2. REVISED May 2009STATE MATERIALS OFFICE

3. Goals in this Session To understand:  The Sampling & Testing process  The Project Certification process  The EAR/DDM process  The Project Administrator’s Statement  What an Exception is, and  The certification tools available

4. Field S & T: An Overview Does it meet Specs? QC Testing Verification Testing EAR Remove & Replace No Resolution No Do they Compare? Yes Material Accepted Yes

5. Project Material Certification Materials Engineer’s Certification Contractor’s Final Certification PA’s Materials Statement Contractor’s Monthly Certification Approved EAR For failing Material Passing & Verified QC results Reported Test Results

6. What should you expect?  A notarized form ─ “Construction Compliance with Specifications and Plans” (700-020-02)  Approved EAR/DDMs  Other documents  NOTE: For the final certification, all of the exceptions to QC sampling and testing must be shown on the form

8. Follow-up Actions by the Project Personnel  Verify the area represented contained acceptable material  Verify all material issues are resolved  Verify Exceptions are complete and accurate  Verify the Exceptions match w/ Pay penalties  Verify all supporting certifications for materials accepted by certification are received and meet specifications

9.  A report prepared by an approved licensed engineer providing analysis of failing material left in place  Evaluation of affected material, e.g., Analysis of additional samples, Life Cycle Cost Analysis, etc  Reporting structural adequacy with reference to the design criteria  “Disposition of Defective Material” form What is an EAR?

10. Form 700-011-01 CONSTRUCTION 07/06 Florida Department of Transportation Disposition of Defective Material Section A: Sample Information and Request for EAR – Project Administrator Financial Project No.: Contract No: Federal Job No: Material ID.:Sample No.:LIMS Sample ID.: Pay Item No.:Quantity:Location: Description of Defective Material: □ EAR Scope attached Section B: Proposal - Project Administrator/Resident Engineer □ Remove and Replace Material □ Follow up Sample Passed (MM 3.1) □ Send to DME for Concurrence with Proposal, EAR Scope attached □ Concurs □ Rejects (See Comments Below) □ Leave in Place, EAR not required Signature:Date: Comments: Section C: EAR Information – District Materials Engineer - Choose one and send form to DCE □ Remove and Replace Material □ Leave in Place – EAR not required, Send to DCE for Concurrence □ Concur with EAR Scope (attached) – Submit EAR Signature:Date: Comments:

11. Bottom of the “DDM” form Section D: Material Disposition Recommendation – District Materials Engineer □ EAR performed, DME recommendation: Chose one and send form to District Construction Engineer □ All material to be left in place. □ All material to be removed. □ Partial removal of material/Other Quantity of material to be removed:____________________________________________________________ Location of material to be removed:____________________________________________________________ DME Concurs with EAR Recommendations -Yes □ No □ Signature:Date: Section E: Concurrence - District Construction Engineer □ Concur with DME Recommendation – Send to Project Administrator □ Do Not Concur with DME recommendation – Send to Director, Office of Construction □ DCE recommendation attached Comments: Signature:Date: Section F: Decision - Director, Office of Construction □ Director, Office of Construction Decision (attached) - Send to Project Administrator Signature:Date: Section G: Record of Final Payment Determination: - Project Administrator Material left in place at % pay Comments: cc: District Materials Office District Construction Office State Construction Office

12. Financial Project #: Federal Project #: Contract #: County: All materials incorporated into the referenced project(s) were accepted in accordance with the STRG or pertinent contract documents and met all applicable requirements. Earthwork density test locations and results are in substantial compliance with the pertinent specification requirements of this project. A spot-check of the project density records indicate substantial compliance with the governing specifications, sampling and testing guides, and procedures. All Contractor Quality Control (QC) material test results have been verified in accordance with contract requirements. The final disposition of all material represented by QC results has been accurately documented. All required certifications and/or certified test reports have been received in accordance with contract requirements. Project Administrator’s Materials Statement

13. Earthwork density test locations and results are in substantial compliance with the pertinent specification requirements of this project. A spot-check of the project density records indicate substantial compliance with the governing specifications, sampling and testing guides, and procedures.

14. All Contractor Quality Control (QC) material test results have been verified in accordance with contract requirements. The final disposition of all material represented by QC results has been accurately documented.

15. All required certifications and/ or certified test reports have been received in accordance with contract requirements.

16. Exceptions

17. What are Exceptions? ( to the Certification ) Material Not Meeting Standards For CQC Testing:  Asphalt does not meet standards if C.P.F. for a Lot is less than 90% However, we are now looking at failing tests at the request of the Bituminous technical unit  Concrete does not meet standards if “payment tests” do not pass  Earthwork does not meet standards if ‘QC’ tests do not pass and are not verified

18. What are Exceptions? ( continued ) Material Not Meeting Standards (cont.) For Non-CQC Testing:  Material does not meet standards if ‘V’ test does not pass. Testing Frequency  Material not tested, or tested at a frequency, not in conformance with the Specifications and left in-place.

19. Qualifications  Sampling and testing performed by unqualified technicians (when specified in the Contract documents).  Testing performed at unqualified laboratories or at qualified laboratories during a time that they were removed from the list of Qualified Laboratories.  Materials produced when the production facility was not on the accepted list, and left in- place. What are Exceptions? ( continued )

20. You have an Exception, how do you report it?  Description  Location  Quantity  Resolution (and at what pay)  Concurrence…obtained?

21. Example of Format Friction Course - Straightedge When the friction course was straightedged, two irregularities were found as indicated. Sta. 167+75, Lane 1 Left Roadway 1/2" High Sta. 167+75, Lane 2 Left Roadway 1/2" High An area of 2400 sq. ft. was left in-place at no pay. The District and State Construction Engineers have concurred.

22. How about a Bio-Break?

23. CHECKLIST for Certification Contract For Lump Sum and Design Build: Job Guide Schedule Additional requirement for Design Build: Design and Construction Criteria PA Material Statement Final Construction Compliance Report form #700-020-02 Laser Profiler Reports and/or Final Straightedge Reports Final Sign Inspection Report (if not included in PA Statement) Final Commercial Inspection for Items Spec 450 (structural steel, cantilevers, etc.) Certification for Prestress Items (Piling, Beams) DDM/EAR (Defective Material forms) with final disposition and signatures Core Out Reports Earthwork: Lot summary sheets from density log (if CQC project) Asphalt: Lot composite pay factor sheets (if CQC Project) Concrete: Spreadsheet by mix design that shows for all verification samples (lots) what QC samples (lots) they represent (if not clear in LIMS) Required Certification Tracking Report from LIMS with items marked if not used (no certs logged in LIMS)LIMS cleared up, all samples approved

24. Who? How much? How often? What? Why?

25. 1 400 4 15CONC CLASS IV (MISCELLANEOUS)2.00 Who? How much? How often? What? Why?

26. Random Sample

27. Tools we use for our Review

28. Project Info Sample State Location Material ID Sample ID (LIMS)

41. Wrap-up We discussed:  The Sampling & Testing process  The Project Certification process  The EAR/DDM process  The Project Administrator’s Statement  What an Exception is, and  Tools to use

43. Questions Comments

44. Lab submits application to DMO DMO reviews accreditation Inspection needed? Lab is added to LIMS Lab corrects deficiencies Y N Inspection OK? NY Producer submits QC Program to DMO DMO reviews QC Program Inspection needed? Producer is added to LIMS Producer corrects deficiencies Y N Inspection OK? NY Contractor submits QCM to SCO DMOs & DCOs review QCM Is QCM OK? QCM is added to Infonet Contractor corrects deficiencies NY Contractor submits QCP to PA PA & DMO reviews QCP Is QCP OK? Contractor QCP is Approved Contractor corrects deficiencies N Y Verification Testing & Inspection Engineering Analysis Report Do they compare? Resolution Testing QC Testing & Inspection Y N Meet Specs? Y N Contractor requests UserID Contractor receives LIMS training Contractor gets connectivity PA processes request Contractor obtains UserID Contractor gets access to LIMS Construction Begins Material Disposition Contractor’s Monthly Material Certification Final Project Material Certification Feedback for Continued Approval ACCEPTANCE PROCESS FLOWCHART