Materials Overview for Business Transformation Office August 25

Materials Overview for Business Transformation Office August 25, 2016 Charles A. Babish, W. R. Bailey and L. J. Lundy Materials Division

Specifications and Materials Requirements • Outline of Presentation • What is the Role of VDOT- Materials Division in Construction and Maintenance? • How is Material Quality controlled? • Why are Material Quantities of concern? • What is the Acceptance/Verification Process? • Why is Documentation important and what documentation is needed for material acceptance? • How do various Materials practices fit into AASHTOWARE Project? • Examples 2

VDOT Materials Division • Staff Level – 56 Positions • Engineering Staff - 49 positions (16 Registered Professional Engineers, 1 Program Administrator, 8 Staff Engineers, 4 Scientists, 20 Engineering Technicians) • Administration and Management – 9 positions • Annual Operating budget – approximately $7 Million • Annual Training budget – approximately $110, 000 • 187 Positions statewide • District Materials Engineers serve as State Materials Engineer representatives on technical matters in the field. 3

VDOT Materials Division of the Deputy Chief Engineer’s Directorate Division’s Primary Functional Areas State Materials Engineer Andy Babish, P. E. Concrete, Structures, Chemistry Quality Assurance Bill Bailey, P. E. Geotechnical Engineering Tommy Schinkel, P. E. (Acting) Business (Procurement, Fiscal, Facilities) Veronica Hendricks Pavement & Asphalt Materials Rob Crandol, P. E. 4

VDOT Central Office Laboratories CO Materials Laboratories Physical Lab AASHTOWARE Chemistry Lab AASHTOWARE Soils Lab MITS/PLAID Structures Inspections PDMS? Quality Assurance QA Programs Notebooks Soils Lab AASHTOWARE Asphalt Mix Lab MITS/PLAID Asphalt Binder AASHTOWARE Geotechnical Engineering Pavement Design 5

VDOT District Materials Sections District Materials Engineer Salem-Culpeper. Hampton Roads-Bristol Physical Laboratory AASHTOWARE Soils Lab MITS/PLAID Quality Assurance Field – IA, VST Notebooks Asphalt Laboratory MITS/PLAID Geotechnical Engineering Pavement Design 6

What is Materials Division’s Role? • Set policy and procedures for Materials Acceptance • Determine sampling and testing frequencies • Establish sampling and testing protocols 7

Virginia Asphalt Acceptance Program Binders & Emulsions AASHTO WARE POJECT 8

Asphalt Plant Independent Assurance and Verification Testing MITS/PLAID 9

Concrete Acceptance Testing for Strength & Permeability AASHTO WARE POJECT 10

Reinforcing Steel & Pre-stressed Wire Strand AASHTO WARE POJECT 11

Soils & Aggregates MITS/PLAID AASHTO WARE POJECT 12

Miscellaneous Materials AASHTO WARE POJECT Curing Compound for Concrete Burlap for Curing Concrete Bridge Decks & Pavements 13

Specifications and Materials Requirements Quality Level Set by Contract Documents Special Provisions Copied Notes Plans Specifications Road & Bridge Standards 14

Specifications and Materials Requirements • Source of Supply (Materials)-Section 106 Road & Bridge specifications • All materials must be approved • New • Sufficient tested Quantities to represent the material 15

Specifications and Materials Requirements • Source of Materials – C 25 form submittal • List of all Suppliers and Materials • 30 days but not less than 7 days before construction start • Notify Department 2 weeks prior to delivery of materials from commercial source • Contractor submits to Project Inspector , District Materials, etc. • Starts with Bid Tabs • Engineers Estimate of Materials and quantities 16

Bid Tab Item No. Spec. No. Description

18

Specifications and Materials Requirements • Acceptance Methods • Testing • Inspection • Certification • Quality Assurance Plans • Approved Lists • Pre-Qualified Lists • CT Process 19

Specifications and Materials Requirements All Acceptance Methods involve Testing 20

Materials Manual of Instructions Sampling Procedures - Chapter II & VIII Test procedures - Chapter II, IV, V and VIII Report Forms – Chapter VIII Acceptance/rejection - Documentation Chapter VII Materials Notebook TL 142 Excel Spreadsheet 21

Specifications and Materials Requirements • Testing – Major Items • • • Plant – MITS/PLAID Asphalt and Central Mix Aggregates Test Reports – TL 50 and TL 52 TL 102 – tons of material delivered to project Price Adjustments Field Placement - AASHTOWARE Project Asphalt, Concrete, Central Mix Aggregates Test Reports – TL 56, 57, 58, 59, 60 TL- 13 and 26 22

Aggregate Base Material Ty. I No. 21 B Item No. – 10128 Spec. No. – Section 308 309 of Road & Bridge Specification Materials Specification Section 208 Acceptance – TL 102 form stamped VDOT QA Acceptance Program 23

Aggregate No. 57 Item No. – Various Spec. No. – Section 302 of Road & Bridge Specification Materials Specification Section 203 24 Acceptance – TL 102 form stamped VDOT QA Modified Acceptance Program

Ready Mix Concrete District Approves Plant Mix Design Test Report – Slump, Air and Strength tested at project 25

Hydraulic Cement Concrete Sidewalk 4” Item No. – 13220 Spec. No. – Section 504 of Road & Bridge Specification Materials Specification Section 217 Acceptance – Tested on Project by Inspector/Materials for slump, air and strength 26

CG 12 Detectable Warning Surface Spec. No. – Section 502 of Road & Bridge Specification and Special Provision Materials Specification Section 217 – A 3 Concrete Road & Bridge Standards – 203. 05 Truncated Dome Detail 27 Acceptance – Certification and submit a sample to be placed on Approved List 72

Hot Mix Asphalt Plant District Approves Plant Mix Design - Asphalt Content - Plant testing Test Report –Density tested at project 28

Specifications and Materials Requirements • Inspections at Fabrication Facilities • Steel • Prestressed • Inspection Reports – Sent to Project 29

Light Pole Item No. – 51321 Spec. No. – Section 700 of Road & Bridge Specification Materials Specification Sections 226 or 229 Acceptance – Shop inspected by VDOT or Consultant Inspection agency 30

Galvanized Steel or Aluminum Poles Item No. – 51321 Spec. Section 407 of Road & Bridge Specification for Fabrication Procedures Welding – AASHTO/AWS Bridge Welding Code D 1. 5 Galvanizing Specification Section - 233 Acceptance – Shop inspected by VDOT or Consultant Inspection agency for VDOT 31

Spec. No. – Section 700 of Road & Bridge Specification Manufacturer’s name on all tags Date of Manufacture on all tags Unique ID number 32

Specifications and Materials Requirements Inspections at Manufacturing Facilities • Sampling and Testing • Test Report – Batch – Quantity – Multiple projects 33

Specifications and Materials Requirements • Inspections – Visual • Project site when material received – Good Condition • Small quantities • No other way to verify (not common or recommended) 34

Specifications and Materials Requirements Certifications • Special Testing • Mill Analysis – Steel • Buy America • Pavement Marking Materials • Same as original sample tested and approved • Harmful chemicals – Lead • Cement, Concrete, Admixtures • Annual 35

Specifications and Materials Requirements Long Term Performance Tests • Approved Lists • Certifications • We certified that the material is the same as the original sample MS 12345 that was tested and approved for List XX • Batch test and/or field test 36

Performance Test Decks Approved List 17, 20, 73, 74, 75 Approved List 46 Approved List 13 37

4” Type A Pavement Markings Item No. – Various Spec. No. – Section 704 of Road & Bridge Specification Materials Specification Section 246 Acceptance – Approved List 20 Certification and C 85 Daily Work report 38

Specifications and Materials Requirements • Quality Assurance Plans – Approved lists • • • Precast Concrete Items List 34 Metal, Concrete and Plastic Pipe List 25, 26 and 42 Asphalt Binder and Emulsions List 50 and 50. 1 Castings – Manhole frames and covers List 61 Monitored by VDOT Materials • Periodic testing & Inspections 39

Precast Concrete QA Program • • Item No. – Various - Drop inlets, risers, adjustment rings Spec. No. – Section 302 of Road & Bridge Specification Materials Specification Section – 232 Acceptance – Approved List 34 and Certified Delivery ticket with statement in 40 accordance with Virginia DOT Precast Concrete QA program

Concrete Pipe QA Program • • Item No. – Various 12” 24” 30” 48” Pipe Spec. No. – Section 302 of Road & Bridge Specification Materials Specification Section – 232 Acceptance – Approved List 26 and Certified Delivery ticket with statement in accordance with Virginia DOT Concrete Pipe QA program 41

Grey Iron Castings QA Program Item No. – 09056 Manhole Frame & Cover Spec. No. – Section 302 of Road & Bridge Specification Materials Spec. No. – Section 224 SPCN – AASHTO M 306 Acceptance – Approved List 61 Gray Iron Castings 42

Guardrail CERTIFICATE OF COMPLIANCE AND GUARANTEE Section 221 of R&B Specifications List 12 Periodic Testing & Inspection 43

Specifications and Materials Requirements Approved QA Suppliers List 44 • • • Miscellaneous Materials Geotextiles Epoxies Curing Compounds Anchor Bolts – ASTM 307 Monitored by VDOT Materials • Periodic Testing & Inspections 44

Filter Fabric Item No. – 27505 Spec. No. – Section 303 of Road & Bridge Specification Materials Specification Section 246 Acceptance – VDOT Miscellaneous QA Supplier List 44 Test Report – GF 12345 45

Unapproved Sources Lowes Home Depot Southern States 46

Approved Sources List 44 Miscellaneous QA Suppliers 47

Specifications and Materials Requirements Approved Lists • Materials Division Lists • Aggregate Properties • Materials from Long Term Testing • Suppliers under QA plans • Traffic Engineering Pre Approved Products List • NCHRP 350 Lists (Crash Tested Items) • Guardrail end treatments • Median Barriers • Truck Mounted Attenuators • Barricades – Visual inspection 48

Group 2 Channelizing Devices Item No. – 24278 Spec. No. – Section 512 of Road & Bridge Specification Materials Specification Section – NCHRP 350 List Acceptance – Visual and Certification to Inspector on job 49

Specifications and Materials Requirements CT Process • Modified Acceptance • Utilities – Certification/Stamped Catalogue Cut • Electrical – Pre Approved Traffic Engineering List – Certification/Stamped Catalogue Cut • Special Items 50

Utilities Fire Hydrant Item No. – Attached or on Plans Spec. No. – Section 520 of Road & Bridge Specification Materials Specification - AWWA C 502 or C 503 Acceptance – Certification or stamped Approved Catalogue Cuts 51

Water Main Ductile Iron Pipe Item No. – 13220 Spec. No. – Section 520 of Road & Bridge Specification Materials Specification Section 232 Acceptance – Certification or stamped Approved Catalogue Cuts 52

Specifications and Materials Requirements Project Documentation and Traceability during Construction • Materials Notebook • Pay Quantities need supporting documents – Invoices – Inspection Reports – Physical Releases TL-109 – Test Reports (TL forms) – Acceptance Tests in Field (TL 13, 28, 59, 60… 141) 53

Specifications and Materials Requirements Project Closeout TL 131 Final Material Document • Certification that all materials met specifications to FHWA • Exceptions for materials accepted outside specification • Reasons Central Office Materials Notebook Audit • One project per month 54

Specifications and Materials Requirements Resource and reference Documents • • Materials Division Manual of Instructions (MOI) Approved List of Materials Special Products Evaluation List (SPEL) Road and Bridge Specification Book Road and Bridge Standards Volume I & II Plans Approved Shop Drawings MUTCD 55

Specifications and Materials Requirements VDOT District Contacts • District Materials Engineer • District Materials QA Engineer (Field Operations) • Approved Ready Mix Suppliers in District • Approved Aggregate Suppliers • Approved Asphalt Suppliers • District Notebook Person 56

Specifications and Materials Requirements Certifications Requirements • Subcontractors - Talk to approved district suppliers • Asphalt, concrete, aggregate, pavement marking • Certifications needed to perform testing • Special certifications environmental – Land Disturbance – Painting steel – containment 57

Materials Division Website Link: http: //www. virginiadot. org/business/materials-download-docs. asp Manual Of Instructions by chapter: II : Methods and Frequencies of sampling Top of website link: Approved Lists (pdf 2 mb) Updated 7/11/14 Pre-Approved NCHRP 350 Crash Tested List (Barriers) (. pdf 90 kb) Pre-Approved Traffic Control Device Listing (Link) Materials Documentation Middle of website link: Source of Materials Resource Document (. pdf 404 kb) 09/10/07 Materials Notebook Resource Document (. pdf 93 kb) 09/10/07 59

Specifications and Materials Requirements • Outline of Presentation • What is the Role of VDOT- Materials Division in Construction and Maintenance? • How is Material Quality controlled? • Why are Material Quantities of concern? • What is the Acceptance/Verification Process? • Why is Documentation important and what documentation is needed for material acceptance? • How do various Materials practices fit into AASHTOWARE Project? • Examples 60

Materials Overview for Business Transformation Office August 25, 2016 Charles A. Babish, W. R. Bailey and L. J. Lundy Materials Division