Project Materials Usage and Concerns

Project Materials and Acceptance QC/QA Specifications QC/QA Specifications Quality Control Plans Quality Control Plans Certified Producers Certified Producers Personnel Qualifications Personnel Qualifications Approved Materials Approved Materials Frequency Manual Frequency Manual Material Testing and Acceptance Material Testing and Acceptance

Types of Specifications METHOD METHOD END RESULT END RESULT QC/QA – Statistically Based QC/QA – Statistically Based PERFORMANCE PERFORMANCE Warranty Warranty Performance Related Performance Related

QC/QA SPECIFICATIONS HOT MIX ASPHALT (HMA) HOT MIX ASPHALT (HMA) PORTLAND CEMENT CONCRETE PAVEMENT (PCCP) PORTLAND CEMENT CONCRETE PAVEMENT (PCCP)

QUALITY CONTROL Activities that have to do with making the Quality of a product what it should be Activities that have to do with making the Quality of a product what it should be

Quality Control Quality Control Plans – ITM 803 Quality Control Plans – ITM 803 Certified Field Supervisors Certified Field Supervisors Producer Technicians Producer Technicians Certified Producers Certified Producers

Project Materials and Acceptance QC/QA Specifications QC/QA Specifications Quality Control Plans Quality Control Plans Certified Producers Certified Producers Personnel Qualifications Personnel Qualifications Approved Materials Approved Materials Frequency Manual Frequency Manual Material Testing and Acceptance Material Testing and Acceptance

QUALITY CONTROL PLANS QCP – A detailed description of the type and frequency of inspection, sampling, and testing deemed necessary to measure and control the various properties of the material QCP – A detailed description of the type and frequency of inspection, sampling, and testing deemed necessary to measure and control the various properties of the material

Quality Control Plans Contract specific Contract specific Signed and dated by Contractor and PE/PS Signed and dated by Contractor and PE/PS Maintained to reflect current status of operations Maintained to reflect current status of operations Shall contain name and duties of all quality control personnel Shall contain name and duties of all quality control personnel Placement operations shall not begin before the QCP has been accepted Placement operations shall not begin before the QCP has been accepted

Quality Control Plans – HMA & PCCP Certified Field Supervisor (HMA) Certified Field Supervisor (HMA) Quality Control Technicians Quality Control Technicians Transportation of Materials to Project Transportation of Materials to Project Paving Operations Paving Operations Joints Joints Materials Sampling and Testing Materials Sampling and Testing Response to Test Results Response to Test Results Pavement Smoothness Pavement Smoothness Documentation Documentation

Quality Control Plans - HMA Milling Procedures Process Balance

Quality Control Plans - PCCP Concrete Batching Trial Batch Finishing, Texturing, and Curing

Quality Control Technicians HMA Quality Control Technicians HMA Paving operations and joint construction Paving operations and joint construction Quality control tests for temperature, density, and smoothness Quality control tests for temperature, density, and smoothness Pavement samples for quality control and acceptance Pavement samples for quality control and acceptance

Quality Control Technicians PCCP Quality Control Technicians PCCP ACI Certified Concrete Field Testing Technician, Grade I ACI Certified Concrete Field Testing Technician, Grade I Trial Batch Trial Batch Quality control tests Quality control tests Gradation of aggregates Gradation of aggregates Flexural strength Flexural strength Air content Air content Unit Weight Unit Weight W/C ratio W/C ratio Surface smoothness Surface smoothness Control charts Control charts

Project Materials and Acceptance QC/QA Specifications QC/QA Specifications Quality Control Plans Quality Control Plans Certified Producers Certified Producers Personnel Qualifications Personnel Qualifications Approved Materials Approved Materials Frequency Manual Frequency Manual Material Testing and Acceptance Material Testing and Acceptance

Certified Producers Certified Aggregate Producers (ITM 211) Certified Aggregate Producers (ITM 211) Certified HMA Producers (ITM 583) Certified HMA Producers (ITM 583) Asphalt Supplier Certification Program (ITM 581) Asphalt Supplier Certification Program (ITM 581) Certified Precast Concrete Producer Program (ITM 813) Certified Precast Concrete Producer Program (ITM 813) Certified Precast Prestressed Concrete Producer Program (ITM 814) Certified Precast Prestressed Concrete Producer Program (ITM 814) Reinforcing Bar and Dowel Bar Certification Program (ITM 301) Reinforcing Bar and Dowel Bar Certification Program (ITM 301) Ready Mixed Concrete Plant Program (ITM 406) Ready Mixed Concrete Plant Program (ITM 406)

Certified Aggregate Producer Program Statistically Based Program Statistically Based Program Quality Control Plan Quality Control Plan Daily Diary Daily Diary Production Testing – gradation, deleterious, & crushed content Production Testing – gradation, deleterious, & crushed content Load-out testing – gradation & decant Load-out testing – gradation & decant

Certified Aggregate Producer Program

Certified HMA Producer Program Quality Control Plan Quality Control Plan Daily Diary Daily Diary Sample and test material from pavement and plant Sample and test material from pavement and plant Control Charts Control Charts Binder content Binder content Air voids Air voids VMA VMA

Certified HMA Producer Program Aggregates (stockpiles & blended ), RAP, and HMA Aggregates (stockpiles & blended ), RAP, and HMA Binder content, moisture content, air voids, CAA, draindown (OG), temperature, and gradation (SMA) Binder content, moisture content, air voids, CAA, draindown (OG), temperature, and gradation (SMA)

Certified Asphalt Supplier Certification (ASC) Program Complete PG binder testing on each grade Complete PG binder testing on each grade Supplies proper storage and handling procedures Supplies proper storage and handling procedures

PG Binder Acceptance - INDOT Lot – one week Lot – one week Sublot – one calendar day Sublot – one calendar day One sample tested per lot One sample tested per lot

In-Line Blending of PG Binders

Certified Precast Concrete Producer Program ACPA or NPCA Certified ACPA or NPCA Certified INDOT Approved Materials INDOT Approved Materials

Certified Precast Concrete Producer Program Markings Markings Date of Manufacture INDOT ID number ACPA – “ACPA Certified Product” or “QCast” emblem NPCA – “NPCA Certified Product” Specification marking INDOT Approved Materials List INDOT Approved Materials List

Certified Precast Prestressed Concrete Producer Program NPCA or PCI PB3 Certified – straight strands NPCA or PCI PB3 Certified – straight strands PB4 Certified – deflected strands PB4 Certified – deflected strands INDOT inspection INDOT inspection

Reinforcing Bar and Dowel Bar Certification Program – ITM 301 Coater – Concrete Reinforcing Steel Institute (CRSI) Certified Coater – Concrete Reinforcing Steel Institute (CRSI) Certified Manufacturer Manufacturer Compliance to specification requirements for heats Compliance to specification requirements for heats Satisfactory testing with INDOT Satisfactory testing with INDOT Satisfactory verification testing Satisfactory verification testing

Reinforcing Bar and Dowel Bar Certification Program – ITM 301 Acceptance – Bars Acceptance – Bars Type B Certification provided by manufacturer Type B Certification provided by manufacturer Acceptance - Coating Acceptance - Coating Type A Certification for coating thickness and adhesion tests Type A Certification for coating thickness and adhesion tests Type C Certification to identify coating material and state that the coating is from the Approved List of Epoxy Coatings for Steel Type C Certification to identify coating material and state that the coating is from the Approved List of Epoxy Coatings for Steel

Certified Ready Mixed Concrete Plant Program NRMCA Plant Certification NRMCA Plant Certification 2 Year cycle for inspection of plant 2 Year cycle for inspection of plant Voluntary program Voluntary program More frequent scale calibrations More frequent scale calibrations INDOT still does inspection INDOT still does inspection

Certified Ready Mixed Concrete Plant Program Delivery trucks included Delivery trucks included 14 month cycle for inspection 14 month cycle for inspection

Project Materials and Acceptance QC/QA Specifications QC/QA Specifications Quality Control Plans Quality Control Plans Certified Producers Certified Producers Personnel Qualifications Personnel Qualifications Approved Materials Approved Materials Frequency Manual Frequency Manual Material Testing and Acceptance Material Testing and Acceptance

Personnel Qualified Technician Program Qualified Technician Program Independent Assurance Program Independent Assurance Program

Qualified Technicians Requirements Requirements Written examination on test procedure Written examination on test procedure Proficiency by Independent Assurance Technician Proficiency by Independent Assurance Technician Proficiency required once per year Proficiency required once per year If no proficiency within three years, the written exam is required again If no proficiency within three years, the written exam is required again

Qualified Technicians - HMA Sampling – ITM 580 Sampling – ITM 580

Qualified Technicians - PCCP AASHTO T 23 – Making and Curing Test Specimens in the Field AASHTO T 23 – Making and Curing Test Specimens in the Field AASHTO T 97 – Flexural Strength AASHTO T 97 – Flexural Strength AASHTO T 119 – Slump AASHTO T 119 – Slump AASHTO T 152 – Air Content by Pressure Method AASHTO T 152 – Air Content by Pressure Method ASTM C 173 – Air Content by Volumetric ASTM C 173 – Air Content by Volumetric ITM 403 – W/C Ratio ITM 403 – W/C Ratio

Qualified Technicians - Soils AASHTO T 191 – Density by Sand Cone AASHTO T 191 – Density by Sand Cone AASHTO T 255 – Moisture Content of Aggregate AASHTO T 255 – Moisture Content of Aggregate AASHTO T 310 – Density by Nuclear Gauge AASHTO T 310 – Density by Nuclear Gauge ASTM D 6951 –Stiffness by DCP ASTM D 6951 –Stiffness by DCP ITM 506 – Field Moisture Content ITM 506 – Field Moisture Content ITM 508 – Stiffness by LWD ITM 508 – Stiffness by LWD

Qualified Technicians - Smoothness ITM Profilographs ITM Profilographs

Project Materials and Acceptance QC/QA Specifications QC/QA Specifications Quality Control Plans Quality Control Plans Certified Producers Certified Producers Personnel Qualifications Personnel Qualifications Approved Materials Approved Materials Frequency Manual Frequency Manual Material Testing and Acceptance Material Testing and Acceptance

Materials Approved Materials List Approved Materials List Materials Materials Sources Sources Material Certifications Material Certifications Pre-Approved Materials Pre-Approved Materials Verification Samples Verification Samples

Approved Materials Lists Approved Materials List Approved Materials List Materials Materials Sources Sources Specification Reference Specification Reference Contact Person Contact Person

Material Certifications Type A Type A Manufacturer Manufacturer Copy of lab report Copy of lab report Certify materials meet specifications Certify materials meet specifications Type B Type B Manufacturer Manufacturer Applicable specifications Applicable specifications Indicate limits of test values Indicate limits of test values Certify materials meet specifications Certify materials meet specifications Type C Type C Manufacturer Manufacturer Applicable specifications Applicable specifications Certify materials meet specifications Certify materials meet specifications

Material Certifications Type D Type D Contractor Contractor Applicable specifications Applicable specifications Certify materials meet specifications Certify materials meet specifications Product identification Product identification Other Types Other Types Described in material’s specifications Described in material’s specifications

Pre-Approved Materials Glass Spheres Glass Spheres Paints Paints Hot Pour Joint Sealants Hot Pour Joint Sealants

Verification Samples Frequency Manual Frequency Manual Cement Cement Fly ash Fly ash Concrete admixtures Concrete admixtures Curing materials Curing materials Reinforcing steel Reinforcing steel Hydrated lime Hydrated lime Geotextiles Geotextiles

Project Materials and Acceptance QC/QA Specifications QC/QA Specifications Quality Control Plans Quality Control Plans Certified Producers Certified Producers Personnel Qualifications Personnel Qualifications Approved Materials Approved Materials Frequency Manual Frequency Manual Material Testing and Acceptance Material Testing and Acceptance

Frequency Manual Minimum required number of tests Minimum required number of tests Location of samples and tests Location of samples and tests Basis of Use – SiteManager Test Template Basis of Use – SiteManager Test Template

Project Materials and Acceptance QC/QA Specifications QC/QA Specifications Quality Control Plans Quality Control Plans Certified Producers Certified Producers Personnel Qualifications Personnel Qualifications Approved Materials Approved Materials Frequency Manual Frequency Manual Material Testing and Acceptance Material Testing and Acceptance

QUALITY ASSURANCE Activities that have to do with making sure that the Quality of a product is what it should be Activities that have to do with making sure that the Quality of a product is what it should be

Quality Assurance - Mix Designs HMA HMA Approved Lab Approved Lab AMRL Inspection AMRL Inspection Sample Proficiency Program Sample Proficiency Program Design Approved by DTE Design Approved by DTE PCCP PCCP Trial Batch Trial Batch Design Approved by DTE Design Approved by DTE

Quality Assurance – HMA DMF Submitted one week prior to use Submitted one week prior to use Based on ESAL and mixture designation Based on ESAL and mixture designation Approved by DTE Approved by DTE

Quality Assurance – HMA JMF JMF submitted for approval to DTE one working day after receipt of test results for binder content, VMA, and air voids from adjustment period JMF submitted for approval to DTE one working day after receipt of test results for binder content, VMA, and air voids from adjustment period Adjustment Period Adjustment Period 5000 tons for Base and Intermediate mixture 5000 tons for Base and Intermediate mixture 3000 tons for Surface mixture 3000 tons for Surface mixture

Quality Assurance HMA Random Sampling – ITM 802 HMA HMA Random sublot ton Random sublot ton Truck containing that ton is selected Truck containing that ton is selected Distance truck places the mixture determined Distance truck places the mixture determined Random transverse and longitudinal distance determined Random transverse and longitudinal distance determined

Quality Assurance Sampling Lots and Sublots - HMA Lots t for Base & Intermediate Lots t for Base & Intermediate t for Surface t for Surface Sublots t for Base & Intermediate Sublots t for Base & Intermediate t for Surface t for Surface

Quality Assurance Sampling - HMA Increasing Station 2 ft (0.6 m) 2 ft (0.6 m) Sample for Gyratory Specimens Random Location MSG and Binder Content Sample Backup Sample for Gyratory Specimens Backup Sample for MSG and Binder Content

Quality Assurance Sampling - HMA

Quality Assurance - CMDS Concrete Trial Batch PCCP PCCP Validate CMD compliance Validate CMD compliance Validate sampling and testing procedures Validate sampling and testing procedures

Quality Assurance - CMDS Concrete Trial Batch Air Content % % Air Content % % Plastic Unit weight -- ± 3.0% of CMDS Plastic Unit weight -- ± 3.0% of CMDS W/C ratio -- ± 0.030% of target value of CMDS and shall not exceed W/C ratio -- ± 0.030% of target value of CMDS and shall not exceed Flexural strength -- minimum of 570 psi Flexural strength -- minimum of 570 psi

Quality Assurance - CMDP Submitted to DTE upon completion of Trial Batch Submitted to DTE upon completion of Trial Batch INDOT Spreadsheet INDOT Spreadsheet Minimum of 3 work days prior to production Minimum of 3 work days prior to production Production shall not start without approved CMDP Production shall not start without approved CMDP

Quality Assurance Sampling Lots and Sublots - PCCP PCCP PCCP Lots syd Lots syd Sublots syd Sublots syd

Quality Assurance Sampling - PCCP Paver – air content and unit weight Paver – air content and unit weight Plant – flexural strength Plant – flexural strength

Quality Assurance Sampling - Cores HMA – Density HMA – Density Concrete - Thickness Concrete - Thickness HMA/PCCP HMA/PCCP Length of sublot x random number Length of sublot x random number Width of pavement x random number Width of pavement x random number

Quality Assurance HMA Acceptance -- INDOT HMA HMA Binder Content Binder Content Air Voids Air Voids VMA VMA Density Density Smoothness Smoothness

Quality Assurance Material Acceptance – Type D Certification 402 – Type D Certification Air voids Air voids Binder content Binder content 1 st 250t and each subsequent 1000t of base and intermediate 1 st 250t and each subsequent 1000t of base and intermediate 1 st 250t and each subsequent 600t for surface 1 st 250t and each subsequent 600t for surface

Quality Assurance Concrete Random Sampling – ITM 802 Plastic Concrete Plastic Concrete Determine the number of sample segments Determine the number of sample segments Determine sample segment size Determine sample segment size Random target area Random target area Length of target area Length of target area Distance to random target area Distance to random target area

Concrete Acceptance - INDOT PCCP PCCP Flexural Strength Flexural Strength Air Content Air Content Unit Weight Unit Weight W/C Ratio W/C Ratio Thickness Thickness

Quality Assurance Smoothness – HMA/PCCP Smoothness – Profilograph Smoothness – Profilograph

Quality Assurance - HMA Pay Factors HMA – Percent Within Limits (PWL) HMA – Percent Within Limits (PWL) Binder Content, Air Voids, VMA, & Density (% MSG) Binder Content, Air Voids, VMA, & Density (% MSG) Smoothness – Profile Index Smoothness – Profile Index

Material Acceptance -- Aggregates CAPP Producer – D number CAPP Producer – D number Subbase Subbase Underdrains Underdrains B Borrow and Structural backfill (may come from a local site) B Borrow and Structural backfill (may come from a local site) Exceptions for CAPP Exceptions for CAPP Precast concrete items Precast concrete items Snow and ice abrasive materials Snow and ice abrasive materials

Material Acceptance -- Soils Moisture Content Moisture Content ITM 506 Density Density Sand Cone Sand Cone AASHTO T 191 Nuclear Gauge AASHTO T 310 Nuclear Gauge AASHTO T 310 Dynamic Cone Penetrometer Dynamic Cone Penetrometer ASTM D 6951 Light Weight Deflectometer Light Weight Deflectometer ITM 508

HMA Appeal Process HMA HMA Appeal in writing within seven days of receipt of results for lot Appeal in writing within seven days of receipt of results for lot Includes QC test results Includes QC test results Backup samples for binder content, air voids, and VMA Backup samples for binder content, air voids, and VMA Additional cores for density Additional cores for density

Quality Assurance PCCP Pay Adjustments PCCP Concrete PCCP Concrete Flexural Strength Flexural Strength Air Content Air Content Lot Range for Air Content Lot Range for Air Content Thickness Thickness Smoothness Smoothness Lot Average Flexural Strength psiPay Factors 570 and above or less*

PCCP Appeal Process PCCP PCCP Appeal in writing within five days of receipt of results for lot Appeal in writing within five days of receipt of results for lot Includes QC test results Includes QC test results Flexural Strength (>50psi) -- cores taken for split tensile strength Flexural Strength (>50psi) -- cores taken for split tensile strength Air Content (>0.5%)– additional cores Air Content (>0.5%)– additional cores

Materials Management Information Approved Lists Geotechnical ConsultantsGeotechnical Consultants A listing of Geotechnical Consultants approved to perform geotechnical work on INDOT projects. Geotechnical Laboratories A listing of Geotechnical Testing Laboratories approved to conduct Soils testing for INDOT contracts HMA Design Labs HMA Design Labs A listing of HMA Design Laboratories approved to conduct HMA Design work for INDOT contracts

Materials Management Information Approved Lists Approved Materials A listing of materials and suppliers pre-approved and tested that meet INDOT specifications for immediate use on INDOT contracts Approved Materials Frequency of Sampling and Testing ManualFrequency of Sampling and Testing Manual (CRA) This is the manual that outlines the Sampling and Testing requirements of materials for acceptance purposes on INDOT CRA contracts Frequency of Sampling and Testing ManualFrequency of Sampling and Testing Manual (SMA) This is the manual that outlines the Sampling and Testing requirements of materials for acceptance purposes on INDOT SiteManager contracts

Materials Management Information PG Asphalt Binder Index PG Average Monthly Price PG Asphalt Binder Index Adjustment Publications and Manuals Geotechnical Manuals and Guidelines Manuals, Guidelines, Forms, and Approved List of Suppliers and Geotechnical Consultants. Indiana Test Methods or Procedures Index Test Methods and Procedures developed by INDOT for use with INDOT Specifications

Materials Management Information Quality Assurance Manuals: Certified Aggregate Technician Manual Certified Aggregate Technician Manual Manual outlining the procedures to be followed by the Certified Aggregate Technicians Certified Hot Mix Asphalt Technician Manual Certified Hot Mix Asphalt Technician Manual Manual outlining the procedures to be followed by the Certified Hot Mix Asphalt Technician Inspection and Sampling Procedures for Fine & Coarse Aggregates Inspection and Sampling Procedures for Fine & Coarse Aggregates Procedures to be followed for the inspection and sampling of fine and coarse aggregate stockpiles Superstructure Concrete Certified Technician Program Manual Manual outlining the procedures to be followed by the Certified Superstructure Concrete Technician Qualified Technician Program Program Description Test Methods