Plans, the Contractor shall submit a revised seal design in accordance with Section 6-19.3(2)B, item 7. 6-19.3(3)I Required Use of Slurry in Shaft Excavation The Contractor shall use slurry, in accordance with Section 6-19.3(4), to maintain a stable excavation during excavation and concrete placement operations once water begins to enter the shaft excavation at an infiltration rate of 12 inches of depth or more in 1 hour. If concrete is to be placed in the dry, the Contractor shall pump all accumulated water in the shaft excavation down to a 3-inch maximum depth prior to beginning concrete placement operations. 6-19.3(4) Slurry Installation Requirements 6-19.3(4)A Slurry Technical Assistance If slurry other than water slurry is used, the manufacturer’s representative, as identified to the Engineer in accordance with Section 6-19.3(2)C, shall: 1. Provide technical assistance for the use of the slurry, 2. Be at the site prior to introduction of the slurry into the first drilled hole requiring slurry, and 3. Remain at the site during the construction of at least the first shaft excavated to adjust the slurry mix to the specific site conditions. After the manufacturer’s representative is no longer present at the site, the Contractor’s employee trained in the use of the slurry, as identified to the Engineer in accordance with Section 6-19.3(2)C, shall be present at the site throughout the remainder of shaft slurry operations for this project to perform the duties specified in items 1 through 3 above. 2020 Standard Specifications M 41-10 Page 6-345 Shafts 6-19 6-19.3(4)B Minimum Level of Slurry in the Excavation When slurry is used in a shaft excavation the following is required: 1. The height of the slurry shall be as required to provide and maintain a stable hole to prevent bottom heave, caving, or sloughing of all unstable zones. 2. The Contractor shall provide casing, or other means, as necessary to meet these requirements. 3. The slurry level in the shaft while excavating shall be maintained above the groundwater level the greater of the following dimensions: a. Not less than 5 feet for mineral slurries. b. Not less than 10 feet for water slurries. c. Not less than 10 feet for synthetic slurries. 4. The slurry level in the shaft throughout all stops as specified in Section 6-19.3(3)A and during concrete placement as specified in Section 6-19.3(7) shall be no lower than the water level elevation outside the shaft. 6-19.3(4)C Slurry Sampling and Testing Mineral slurry and synthetic slurry shall be mixed and thoroughly hydrated in slurry tanks, ponds, or storage areas. The Contractor shall draw sample sets from the slurry storage facility and test the samples for conformance with the specified viscosity and pH properties before beginning slurry placement in the drilled hole. Mineral slurry shall conform to the material specifications in Section 9-36.2(1). Synthetic slurry shall conform to Section 9-36.2(2), the quality control plan included in the shaft installation narrative in accordance with Section 6-19.3(2)B, item 4. A sample set shall be composed of samples taken at mid-height and within 2 feet of the bottom of the storage area. When synthetic slurry is used, the Contractor shall keep a written record of all additives and concentrations of the additives in the synthetic slurry. These records shall be submitted as a Type 1 Working Drawing once the slurry system has been established in the first drilled shaft on the project. The Contractor shall provide revised data to the Engineer if changes are made to the type or concentration of additives during construction. The Contractor shall sample and test all slurry in the presence of the Engineer, unless otherwise directed. The date, time, names of the persons sampling and testing the slurry, and the results of the tests shall be recorded. A copy of the recorded slurry test results shall be submitted to the Engineer at the completion of each shaft, and during construction of each shaft when requested by the Engineer. Sample sets of all slurry, composed of samples taken at mid-height and within 2 feet of the bottom of the shaft and the storage area, shall be taken and tested once every 4 hours minimum at the beginning and during drilling shifts and prior to cleaning the bottom of the hole to verify the control of the viscosity and pH properties of the slurry. Sample sets of all slurry shall be taken and tested at least once every 2 hours if the previous sample set did not have consistent viscosity and pH properties. All slurry shall be Page 6-346 2020 Standard Specifications M 41-10 6-19 Shafts recirculated, or agitated with the drilling equipment, when tests show that the sample sets do not have consistent viscosity and pH properties. Cleaning of the bottom of the hole shall not begin until tests show that the samples taken at mid-height and within 2 feet of the bottom of the hole have consistent viscosity and pH properties. Sample sets of all slurry, as specified, shall be taken and tested to verify control of the viscosity, pH, density, and sand content properties after final cleaning of the bottom of the hole just prior to placing concrete. Placement of the concrete shall not start until tests show that the samples taken at mid-height and within 2 feet of the bottom of the hole have consistent specified properties. 6-19.3(4)D Maintenance of Required Slurry Properties The Contractor shall clean, recirculate, de-sand, or replace the slurry to maintain the required slurry properties. 6-19.3(4)E Maintenance of a Stable Shaft Excavation The Contractor shall demonstrate to the satisfaction of the Engineer that stable conditions are being maintained. If the Engineer determines that stable conditions are not being maintained, the Contractor shall immediately take action to stabilize the shaft. The Contractor shall submit a revised shaft installation narrative that addresses the problem and prevents future instability. The Contractor shall not continue with shaft construction until the damage that has already occurred is repaired in accordance with the specifications, and until receiving the Engineer’s review of the revised shaft installation narrative. When mineral slurry conforming to Section 9-36.2(1) is used to stabilize the unfilled portion of the shaft, the Contractor shall remove the excess slurry buildup inside of the shaft diameter prior to continuing with concrete placement. The Contractor shall use the same methods of shaft excavation and the same diameter of drill tools to remove the excess slurry buildup as was used to excavate the shaft to its current depth. 6-19.3(4)F Disposal of Slurry and Slurry Contacted Spoils The Contractor shall manage and dispose of the slurry wastewater in accordance with Section 8-01.3(1)C. Slurry-contacted spoils shall be disposed of as specified in the shaft installation narrative in accordance with Section 6-19.3(2)B, item 8, and in accordance with the following requirements: 1. Uncontaminated spoils in contact with water-only slurry may be disposed of as clean fill. 2. Uncontaminated spoils in contact with water slurry mixed with flocculants approved in Section 8-01.3(1)C3 may be disposed of as clean fill away from areas that drain to surface waters of the state. 3. Spoils in contact with synthetic slurry or water slurry with polymer-based additives or flocculants not approved in Section 8-01.3(1)C3 shall be disposed of in accordance with Section 2-03.3(7)C. With permission of the Engineer, the Contractor may re-use these spoils on-site. 2020 Standard Specifications M 41-10 Page 6-347 Shafts 6-19 4. Spoils in contact with mineral slurry shall be disposed of in accordance with Section 2-03.3(7)C. With permission of the Engineer, the Contractor may re-use these spoils on-site. 6-19.3(5) Assembly and Placement of Reinforcing Steel 6-19.3(5)A Steel Reinforcing Bar Cage Assembly The reinforcing cage shall be rigidly braced to retain its configuration during handling and construction. Individual or loose bars will not be permitted. The Contractor shall show bracing and any extra reinforcing steel required for fabrication of the cage on the shop drawings. Shaft reinforcing bar cages shall be supported on a continuous surface to the extent possible. All rigging connections shall be located at primary handling bars, as identified in the reinforcing steel assembly and installation plan. Internal bracing is required at each support and lift point. The reinforcement shall be carefully positioned and securely fastened to provide the minimum clearances listed below, and to ensure no displacement of the reinforcing steel bars occurs during placement of the concrete. The steel reinforcing bars shall be securely held in position throughout the concrete placement operation. 6-19.3(5)B Steel Reinforcing Bar Cage Centralizers The Contractor shall submit details of the proposed reinforcing cage centralizers along with the shop drawings. The reinforcing steel centralizers at each longitudinal space plane shall be placed at least at the quarter points around the circumference of the steel reinforcing bar cage, and at a maximum longitudinal spacing of either 2.5 times the shaft diameter or 20 feet, whichever is less. The Contractor shall furnish and install additional centralizers as required to maintain the specified concrete cover throughout the length of the shaft. 6-19.3(5)C Concrete Cover Over Steel Reinforcing Bars Steel reinforcing bars shall be placed as shown in the Plans with minimum concrete cover as shown below: Shaft Diameter (feet) Minimum Concrete Cover, and Concrete Cover Tolerance, Except at Permanent Slip Casing (inches) Minimum Concrete Cover at Permanent Slip Casing (inches) Less than or equal to 3 3, -1½1½ Greater than 3 and less than 4 4, -2 1½ Greater than or equal to 4 and less than 5 4, -2 2 5 or larger 6, -3 3 The concrete cover tolerances specified above apply to the concrete cover specified in the Plans, even if it exceeds the minimum concrete cover. Page 6-348 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(5)D Steel Reinforcing Bar Cage Support at Base of Shaft Excavation For shafts with temporary casing within 15 feet of the bottom of shaft elevation as specified in the Plans, the Contractor may place quarry spalls or other rock backfill acceptable to the Engineer into the shaft below the specified bottom of shaft elevation as a means to support the steel reinforcing bar cage, provided that the materials and means to accomplish this have been addressed by the shaft installation narrative, as specified in Section 6-19.3(2)B, item 9. The use of bar boots and/or rebar cage base plates is required when quarry spalls or other rock backfill is placed at the base of the shaft excavation. 6-19.3(6) Contractor Furnished Accessories for Nondestructive QA Testing 6-19.3(6)A Shafts Requiring Access Tubes The Contractor shall furnish and install access tubes in all shafts receiving CSL testing or the thermal probe method of TIP testing, except as otherwise noted in Section 6-19.3(1)B1. 6-19.3(6)B Orientation and Assembly of the Access Tubes The Contractor shall securely attach the access tubes to the interior of the reinforcement cage of the shaft. One access tube shall be furnished and installed for each foot of shaft diameter, rounded to the nearest whole number, as shown in the Plans. The number of access tubes for shaft diameters specified as “X feet 6 inches” shall be rounded up to the next higher whole number. The access tubes shall be placed around the shaft, inside the spiral or hoop reinforcement, and bundled with the vertical reinforcement. Where circumferential components of the rebar cage bracing system prevent bundling the access tubes directly to the vertical reinforcement, the access tubes shall be placed inside the circumferential components of the rebar cage bracing system as close as possible to the nearest vertical steel reinforcement bar. The access tubes shall be installed in straight alignment and as near to parallel to the vertical axis of the reinforcement cage as possible. The access tubes shall extend from the bottom of the reinforcement cage to at least 2 feet above the top of the shaft. Splice joints in the access tubes, if required to achieve full length access tubes, shall be watertight. The Contractor shall clear the access tubes of all debris and extraneous materials before installing the access tubes. The tops of access tubes shall be deburred. Care shall be taken to prevent damaging the access tubes during reinforcement cage installation and concrete placement operations in the shaft excavation. 6-19.3(6)C Care for Access Tubes From Erection Through Nondestructive QA Testing The access tubes shall be filled with potable water before concrete placement, and the top watertight PVC caps shall be reinstalled and secured in accordance with Section 9-36.4. The Contractor shall keep all of a shaft’s access tubes full of water through the completion of nondestructive QA testing of that shaft. When temperatures below freezing are possible, the Contractor shall protect the access tubes against freezing by 2020 Standard Specifications M 41-10 Page 6-349 Shafts 6-19 wrapping the exposed tubes with insulating material, adding antifreeze to the water in the tubes, or other methods acceptable to the Engineer. 6-19.3(6)D Shafts Requiring Thermal Wire The Contractor shall furnish and install thermal wire in all shafts receiving the thermal wire method of TIP testing, except as otherwise noted in Section 6-19.3(1)B1. 6-19.3(6)E Thermal Wire and Thermal Access Points (TAPs) The thermal wire and associated couplers shall be obtained from the source specified in the Special Provisions. The Contractor shall securely attach the thermal wire to the interior of the reinforcement cage of the shaft in conformance with the supplier’s instructions. At a minimum, one thermal wire shall be furnished and installed for each foot of shaft diameter, rounded to the nearest whole number, as shown in the Plans. The number of thermal wires for shaft diameters specified as “X feet 6 inches” shall be rounded up to the next higher whole number. The thermal wires shall be placed around the shaft, inside the spiral or hoop reinforcement, and tied to the vertical reinforcement with plastic “zip” ties at a maximum spacing of 2-feet. Steel tie wire shall not be used. The thermal wire shall be installed in straight alignment and taut, but with enough slack to not be damaged during reinforcing cage lofting. The wires shall be as near to parallel to the vertical axis of the reinforcement cage as possible. The thermal wire shall extend from the bottom of the reinforcement cage to the top of the shaft, with a minimum of 5-feet of slack wire provided above the top of shaft. All thermal wires in a shaft shall be equal lengths. Care shall be taken to prevent damaging the thermal wires during reinforcement cage installation and concrete placement operations in the shaft excavation. After completing shaft reinforcement cage fabrication at the site and prior to installation of the cage into the shaft excavation, the Contractor shall install and connect thermal access points (TAPs) to the thermal wires. The TAPs shall record data for at least one hour after the cage is placed in the excavation to measure the slurry temperature and enable the steel and slurry temperatures to equilibrate prior to placing concrete in the shaft. The TAPs shall record and store data every 15 minutes. The TAPs shall remain active for a minimum of 36 hours. Prior to beginning concrete placement the TAPs shall be checked to ensure they are recording data and that the wires have not been damaged. If a TAP unit is not functioning due to a damaged wire, the Contractor shall repair or replace the wire. If a TAP unit fails or a wire breaks after concrete placement has started, the Contractor shall not stop the concrete placement operation to repair the wire. Page 6-350 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(6)F Use of Access Tubes for TIP Testing Under the Thermal Probe Method The Contractor may use access tubes for TIP testing under the thermal probe method. Access tubes shall be cared for in accordance with Section 6-19.3(6)C. Prior to TIP testing under the thermal probe method, the water in each tube shall be removed, collected, and stored in an insulated container. The access tube shall be blown dry and swabbed to remove residual water. After TIP testing, the collected and stored tube water shall be introduced back into the access tube. New potable water may be used, provided the water temperature is not more than 10°F cooler than the average concrete temperature measured by the probe. 6-19.3(7) Placing Concrete 6-19.3(7)A Concrete Class for Shaft Concrete Shaft concrete shall be Class 5000P conforming to Section 6-02. 6-19.3(7)B Concrete Placement Requirements Concrete placement shall commence immediately after completion of excavation by the Contractor and inspection by the Engineer. Immediately prior to commencing concrete placement, the shaft excavation and the properties of the slurry (if used) shall conform to Sections 6-19.3(3)D and 6-19.3(4), respectively. Concrete placement shall continue in one operation to the top of the shaft, or as shown in the Plans. The Contractor shall place concrete between the upper construction joint of the shaft and the top of the shaft in the dry. During concrete placement, the Contractor shall monitor, and minimize, the difference in the level of concrete inside and outside of the steel reinforcing bar cage. The Contractor shall conduct concrete placement operations to maintain the differential concrete head as 1-foot maximum. If water is not present, the concrete shall be deposited through the center of the reinforcement cage by a method that prevents segregation of aggregates and splashing of concrete on the reinforcement cage. The concrete shall be placed such that the free- fall is vertical down the center of the shaft without hitting the sides, the steel reinforcing bars, or the steel reinforcing bar cage bracing. The Section 6-02.3(6) restriction for 5 feet maximum free fall shall not apply to placement of concrete into a shaft. 6-19.3(7)C Concrete Vibration Requirements When placing concrete in the dry, only the top 5 feet of concrete shall be vibrated, in accordance with Section 6-02.3(9), except that the entire depth of concrete placed in the shaft-column steel reinforcing bar splice zone shall be vibrated. If a temporary casing is used, it shall be removed before vibration. This requirement may be waived if a temporary casing is used and removed with a vibratory hammer during the concrete placement operation. Vibration of concrete does not affect the maximum slump allowed for the concrete class specified. 2020 Standard Specifications M 41-10 Page 6-351 Shafts 6-19 6-19.3(7)D Requirements for Placing Concrete Underwater When placing concrete underwater, including when water in a shaft excavation exceeds 3 inches in depth, the Contractor shall place the concrete by pressure feed using a concrete pump, with a watertight tube having a minimum diameter of 4 inches. The discharge end of the tube on the concrete pump shall include a device to seal out water while the tube is first filled with concrete. Alternatively, the Contractor may use a plug that is inserted at the hopper of the concrete pump and travels through the tremie to keep the concrete separated from the water and slurry. Concrete placement by gravity feed is not allowed. Throughout the underwater concrete placement operation, the discharge end of the tube shall remain submerged in the concrete at least 5 feet and the tube shall always contain enough concrete to prevent water from entering. The concrete placement shall be continuous until the work is completed, resulting in a seamless, uniform shaft. 6-19.3(7)E Testing and Repair of Shaft Concrete Placed Underwater If the underwater concrete placement operation is interrupted, the Engineer may require the Contractor to prove by core drilling or other tests that the shaft contains no voids or horizontal joints. If testing reveals voids or joints, the Contractor shall repair them or replace the shaft at no expense to the Contracting Agency. Responsibility for coring costs, and calculation of time extension, shall be in accordance with Section 6-19.3(9)H. 6-19.3(7)F Cleaning and Removal of Previously Placed Shaft Concrete Before placing any fresh concrete against concrete deposited in water or slurry, the Contractor shall remove all scum, laitance, loose gravel, and sediment on the upper surface of the concrete deposited in water or slurry and chip off any high spots on the upper surface of the existing concrete that would prevent the steel reinforcing bar cage from being placed in the position required by the Plans. Prior to performing any of the crosshole sonic log testing operations specified in Section 6-19.3(9), the Contractor shall remove the concrete at the top of the shaft down to sound concrete. 6-19.3(7)G Protection of Fresh and Curing Concrete From Vibration The Contractor’s construction operation in the vicinity of a shaft excavation with freshly placed concrete and curing concrete shall conform to Section 6-02.3(6)D. 6-19.3(7)H Uniform Yield Form Except for shafts where the shaft concrete is placed in the dry, the Contractor shall complete a uniform yield form, consistent with the sample form submitted to the Engineer as part of the shaft installation narrative as specified in Section 6-19.3(2)B, item 6, for each shaft and shall submit the completed form to the Engineer within 24 hours of completing the concrete placement in the shaft. Page 6-352 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(7)I Requirements for Placing Concrete Above the Top of Shaft Concrete shall not be placed above the top of shaft (for column splice zones, columns, footings, or shaft caps) until the Contractor receives the Engineer’s acceptance of nondestructive QA testing, if performed at that shaft, and acceptance of the shaft. 6-19.3(8) Casing Removal 6-19.3(8)A Concrete Head Requirements During Temporary Casing Removal As the temporary casing is withdrawn, the Contractor shall maintain the concrete and slurry inside the casing at a level sufficient to balance the hydrostatic pressure outside the casing. 6-19.3(8)B Removing Portions of Permanent Casing Above the Top of Shaft Tops of permanent casings for the shafts shall be removed to the top of the shaft or finished groundline, whichever is lower, unless directed otherwise by the Engineer. For those shafts constructed within a permanent body of water, tops of permanent casings for shafts shall be removed to the low water elevation, unless directed otherwise by the Engineer. 6-19.3(8)C Requirements for Leaving Temporary Casing in Place The Contractor shall completely remove all temporary casings, except as noted. The Contractor may leave some or all of the temporary casing in place provided all the following conditions are satisfied: 1. The Contractor shall submit a Type 2E Working Drawing of the following information: a. The Contractor shall completely describe the portion of the temporary casing to remain. b. The Contractor shall specify the reason(s) for leaving the portion of the temporary casing in place. c. The Contractor shall submit structural calculations, using the design specifications and design criteria specified in the General Notes of the structure Plans, indicating that leaving the temporary casing in place is compatible with the structure as designed in the Plans. 6-19.3(9) Nondestructive QA Testing of Shafts The Contractor shall provide nondestructive QA testing and analysis on all shafts with access tubes or thermal wires and TAPs facilitating the testing (See Section 6-19.3(1)B). The testing and analysis shall be performed by the testing organizations identified by the Contractor’s submittal in accordance with Section 6-19.3(2)D. 2020 Standard Specifications M 41-10 Page 6-353 Shafts 6-19 The Engineer may direct that additional testing be performed at a shaft if anomalies or a soft bottom are detected by the Contractor’s testing. If additional testing at a shaft confirms the presence of a defect(s) in the shaft, the testing costs and the delay costs resulting from the additional testing shall be borne by the Contractor in accordance with Section 1-05.6. If the additional testing indicates that the shaft has no defect, the testing costs and the delay costs resulting from the additional testing will be paid by the Contracting Agency in accordance with Section 1-05.6, and, if the shaft construction is on the critical path of the Contractor’s schedule, a time extension equal to the delay created by the additional testing will be granted in accordance with Section 1-08.8. 6-19.3(9)A TIP Testing Using Thermal Probes or CSL Testing If selected as the nondestructive QA testing method by the Contractor, TIP testing using thermal probes, or CSL testing shall be performed after the shaft concrete has cured at least 96 hours. Additional curing time prior to testing may be required if the shaft concrete contains admixtures, such as set retarding admixture or water-reducing admixture, added in accordance with Section 6-02.3(3). The additional curing time prior to testing required under these circumstances shall not be grounds for additional compensation or extension of time to the Contractor in accordance with Section 1-08.8. 6-19.3(9)B Inspection of Access Tubes After placing the shaft concrete and before beginning the crosshole sonic log testing of a shaft, the Contractor shall inspect the access tubes. Each access tube that the test probe cannot pass through shall be replaced, at the Contractor’s expense, with a 2-inch diameter hole cored through the concrete for the entire length of the shaft. Unless directed otherwise by the Engineer, cored holes shall be located approximately 6 inches inside the reinforcement and shall not damage the shaft reinforcement. Descriptions of inclusions and voids in cored holes shall be logged and a copy of the log shall be submitted to the Engineer. Findings from cored holes shall be preserved, identified as to location, and made available for inspection by the Engineer. 6-19.3(9)C TIP Testing With Thermal Wires and TAPs If selected as the nondestructive QA testing method by the Contractor, TIP testing with thermal wires and TAPs (See Section 6-19.3(6)E) shall be performed. The TIP testing shall commence at the beginning of the concrete placement operation, recording temperature readings at 15-minute intervals until the peak temperature is captured in the data. Additional curing time may be required if the shaft concrete contains admixtures, such as set retarding admixture or water-reducing admixture, added in accordance with Section 6-02.3(3). The additional curing time required under these circumstances shall not be grounds for additional compensation or extension of time to the Contractor in accordance with Section 1-08.8. TIP testing shall be conducted at all shafts in which thermal wires and TAPs have been installed for thermal wire analysis (Section 6-19.3(6)A). Page 6-354 2020 Standard Specifications M 41-10 6-19 Shafts 6-19.3(9)D Nondestructive QA Testing Results Submittal The Contractor shall submit the results and analysis of the nondestructive QA testing for each shaft tested. The Contractor shall submit the test results within three working days of testing. Results shall be a Type 2E Working Drawing presented in a written report. TIP reports shall include: 1. A map or plot of the wire/tube location within the shaft and their position relative to a known and identifiable location, such as North. 2. Graphical displays of temperature measurements versus depth of each wire or tube for the analysis time selected, overall average temperature with depth, shaft radius or diameter with depth, concrete cover versus cage position with depth, and effective radius. 3. The report shall identify unusual temperatures, particularly significantly cooler local deviations from the overall average. 4. The report shall identify the location and extent where satisfactory or questionable concrete is identified. a. Satisfactory (S) – 0 to 6 percent Effective Radius Reduction and Cover Criteria Met b. Questionable (Q) – Effective Local Radius Reduction > 6 percent, Effective Local Average Diameter Reduction > 4 percent, or Cover Criteria Not Met 5. Variations in temperature between wire/tubes (at each depth) which in turn correspond to variations in cage alignment. 6. Where shaft specific construction information is available (e.g. elevations of the top of shaft, bottom of casing, bottom of shaft, etc.), these values shall be noted on all pertinent graphical displays. CSL reports shall include: 1. A map or plot of the tube location within the shaft and their position relative to a known and identifiable location, such as North. 2. Graphical displays of CSL Energy versus Depth and CSL signal arrival time versus depth or velocity versus depth. 3. The report shall identify the location and extent where good, questionable, and poor concrete is identified, where no signal was received, or where water is present. a. Good (G) – No signal distortion and decrease in signal velocity of 10 percent or less is indicative of good quality concrete. b. Questionable (Q) – Minor signal distortion and a lower signal amplitude with a decrease in signal velocity between 10 percent and 20 percent. c. Poor (P) – Severe signal distortion and much lower signal amplitude with a decrease in signal velocity of 20 percent or more. d. No Signal (NS) – No signal was received. e. Water (W) – A measured signal velocity of nominally V = 4,800 to 5,000 fps.