2002 FDOT/FTBA Construction Conference QC 2000 Concrete Specifications Mike Bergin State Materials Office Email: michael.bergin@dot.state.fl.us

The Presentation will include Highlights of Changes to Section 346 A draft Resolution Procedure to assist project personnel April 3, 2002 2002 Construction Conference

2002 Construction Conference QC 2000 Is not NEW any more But the specs have changed and the major changes will be addressed today. Jobs have been let under QC 2000 for several years, as of July 1, 2002 all FDOT projects will be let with QC 2000 Specifications approved by FHWA. The current 346 for QC 2000 is version 4 April 3, 2002 2002 Construction Conference

2002 Construction Conference What’s New in Section 346 New references to Section 6.8, 6.9 and 105 and reference to Chapter 9.2 in the Materials Manual Section 6.8 -Quality Control Program Section 6.9 -Laboratory Qualifications Section 105 -Quality Control Program Requirements April 3, 2002 2002 Construction Conference

What’s New in Section 346 (cont.) Chapter 9.2 of the Materials Manual (MM) –Information pertaining to concrete plants. April 3, 2002 2002 Construction Conference

What’s New in Section 346 (cont.) Changes in almost every subsection. This presentation will focus on the major changes and how these changes affect Construction and Materials. Especially the relation between Construction and Materials, and the Resolution Process April 3, 2002 2002 Construction Conference

2002 Construction Conference Standard Operating Procedures for the Quality Control of Concrete (SOP) is gone The Level I of the SOP identified how producers batched concrete to meet the requirements of the Specification. This information is now moved to Chapter 9.2 of the Materials Manual (MM), “Concrete Production Facilities Guidelines” (CPFG) and is located on the DOT website. April 3, 2002 2002 Construction Conference

Standard Operating Procedures,… is gone (cont.) MM Includes the requirements for batch plants such as: Plant specific QC plan QC plan no longer job specific Design mix requirements (change) Hot weather,old 346, mix temp is 94 F at the end of the mixing cycle Hot weather, new 346, mixes are held at 94 F during entire mixing cycle Plant specific- producer gives contractor the plant qc plan and producer is ready to place concrete? April 3, 2002 2002 Construction Conference

Standard Operating Procedures,… is gone (cont.) The Level II from the SOP has been moved directly into Section 346. The Contractor describes how he will maintain the quality of the concrete once it arrives at the job site. April 3, 2002 2002 Construction Conference

2002 Construction Conference Mass Concrete (3.1) Requires a Specialty Engineer to formulate, implement, administer and monitor the temperature control plan. April 3, 2002 2002 Construction Conference

2002 Construction Conference Mass Concrete (3.1) Department no longer approves the plan but accepts the Contractor’s proposed plan. The responsibility is the Contractor’s to ensure that the plan meets the specification. Contractor’s QC Manager is responsible to ensure the plan is followed during and after placement. No concrete is placed unless there is an accepted Mass Concrete plan April 3, 2002 2002 Construction Conference

Sampling and Testing (5.1) ASTM is now the standard for all concrete tests except for following two FM’s early sampling of fresh concrete FM 5-501 testing of chlorides in hardened concrete FM 5-516 April 3, 2002 2002 Construction Conference

2002 Construction Conference Control of Quality (6.1) The Contractor maintains one quality control plan for his entire project. The guidelines are identified in Section 6.8. Section 5.6 of MM identifies QC information for material producers He is responsible to identify how the quality of material will be maintained. Failure to meet specifications or contract documents voids that portion of the QC plan. Where is section 10.5, specs? MM? Is not in 346 April 3, 2002 2002 Construction Conference

Delivery Certification of Concrete (6.3) Delivery ticket requirements have been moved to the “Concrete Production Facility Guidelines”, Chapter 9.2 of the MM. Batch Plant Operator (BPO) signs stating that the batch was produced in accordance with the approved design mix April 3, 2002 2002 Construction Conference

Delivery Certification of Concrete (6.3) The Contractor or his agent signs stating the W/C ratio was not exceeded at the project site and that the concrete meets the requirements of the specs. April 3, 2002 2002 Construction Conference

Adding Water at the Placement Site (7.7) Contractor must perform a slump test before any water is added to the load. April 3, 2002 2002 Construction Conference

Plastic Concrete Sampling and Testing (8) The Contractor is responsible for ensuring that plastic properties, determination of the w/c ratio and compressive strength of cylinders are in compliance with the Specifications. April 3, 2002 2002 Construction Conference

Plastic Concrete Sampling and Testing (8) Testing will be performed: by CTQP qualified technicians. on each lot of concrete from a random load within that lot. April 3, 2002 2002 Construction Conference

Plastic Concrete Sampling and Testing (8) A Lot is 50 yd3 or one days production which ever is less except for: Pav’t – one lane mile or one days production I Special –150 yd3 or one days production III Seal – Each placement April 3, 2002 2002 Construction Conference

Plastic Concrete Sampling and Testing (8) The Department will randomly select 1 of every 4 lots to compare QC with Verification tests. Use a Random number generator April 3, 2002 2002 Construction Conference

Plastic Concrete Sampling and Testing (8) 3 consecutive lots or 5 lots in two days out of tolerance (in the same mix) – the Contractor will suspend production from this plant. Department may perform independent verification test any time. April 3, 2002 2002 Construction Conference

Acceptance Sampling and Testing (9.1) Contractor will cast a set of 3 cylinders from each lot, from a random load within the lot For each lot that the Department verifies with the Contractor, cast an additional “hold” cylinder. The “hold” cylinder will be used for resolution if the QC tests do not compare with the Verification tests. April 3, 2002 2002 Construction Conference

Acceptance Sampling and Testing (9.1) The laboratory performing the compressive strength tests shall meet the requirements of Section 6-9 The concrete is verified when the Contractors quality control (QC) cylinders compare within 750 psi with the Verification cylinders. If QC does not compare within the 750 psi of Verification then the Engineer will initiate the Resolution Procedure. April 3, 2002 2002 Construction Conference

Reduced Frequency for Acceptance Tests (9.2.1) If the Contractor can show consistency in his QC tests, the sample frequency can be reduced and lot size will be increased to 100 yds3. Minimum of 15 consecutive strength tests, same mix, same plant, same sub. Data can come from another project using the same mix but last compressive test must have been performed within 60 days. April 3, 2002 2002 Construction Conference

Acceptance of Hardened Concrete (9.4) When 1 of the 3 QC cylinders are lost, damaged or destroyed, Average the remaining 2 cylinders and payment for the lot is reduced by 10% When more than 1 of the QC cylinders is lost, damaged, or destroyed The contractor, at the discretion of the engineer, will core the structure to determine if the minimum strength is met and no payment is made for that lot. April 3, 2002 2002 Construction Conference

Resolution Procedure (9.5) Is initiated when QC and Verification do not compare. The Department may initiate an Independent Assurance (IA) review of: plastic properties calculation of w/c ratio handling of cylinders April 3, 2002 2002 Construction Conference

Resolution Procedure (9.5) curing procedures initial final compressive strength testing cores may be required April 3, 2002 2002 Construction Conference

Resolution Procedure (9.5) “Hold” cylinders are tested within 7 days of the 28-day strength tests. April 3, 2002 2002 Construction Conference

Resolution Procedure (9.5) Concrete is accepted based on the strength test results deemed by the Department to be the most accurate If Verification is the most accurate, then Verification represents the 4 lots, -Contractor pays for the Resolution testing If QC is the most accurate, QC represents the 4 lots, -Department pays for the Resolution testing. April 3, 2002 2002 Construction Conference

Resolution Procedure (9.5) When the Department cannot determine that either QC or Verification data is in error, the concrete representing the four lots will be evaluated based on the results of the resolution investigation. April 3, 2002 2002 Construction Conference

Rest of Section 346 relatively unchanged Same requirements for Investigation of low strength concrete for structural adequacy (10) Pay adjustments for low strength concrete (11) April 3, 2002 2002 Construction Conference

State Materials Office Develops a Resolution Procedure: The intent is to inform both Construction and Materials personnel of a consistent process in the event that Resolution is needed on their projects. April 3, 2002 2002 Construction Conference These Cylinders are from the same Lot, same load of concrete

2002 Construction Conference XXXXXXXXXXX XXXXXXXXXX These are the hold cylinders from the same load of concrete April 3, 2002 2002 Construction Conference

2002 Construction Conference XXXXXXXXXXXXXXXXXXXXXX April 3, 2002 2002 Construction Conference

The DRAFT Resolution Procedure will be available on the SMO website. April 3, 2002 2002 Construction Conference

In General the DRAFT Resolution Procedure identifies what is needed: At start of project, the Project Engineer should designate one person to; make data entrees and track cylinder testing. make the comparisons between QC and Verification test results. April 3, 2002 2002 Construction Conference

After the Concrete is Placed: When placement is completed, the plastic property data should be entered into the 6 screen of the CQR system within one working day of the concrete placement by the Project Engineer’s designee. Why does this need to be in the 6 screen within one day? April 3, 2002 2002 Construction Conference

After the 28 day Strength Tests are completed QC and Verification Labs should notify the Project Engineer, or his designee of test results on the first working day after testing and; within 3 working days of obtaining the data it should be entered into the 7 screen of the CQR system April 3, 2002 2002 Construction Conference

2002 Construction Conference CQR Codes Verification Samples V =Verification compares with QC N =Verification did not compare with QC Project Engineer reviews the data and verifies the comparison or non-comparison April 3, 2002 2002 Construction Conference

When QC and Verification do not Compare Notify your District Concrete Engineer immediately He may initiate an IA review of QC and Verification procedures He will notify the State Materials Office April 3, 2002 2002 Construction Conference

2002 Construction Conference Transport the “hold” cylinders to the designated Resolution laboratory: Each sample is accompanied with a new C-22 card, with all information included. The QC and Verification Laboratories will enter a new 6 screen into CQR April 3, 2002 2002 Construction Conference

2002 Construction Conference The Resolution Laboratory will enter the 7 screen data and indicate the status of the resolution samples under new codes. April 3, 2002 2002 Construction Conference

NEW CQR Codes for Resolution Samples RQ =Resolution confirms QC results or both QC and Verification results RV =Resolution results confirm Verification results RR =Resolution results do not confirm QC or Verification results. April 3, 2002 2002 Construction Conference

2002 Construction Conference If you have any questions concerning these new CQR codes please contact: Glen Mans in Certifications at the SMO (352) 337-3146 SC 642-3146 glen.mans@dot.state.fl.us April 3, 2002 2002 Construction Conference

Thank You for your time and attention - Any Questions? April 3, 2002 2002 Construction Conference