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CMM May 2011 Transmittal

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					                                             CMM Transmittal
Date:      May 31, 2011
To:        Construction and Materials Manual Users
From:      David Castleberg, Bureau of Project Development
Subject:   Update - Construction and Materials Manual

Please review the portions of the Construction and Materials Manual (CMM) revised for the May 2011 update.
The summary of changes in this memo provides a brief synopsis of substantive revisions. The revisions are
highlighted in yellow in the May 2011 transmittal.
Hardcopies of the transmittal and the complete CMM can be ordered from the following site:
                http://roadwaystandards.dot.wi.gov/standards/cmm/hidden/printrequests/index.htm



The CMM is available on the department's roadway standards web page for viewing, printing, or downloading.
No login or password is required. Users can print paper copies or burn CD's. The CMM is located at:
                         http://roadwaystandards.dot.wi.gov/standards/cmm/index.htm



If you wish to be notified when the CMM is updated, you must sign up for this service. This applies to both
WisDOT staff and non-WisDOT partners. Sign up is located at:
                         http://roadwaystandards.dot.wi.gov/standards/subscribe/index.htm
Please call or e-mail if you have any questions or problems with the CMM documents, website, or notification
service.
Thank you,
        David Castleberg, P.E.
        Bureau of Project Development
        608-264-7606
        david.castleberg@dot.wi.gov




                                                                                                               Page 1
                                    Summary of Changes


         CHAPTER              PROCEDURE                           REMARKS

CMM Table of Contents            0.00       Add entry for section 215.

1 - General Provisions                      2011 construction notes
                                 1.10
                                            1. Erosion Control Mobilizations

                                 1.55       Change Risk Management Unit contact person.

2 - Contract Administration      2.00       Add entry for section 215.

                                 2.15       New section: Transparency Efforts for Projects

                                            Update 30 percent Rule worksheet download
                                 2.60
                                            procedure.

4 - Pavements                    4.21       Changes to concrete joint layouts

                                 4.24       Add joint layout to list of contractor cause for cracks

5 - Structures                   5.25       Removed 5.25.2.6 on Epoxy Pavement Markings.

6 - Miscellaneous                           1. Update Erosion Control Order form and directions.
Construction                                2. Revise instructions for Mobilization of Erosion
                                 6.45       Control.
                                            3. Revise instructions for Emergency Mobilization of
                                            Erosion Control.

8 - Materials Testing,
                                 8.36       Update procedures for QMP-HMA
Sampling, Acceptance

                                 8.50       Update remarks for Corrugated Polyethylene Pipe




                                                                                                      Page 2
    CMM 0.00 Table of Contents

                                                                           Wisconsin Department of Transportation
               Construction and Materials Manual
                                                 Table of Contents

                                                  CMM Foreword
           0.10..... Contractual References 

                                         Chapter 1 - General Provisions
           1.10..... Construction Notes 

           1.15..... Glossary 

           1.20..... Forms/Worksheets 

           1.30..... Hazardous Materials 

           1.35..... Safety 

           1.40..... Field Facilities and State-Owned Equipment 

           1.45..... Traffic Control 

           1.50..... Construction Equipment 

           1.55..... Construction Site Crashes 

           1.58..... Archaeological and Burial Considerations 

           1.60..... Construction Inspection 

           1.65..... Contract Records 

           1.70..... Performance Measures 

                                      Chapter 2 - Contract Administration
           2.10..... Contracts and Agreements 

           2.14..... Federal Aid Local Road Projects

           2.15..... Transparency Efforts for Projects

           2.16..... Consultant Contracts for Construction Services 

           2.18..... Project Relationships and Communication 

           2.19..... Construction Services by Local Units of Government

           2.20..... Public Relations 

           2.22..... Notice to Proceed 

           2.24..... Labor Compliance 

           2.26..... Preconstruction Meeting 

           2.28..... Laws and Standards 

           2.30..... Right-of-Way

           2.32..... Measurement and Payment 

           2.34..... Site Time - Damages and Incentives 

           2.36..... Intermediate/Tentative/Final Estimates 

           2.38..... Administrative Items 

           2.40..... Prompt Payment 

           2.42..... Contract Modifications 

           2.44..... Cost Reduction Incentive 

           2.46..... Force Accounts 

           2.48..... Suspension of Work 

           2.50..... Project Acceptance 

           2.52..... Bonds and Warranties 

           2.54..... Contract Claims 

           2.56..... Utilities 

           2.58..... Railroad Agreement

           2.60..... Subcontracting 

                                        Chapter 3 - Earthwork and Bases
           3.10..... Clearing and Grubbing 

           3.15..... Removing Miscellaneous Structures 

           3.20..... Roadway and Drainage Excavation 


May 2011                                                                                                            Page 1
CMM 0.00 Table of Contents



             3.25..... Structure Excavation 

             3.30..... Embankments 

             3.35..... Borrow Excavation 

             3.40..... Granular Subbase Course

             3.45..... Dust Control 

             3.50..... Rubblizing Concrete Pavement 


                                                Chapter 4 - Pavements
             4.10..... Concrete Pavement - General 

             4.11..... Preparing the Grade for Concrete Paving 

             4.15..... Hauling and Placing Concrete 

             4.16..... Concrete Consolidation 

             4.17..... Concrete Finishing 

             4.18..... Concrete Texturing and Tining 

             4.19..... Protecting Freshly Placed Concrete 

             4.21..... Pavement Joints 

             4.24..... Concrete Paving Inspection 

             4.50..... Asphalt Pavement - General 

             4.51..... Mixing Plants 

             4.53..... Mix Production 

             4.54..... Preparation of Foundation for Asphalt Pavement 

             4.56..... Hauling Asphaltic Mixture 

             4.57..... Asphalt Pavers 

             4.58..... Placing Asphalt Mixtures 

             4.59..... Asphalt Mat Inspection 

             4.61..... Compaction and Density of Asphalt Pavement

             4.65..... Pavement Marking, Roads Open to Traffic

                                                Chapter 5 - Structures
             5.10..... Concrete Masonry 

             5.15..... Concrete Structures 

             5.20..... Steel Bridges 

             5.25..... Bridge Decks 

             5.28..... Concrete Deck Overlays and Structure Repairs 

             5.30..... Painting 

             5.40..... Piling 

             5.45..... Railing 

             5.50..... Pipe Culverts 

             5.55..... Shop Fabrication Plans 

             5.60..... Post Award Acceptance of Design/Build Retaining Walls 


                                      Chapter 6 - Miscellaneous Construction
             6.10..... Concrete Curb and Gutter 

             6.15..... Storm Sewer 

             6.20..... Manholes and Inlets 

             6.25..... Marker Posts, Cable Guard Fence, and Steel Plate Beam Guard 

             6.30..... Property Fence and Right-of-Way Fence 

             6.35..... Maintenance and Repair of Haul Roads 

             6.40..... Landscaping 

             6.45..... Erosion Control 

             6.50..... Pavement Marking 

             6.55..... Electrical Construction 

             6.60..... Well Construction and Borehole Abandonment

                                        Chapter 7 - Construction Surveying
             7.10..... Construction Surveying - General


May 2011                                                                               Page 2
CMM 0.00 Table of Contents



             7.15..... Highway Staking 

             7.18..... GPS Machine Guidance 

             7.20..... Staking Storm Sewer System 

             7.25..... Staking Subgrade and Base 

             7.30..... Staking Curb, Gutter, Curb and Gutter, and Concrete Barrier 

             7.35..... Staking Pipe Culverts

             7.40..... Staking Structure Layout

             7.45..... Staking Concrete Pavement 

             7.50..... Staking Re-Surfacing Reference 

             7.55..... Staking Electrical Installations 

             7.60..... Staking Supplemental Control 

             7.62..... Slope Stakes 

             7.65..... Staking Right-of-Way

             7.70..... Cross Sections and Digital Terrain Models 

             7.75..... Staking Borrow Pits 

             7.80..... Constructing and Restoring Access Points 

             7.85..... Survey Monuments 

                              Chapter 8 - Materials Testing, Sampling, Acceptance
             8.10..... Materials - General

             8.13..... Weighed Materials 

             8.15..... Density Testing 

             8.20..... Independent Assurance Program

             8.30..... QMP - General 

             8.32..... QMP - Subgrade 

             8.34..... QMP - Aggregate 

             8.35..... QMP - Concrete 

             8.36..... QMP - HMA

             8.38..... QMP - Ride 

             8.40..... Materials Sampling 

             8.45..... Materials Testing and Acceptance - General

             8.50..... Materials Testing and Acceptance Guide 

             8.55..... Materials Testing and Acceptance - Earthwork 

             8.60..... Materials Testing and Acceptance - Aggregates 

             8.65..... Materials Testing and Acceptance - Asphalt 

             8.70..... Materials Testing and Acceptance - Concrete 

             8.75..... Materials Testing and Acceptance - Structures 





May 2011                                                                               Page 3
test
    CMM 1.10 Construction Notes

                                                                               Wisconsin Department of Transportation
                Construction and Materials Manual
                 Construction Notes

    GENERAL
    Construction notes address changes in department policy or specifications that are not included in the contract.
    Implementation requires a contract change order that both department staff and the contractor agree to.
    Construction notes offer optional fixes to known problems, but are not contractual mandates. Solutions outlined
    in construction notes are endorsed by both the department and the industry.
    The department issues a new set of construction notes in the early part of the construction season. Additional
    notes are released during the construction season if an issue warrants a rapid response. Later issuances
    include or supersede earlier issuances.
    Typical construction notes address late breaking technical specification changes, while others may address
    contract administration issues. Each note provides background information, a problem statement, and a solution
    to that problem in the form of contract change order language field staff can incorporate in their contracts.
    Construction notes are advisory regarding cost and thus only make suggestions regarding how the proposed
    contract change might be priced. No-cost solutions are generally recommended, but many situations will require
    renegotiation of the contract bid prices for affected items. Some changes may require the addition or deletion of
    bid items.
    CURRENT CONSTRUCTION NOTES
                                               2010 Construction Notes
            1. Curing Compounds on Urban Projects
            2. Electronic Reporting of Concrete Pavement Thickness Data
            3. Piling
            4. Standard Details for Concrete Bases
            5. Illinois Temporary Concrete Barrier
            6. Buy America
            7. Materials Documentation Submittal
            8. Detectable Warning Fields
            9. Temporary Paint - obsolete
            10. Temporary Concrete Barrier Chamfers

                                               2011 Construction Notes
            1. Erosion Control Mobilizations




May 2011                                                                                                                Page 1
CMM 1.10 Construction Notes



                                                                                  Wisconsin Department of Transportation
                 Construction and Materials Manual
                   2010 Construction Note Number 1 - January 2010
                   Subject: Curing Compounds on Urban Projects

    BACKGROUND
    Appearance of concrete items is important in urban settings where these items are highly visible to the general
    public. WisDOT has observed an increase in the frequency of scaling problems over the first winter on concrete
    items on urban projects in recent years.
    PROBLEM
    Concrete items are most vulnerable to scaling damage during the first winter of service when the concrete is still
    relatively green, and it is subjected to severe exposure to de-icing salts and freeze-thaw cycling while in a
    saturated condition. Concrete items such as pavement, curb and gutter, driveway aprons, sidewalk, etc. in
    urban settings have frequently been showing significant scaling after the first winter, especially in areas where
    chloride-laden snow banks sat for an extended period of time. The poor appearance of areas where this scaling
    occurs has generated numerous complaints from municipalities and the public.
    SOLUTION
    WisDOT is seeking to mitigate this problem by upgrading the type of curing compound used on exposed
    concrete items on urban projects and roundabouts regardless of location. Linseed oil type curing compound has
    been shown by past experience to provide increased scaling resistance over the first winter. Standard
    specifications are currently being changed to require the use of linseed oil type curing compound on urban work
    to increase scaling resistance.
    Use a contract change order (CCO) to implement the change to linseed oil cure on active projects where the
    standard wax type water based cure is currently specified. The price increase should be negotiated with the
    contractor on the basis of increased materials cost to substitute the linseed oil cure in place of the standard
    cure. This change should be applied to all exposed concrete items within the right of way that have standard
    gray color and standard finish specified. This would include, but not be limited to, Concrete Pavement, Curb and
    Gutter, Driveway Aprons and Sidewalk.
    This change would not apply to any items with special color and/or texture such as stamped and/or colored
    concrete for which clear cure and seals are specified by special provision.
    Add the following language as a change order to contracts that include the above items in an urban setting or
    any roundabouts. For a project that is partially urban and partially rural, apply the change to the entire project.
        Use linseed oil cure in place of the curing compound required by the standard specifications for the concrete
        items in this contract listed below
        Item Number                   Item Name                         Quantity and Units
        ___________                   ___________________               ________________________
        ___________                   ___________________               ________________________
        ___________                   ___________________               ________________________
        The linseed oil cure shall meet the following requirements:
        Furnish liquid membrane-forming curing compounds composed of a blend of boiled linseed oil and high
        viscosity, heavy bodied linseed oil emulsified in a water solution conforming to AASHTO M 148, type 2 class
        B. Test material at an application rate of 1 gallon per 200 square feet.
        The drying time requirements shall be waived. The chemical requirements (volumes are exclusive of added
        pigments) are as follows:
            Oil phase (50+/- 4% by volume)                     (Percent by Mass)
                   Boiled Linseed Oil………………………………….. 80
                   Z-8 Viscosity Linseed Oil…………………………...20
            Water phase (50 +/- 4% by volume)………….............…..100
    Standard specifications requiring the use of linseed oil type curing compound on urban work and roundabouts
    will be in place for the 2011 construction season.
    Call Jim Parry at 608-246-7939 for more information about this note.

May 2011                                                                                                                   Page 2
CMM 1.10 Construction Notes



                                                                               Wisconsin Department of Transportation
                Construction and Materials Manual
                   2010 Construction Note Number 2 - January 2010
 

                   Subject: Electronic Reporting of Concrete Pavement Thickness Data
 


    BACKGROUND
    The department is phasing in the use of the Materials Reporting System (MRS) system for contractors to
    electronically submit construction and materials data to the department. The MRS software allows contractors to
    submit data to the department electronically, estimate pay adjustments, and print selected reports. Qualified
    personnel may obtain MRS software from the department’s web site at:
                                          http://www.atwoodsystems.com/mrs
    PROBLEM
    The department will be requiring contractors to use the MRS system to report concrete thickness data starting
    with projects let in March 2010, but contracts let before March 2010 will not have language requiring the
    contractor to use the MRS. Also, field staff have asked for clarification on how to handle thickness measurement
    for shoulders, ramps, and other longer units of constant cross section.
    SOLUTION
    The standard specifications will be revised to require the use of the MRS system to report concrete thickness
    probing data.
    Implement new specification language calling for the establishment of special units to measure thickness of
    concrete pavement in long stretches less than 10 feet wide, such as shoulders and ramps. Each special unit is
    limited to a maximum of 350 square yards. When entering thickness data into the MRS for special units provide
    a description of the location or locations and any alternate methods used instead of probing for special units.
    Add the following language as a no cost change order to contracts let before March 2010 that include concrete
    pavement bid items. This language supersedes that of the December 2009 concrete pavement thickness data
    construction note.




May 2011                                                                                                                Page 3
CMM 1.10 Construction Notes




    415.3.18.1 General
    Replace paragraphs two and three with the following:
     (2)	   The department will use contractor probing of the freshly placed concrete as the primary method for
            determining thickness. The department will base acceptance and payment on the contractor's quality control
            tests until shown through the validation, verification, or dispute resolution process that the contractor's test
            results are in error. The department will validate all contractor data before determining pay adjustments. The
            department will determine areas with deficient thickness by coring.
     (3)	   Within 30 calendar days after probing, submit the thickness data electronically using the department's
 

            materials reporting system (MRS) software available at: 

                                                 http://www.atwoodsystems.com/mrs
    415.3.18.3 Pavement Units
    Replace paragraph three with the following:
     (3)	   Establish special units for areas of fillets, intersections, gaps, and other areas not included in basic units.
            Also establish special units for shoulders, ramps, and other long areas of constant cross section less than 10
            feet wide. Limit the size of special units to a maximum of 350 square yards.
    415.3.18.4.3 Alternate Methods
    Replace paragraph one with the following:
     (1)	   The contractor may employ an alternate method, agreeable to the engineer, to determine the measured

            thickness of special units. Measure the depth of a special unit at a minimum of 2 locations as the engineer 

            approves. Include a brief description of the alternate method as a part of the MRS submittal. 

    415.3.18.9 Nonconforming Areas
    Replace the entire text with the following:
     (1)	   If the final thickness of a basic unit is nonconforming, the department will make the pay adjustment for that
            unit contingent upon the final thickness of the next basic unit in that lane. If the location for the next required
            random probing series is within 125 feet of the first test location, the contractor may select and document a
            new random location to provide space for corrective action.
     (2)	   If the final thickness of the next basic unit is conforming, the department will not assess any pay adjustments
            for either basic unit. If the final thickness of the next basic unit is nonconforming or unacceptable, the
            department will adjust the pay for both basic units. The department will continue pay adjustment for each
            succeeding basic unit until the contractor produces a basic unit with conforming final thickness.
     (3)    If the final thickness of a special unit is nonconforming, the department will adjust the pay for that unit.
    These specification revisions will be incorporated into contracts effective with the March 2010 letting using
    Additional Special Provision 6 (ASP 6) and will be included in the 2011 edition of the standard specifications
    effective with the December 2010 letting.
    Call Wayne Chase at 608-245-8960 for more information regarding this note.




May 2011	                                                                                                                     Page 4
CMM 1.10 Construction Notes



                                                                                      Wisconsin Department of Transportation
                     Construction and Materials Manual
                        2010 Construction Note Number 3 - March 2010
                        Subject: Pile Driving

    BACKGROUND
    WisDOT has revised the resistance factor for pile driving in “Chapter 11 Foundation Support” of the Bridge
    Manual. The resistance factor has been increased from 0.4 to 0.5 for determining the “Required Driving
    Resistance” for piles using the modified Gates dynamic formula. The value of 0.5 is based upon research
    performed on piles driven in Wisconsin.
    PROBLEM
    Piles are currently being driven longer than plan estimates and to excessive capacities. This has resulted in the
    following issues:
              -	   Damage of the piling caused by driving the pile to high capacities.
              -	   Project time delays as a result of more time required to drive the piling.
              -	   Contractors needing to provide larger pile driving hammers and cranes.
              -	   Project cost overruns because plan pile estimates are exceeded.
    SOLUTION
    Execute a contract change order (CCO) revising structural plan notes relating to pile driving. The pertinent
    structural notes are typically located in two areas of the structure plan: (1) the “Foundation Data” notes on the
    first sheet and (2) the abutment and pier (if applicable) sheets. These revisions consist of changing plan notes
    relating to the required driving resistance and the associated resistance factor. Calculate the revised driving
    resistance and change the modified Gates resistance factor as follows:
              -	 Compute the revised required driving resistance(s) by multiplying the plan required driving
                 resistance(s) by 80 percent (0.4/0.5).
              -	 Change the modified Gates resistance factor from 0.4 to 0.5.
    (1.) Foundation Data Note
    Replace the existing Foundation Data note in its entirety, with the revised driving resistance and resistance
    factor values as calculated above. Example existing and replacement notes are shown below.

            Existing Note:
            FOUNDATION DATA
            ABUTMENTS TO BE SUPPORTED ON HP 12 X 53 STEEL PILING DRIVEN TO A REQUIRED
              DRIVING RESISTANCE OF 350 TONS** PER PILE AS DETERMINED BY THE MODIFIED
              GATES DYNAMIC FORMULA.

            **THE FACTORED AXIAL RESISTANCE OF PILES IN COMPRESSION USED FOR DESIGN IS
               THE REQUIRED DRIVING RESISTANCE MULTIPLIED BY A RESISTANCE FACTOR OF
               0.4 USING MODIFIED GATES TO DETERMINE DRIVEN PILE CAPACITY.
            Replacement Note:
            FOUNDATION DATA
            ABUTMENTS TO BE SUPPORTED ON HP 12 X 53 STEEL PILING DRIVEN TO A REQUIRED
              DRIVING RESISTANCE OF 280 TONS** PER PILE AS DETERMINED BY THE MODIFIED
              GATES DYNAMIC FORMULA.

            **THE FACTORED AXIAL RESISTANCE OF PILES IN COMPRESSION USED FOR DESIGN IS
               THE REQUIRED DRIVING RESISTANCE MULTIPLIED BY A RESISTANCE FACTOR OF
               0.5 USING MODIFIED GATES TO DETERMINE DRIVEN PILE CAPACITY.




May 2011	                                                                                                                      Page 5
CMM 1.10 Construction Notes



    (2.) Legend Note on Abutment and Pier (If Applicable) Sheets
    When the plan includes an abutment and/or pier sheet, replace the legend note in its entirety with the revised
    driving resistance values, as calculated above. Example existing and replacement notes are shown below.

           Existing Note:
           LEGEND
           HP 12 X 53 STEEL PILING WITH A REQUIRED DRIVING RESISTANCE OF 350 TONS PER
             PILE AS DETERMINED BY THE MODIFIED GATES DYNAMIC FORMULA. ESTIMATED
             PILE LENGTH = 90 FEET.


           Replacement Note:
           LEGEND
           HP 12 X 53 STEEL PILING WITH A REQUIRED DRIVING RESISTANCE OF 280 TONS PER
             PILE AS DETERMINED BY THE MODIFIED GATES DYNAMIC FORMULA. ESTIMATED
             PILE LENGTH = 90 FEET.


    General
    This change only effects the installation requirements of the piling and does not affect the design pile capacities
    or pile number/configuration. The driven pile lengths may or may not be less than the estimated plan pile
    lengths. Contact the structure design engineer to verify that the lower required driving resistance and the
    potential reduction in pile length will not be detrimental to the performance of the substructure due to downdrag
    or scour concerns.
    This change may result in a minimal reduction in the unit bid price for the piling. The bridge contractors have
    noted increased cost of pile installation due to the current driving loads, longer drive times, and the use of larger
    pile hammers and cranes.
    The engineer must submit a copy of the completed CCO to Scot Becker, Structures Development Section for
    incorporation into final “As-built” statewide records.
    Contact Bill Dreher (608-266-8489), Bob Arndorfer (608-246-7940) or Jeff Horsfall (609-243-5993) for more
    information regarding this note.




May 2011                                                                                                                Page 6
CMM 1.10 Construction Notes



                                                                               Wisconsin Department of Transportation
                Construction and Materials Manual
                   2010 Construction Note Number 4 - April 2010
                   Subject: Standard Details for Concrete Bases

    BACKGROUND
    The department has experienced problems with the construction of type 10 and 13 concrete bases, including
    misalignment of anchor bolts. Beginning with the 2010 construction season, the department is now requiring the
    use of a bottom template, which has generated changes to the diameter and re-bar lengths.
    PROBLEM
    Standard detail drawings for type 10 and 13 bases in current construction contracts must be replaced with new
    detail drawings. The details have changed as shown in the table below:


     Existing Detail    New Detail                 Name                              Reason for Change
    9E 9-2             9C 11-1        Concrete Base Type 10              Requiring bottom template
    9E 10-2            9C 12-1ab      Concrete Base Type 13              Requiring bottom template, larger diameter
                                                                         form, revised re-bar lengths
    9E 11-1            9C 13-1        Concrete Base Type 10 & 13         Changes to the tables for reinforcement
                                      Extensions                         and concrete quantities


    SOLUTION
    If your contract includes type 10 or type 13 bases, execute a contract change order replacing standard detail
    drawings as below:
    Existing Standard Detail                              New Standard Detail
    9E 9-2 Concrete Base Type 10                          9C 11-1 Concrete Base Type 10
    9E 10-2 Concrete Base Type 13                         9C 12-1ab Concrete Base Type 13
    9E 11-1 Concrete Base Type 10 & 13 Extensions         9C 13-1 Concrete Base Type 10 & 13 Extensions


    The cost of the change order will need to be negotiated based on the required additional templates and changes
    in steel and concrete quantities.
    Contact Jim Kazda (608-266-8416) for more information regarding this note.




May 2011                                                                                                                Page 7
CMM 1.10 Construction Notes



                                                                                    Wisconsin Department of Transportation
                 Construction and Materials Manual
                    2010 Construction Note Number 5 - May 2010
                    Subject: Illinois Temporary Concrete Barrier

    BACKGROUND
    During 2009, WisDOT received a contractor request to substitute Illinois Department of Transportation
    temporary concrete barrier for WisDOT’s temporary concrete barrier. Based on a limited review, WisDOT
    approved the substitution for that individual project.
    Earlier this year, WisDOT received another inquiry about the acceptability of Illinois temporary concrete barrier
    for potential statewide use. This inquiry prompted WisDOT to conduct a more thorough evaluation of the Illinois
    temporary concrete barrier.
    PROBLEM
    Based on discussions with researchers, the WisDOT Bureau of Project Development (BPD) evaluation of the
    Illinois temporary concrete barrier revealed two concerns:
            -	 Compatibility of Illinois temporary barrier with Wisconsin’s barrier design.
            -	 Concerns with anchoring the barrier into pavement.
    When Illinois barrier is connected to WisDOT barrier, the connection between barriers does not have a double
    sheer connection due to the different loop bar placement locations each system uses. Figure 1 shows a picture
    of the connection of Illinois to WisDOT barrier with the shear connection missing. Figure 2 shows the shear
    connection detail. If the double shear connection is missing, during an impact:
            -	 The pin may fly up into the air resulting in a penetration hazard, or hazard to people nearby.
            -	 Force may not properly transfer from one barrier section to the next (e.g. connection failure causing
               vehicle to hit hazard being protected).
            -	 Barrier may form a ramp causing the errant vehicle to launch into the air or roll over.
            -	 The one section of the barrier may form a blunt end. Abrupt deceleration of the vehicle can cause
               severe occupant injuries.
    Figure 3 provides a detail of the Illinois temporary concrete barrier. Printable version of Illinois temporary
    concrete barrier details are available at the following link:
                                                   Illinois temporary barrier
    The department has concerns with the installation and related performance issues described above, but does
    not have any concerns with the overall safety of the Illinois temporary concrete barrier.
    SOLUTION
    Based on WisDOT evaluation, the department does not consider the Illinois temporary concrete barrier an equal
    alternative to WisDOT barrier, and WisDOT will not allow Illinois temporary concrete barrier as a substitute for
    WisDOT temporary concrete barrier.
    Projects that have already installed Illinois barrier are to contact the oversight engineer in BPD Project Services
    Section.
    If a contractor wishes to substitute a different temporary barrier system (i.e. not Illinois), project staff should
    review CMM 1.45.12 before accepting a substitution.
    As always, proper installation and quality of the temporary barrier should also be reviewed. See CMM 1.45.
    Questions on acceptability of temporary should be directed to the region oversight engineer.
    Technical sponsor Erik Emerson (608-266-2842).




May 2011	                                                                                                                    Page 8
CMM 1.10 Construction Notes




                              Figure 1: Temporary Concrete Barrier Shear Connection




May 2011                                                                              Page 9

CMM 1.10 Construction Notes




                              Figure 2: Barrier Connection Detail




May 2011                                                            Page 10

CMM 1.10 Construction Notes




                              Figure 3: Illinois Temporary Concrete Barrier Detail




May 2011                                                                             Page 11

CMM 1.10 Construction Notes



                                                                                Wisconsin Department of Transportation
                Construction and Materials Manual
                   2010 Construction Note Number 6 - June 2010
                   Subject: Buy America

    BACKGROUND
    Since 1982, federal law has required that all steel and iron permanently incorporated into federally-funded
    transportation projects be domestic and all manufacturing and coating processes occur within the United States.
    Manufacturing processes include smelting, bending, shaping, and any other manufacturing performed on the
    product. Coating processes include epoxy, galvanizing, painting, and any other coating that protects or
    enhances the value of a material.
    The requirements are found within a federal provision in the special provisions for each contract. Guidance can
    be found within CMM 2.28.4. The following items are examples that contain materials covered by the Buy
    America requirements.
            Anchor Assemblies, Bolts, Rods (for structures and bases)
 

            Bearing Pads 

            Bridge Secondary Fabricated Items:
 

            Rail Posts, Sleeves, Shims, Rail Panels, Structural Fasteners, Expansion Devices, Cover Plates, Floor 

              Drains, Guardrail Anchors, Bearing Assemblies, Steel Diaphragms 

            Castings (including inlet & manhole covers) 

            Bar Steel (coated & uncoated) 

            Tie Bars 

            Dowel Bars

            Hook Bolts

            Concrete Culverts, Pipes, Endwalls, Catch Basins, Inlets, Manholes (steel reinforcement) 

            Pre-stressed Concrete Members (steel reinforcement) 

            Metal Pipes & Endwalls

            Delineator Posts & Hardware

            Drains & Downspouts 

            Pull Boxes, Poles, Mast Arms, Metallic Conduit

            Fencing Fabric, Rails, Tension Wire, Barbed Wire

            High Strength Bolts 

            Steel Piling 

            Sign Bridges & Supports 

            Steel Sign Posts 

            Steel Grid Floor 

            Steel Plate Beam Guard

            Structural Steel 

            Stud Shear Connectors 

    PROBLEM
    Often the manufacturers and suppliers do not provide adequate certification that all processes conform to Buy
    America. Many times a document will state that the material was produced in the United States, but does not
    certify that subsequent manufacturing and/or coating processes occurred within the U.S.
    SOLUTION
    Manufacturers and/or suppliers must ensure that they meet the Buy America requirements, certify their
    compliance on the appropriate documents, and submit the documentation to the department in a timely manner.
    Each manufacturer and/or supplier who performs a process on the material must certify their compliance for that
    process. Department project personnel will review all certifications and invoices at the time of submittal for the
    necessary Buy America certification statements.
    Contact Wayne Chase at 608-245-8960 for more information regarding this note.




May 2011                                                                                                             Page 12
CMM 1.10 Construction Notes



                                                                              Wisconsin Department of Transportation
                Construction and Materials Manual
                   2010 Construction Note Number 7 - June 2010
                   Subject: Materials Documentation Submittal

    BACKGROUND
    The department requires contractors to submit documentation and testing data as part of the acceptance criteria
    for construction materials. Examples of documents may include: certificates of compliance, certified reports of
    tests, and shop inspection reports. Required documents are to be submitted before incorporating the materials
    into the work to ensure that acceptable materials are used. Results of required contractor field tests are to be
    documented and submitted as the work is being performed, using worksheets or the Materials Reporting
    System (MRS) as required by the specifications.
    PROBLEM
    Each year, the Legislative Audit Bureau (LAB) conducts audits on department construction contracts that are
    completed. The auditors randomly select construction contracts to review. The audits include a review of the
    documentation and data submittals. Recent audits have found many instances when the required
    documentation or data has not been submitted in a timely manner or not submitted at all. When the appropriate
    documents or data are not submitted, the department has no basis for acceptance of the material.
    SOLUTION
    Contractors must ensure that the required materials documentation is submitted in a timely manner before
    incorporating the material into the work. Contractors must document and submit required test results as they are
    developed. Department project personnel will review documentation at the time of submittal to ensure the
    materials are conforming and request submittal of any missing documents before incorporation of the materials
    in the work. The department may hold full or partial payment of bid items containing materials for which the
    required documentation or data has not been submitted.
    The Legislative Audit Bureau and the department will continue to review construction contracts to ensure
    compliance with specifications. The department will monitor the results of future audits, and may implement
    stronger mandates related to materials documentation and data submittals, if needed.
    Contact Wayne Chase at 608-245-8960 for more information regarding this note.




May 2011                                                                                                           Page 13
CMM 1.10 Construction Notes



                                                                                Wisconsin Department of Transportation
                Construction and Materials Manual
                   2010 Construction Note Number 8 - June 2010
                   Subject: Detectable Warning Fields

    BACKGROUND
    The Americans with Disabilities Act Accessibility Guidelines (ADAAG) require detectable warnings on curb
    ramps at all legal crossings, sidewalk, and multi-use trails. A grid of small truncated domes raised above the
    walking surface indicates the change from pedestrian to vehicular use so that a pedestrian traveling without
    visual cues will not inadvertently step into the roadway.
    Until February 2, 2010 the department had allowed two types of materials for the detectable warning fields: cast
    iron and sheet metal.
    PROBLEM
    The department has discovered that when the sheet metal detectable warning fields fail they can leave sharp
    edges exposed, resulting in a significant hazard to bicyclists and pedestrians. Refer to Figure 1.




    Figure 1: Sharp Edges Exposed on Sheet                    Figure 2: Natural Patina Cast Iron Detectable
             Metal Detectable Warning Field                             Warning Field

    SOLUTION
    As of February 2, 2010 the department has removed sheet metal detectable warning field products from the
    approved products lists. The products remaining on the approved list for detectable warning fields are cast iron.
    Figure 2 shows an example installation of an uncoated natural patina cast iron warning field.
    Approved products can be found in WisDOT's approved products list under the heading Curb Ramp Detectable
    Warning Field:
    http://www.dot.wisconsin.gov/business/engrserv/docs/ap0/approved-lists.pdf
    For projects let before February 2, 2010, remove from the contract the sheet metal warning fields that have not
    yet been constructed and replace them with the currently approved cast iron warning fields. Contractors can
    negotiate a price providing proof that their bid was based on using sheet metal detectable warning fields.
    Contact Don Greuel at 608-267-7774 for more information regarding this note.




May 2011                                                                                                             Page 14
CMM 1.10 Construction Notes



    CMM 1.10 Construction Notes

                                                                               Wisconsin Department of Transportation
                Construction and Materials Manual
                   2010 Construction Note Number 10 - June 2010
                   Subject: Temporary Concrete Barrier Chamfers

    BACKGROUND
    WisDOT Bureau of Project Development received a request on the acceptability of providing additional
    chamfers on vertical and horizontal edges of 12.5-FT Temporary Concrete Barrier. Various locations on the
    current standard detail drawings allow for 1” and 3/4” chamfers. However, some edges do not have chamfers.
    PROBLEM
    During placement or removing operations, temporary concrete barriers have a tendency to become damaged. If
    damage is severe, the barrier may not function as intended For example, a snag point may develop or damage
    end sections can allow too much barrier rotation.
    Industry has indicated that damage tends to happen near non-chamfered edges. Adding a chamfer may limit the
    barrier damage.
    SOLUTION
    It is acceptable to use 1” chamfer on the horizontal and vertical edges of the barrier, as shown in Figure 1
    below. In September 2010, a SDD change will incorporate the information provided in this construction note.
    Older barriers that use ¾” chamfers are acceptable, as shown in Figure 2 and Figure 3 below.
    If a contractor proposes to use 1” chamfers before issuance of the SDD, project staff are to process a no cost
    change order.
    Technical sponsor: Erik Emerson 608-266-2842




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CMM 1.10 Construction Notes




                                Figure 1: Chamfer on Temporary Concrete Barrier




                       Figure 2: Connection Pin Detail Showing Allowable 3/4" or 1" Chamfer




May 2011                                                                                      Page 16
CMM 1.10 Construction Notes




                    Figure 3: Barrier Taper Section Detail Showing Allowable 3/4" or 1" Chamfer




May 2011                                                                                          Page 17

CMM 1.10 Construction Notes



                                                                                  Wisconsin Department of Transportation
                   Construction and Materials Manual
                      2011 Construction Note Number 1 - May 2011
                      Subject: Erosion Control Mobilizations

    BACKGROUND
    Federal regulatory requirements, including the Clean Water Act, require that specific actions be taken to
    minimize or prevent sediment loss from construction sites. Erosion control best practices have been
    implemented to help meet the regulatory requirements and be a good steward of the environment. The
    department has identified that current design practice does not include enough quantity of the bid item
    Mobilizations Erosion Control. An adequate number of mobilizations are required to get the proper erosion
    control items in place in a timely fashion to protect the environment.
    Throughout the contract it may be necessary to adjust the types, quantity, location and staging of erosion control
    installations. If necessary, proper documentation of the change in the form of an amendment to the ECIP by the
    contractor is required.
    Construction procedure also requires that the contractor be notified in writing, using the Erosion Control form
    (WS1074), if a site inspection determines that corrective action is necessary. Proper guidance on the use of the
    form is needed.
    PROBLEM
    The current design guidelines for estimating Erosion Control Mobilizations understate what is necessary.
    Current guidelines for adding Erosion Control Mobilizations for ECIP amendments are vague and lead to
    problems in meeting compliance.
    SOLUTION
    Execute a change order for contracts let after December 1, 2010 but not yet started that incorporates the
    following three changes:
              1. Increase the quantity of the Mobilizations Erosion Control bid item (methodology below).
              2. Include a provision to add a Mobilization every time the ECIP is amended.
              3. Add guidance on the use of the Erosion Control Order form.
    This change order will increase the quantity but not the contract unit price for the Mobilizations Erosion Control
    bid item. An ECIP amendment is also required if the ECIP has already been approved. Where possible,
    contracts in the PS&E process will be corrected either by the designer or Central Office Plan Checkers prior to
    letting.
    Part 1:
    Increase the quantity of the Mobilizations Erosion Control bid item based on the following new guidance to be
    published in the Facilities Development Manual in April 2011, effective with the December 2011 letting:
    Estimate how many times an erosion control or landscaping contractor may need to be mobilized given the type
    of work and environmental or customer sensitivity of the area. It is important to provide adequate quantities for
    this item commensurate with applicable environmental requirements
    Practice indicates that landscapers are typically mobilized up to 5 times for small bridge projects. For example:
              1. Install silt fence prior to earthwork
              2. Install temporary ditch checks
              3. Install turbidity barrier prior to abutment or pier work
              4. Bring erosion control measures up to the Q2 elevation after the substructure work is complete but prior
                 to work on the superstructure
              5. Perform final restoration and landscaping
    Some examples of estimating Mobilizations Erosion Control are:
              1. Three mobilizations for each earthwork balance point
              2. Three mobilizations for each construction staging sequence
              3. One mobilization for each 2-3 weeks of contract duration

May 2011                                                                                                               Page 18
CMM 1.10 Construction Notes



              4. One mobilization for each 1/4 to 1/2 mile of project length
    Use whichever method indicates the most mobilizations. Also include quantities associated with any restrictions
    on how much area may be exposed at any one time.
    Part 2:
    Include a provision to add a Mobilization every time the ECIP is amended.
    Add the following language to the change order:
    Amendments to the ECIP not necessitated by the contractor being out of compliance with Trans 401, or
    associated with contractor-selected waste or borrow sites, which result in the landscaper needing to mobilize to
    the project with additional equipment or manpower, will result in one additional mobilization granted per ECIP
    amendment.
    This guidance will be included in the May 2011 CMM release.
    Part 3:
    Update and add guidance on the use of the “Erosion Control Order” form.
    The Erosion Control Order form has been updated to rename the first check box to “Erosion Control Corrective
    Actions”. Obtain the updated form, WS1074, published in the CMM, at:
                            http://roadwaystandards.dot.wi.gov/standards/cmm/forms/ws1074.doc
    Add the following language to the change order:
    To accomplish required erosion control work, the project engineer will complete an “Erosion Control Order” form
    and give it to the prime contractor. Upon completion of the work, the prime contractor must complete the bottom
    portion of the form and return it to the project engineer. A record of all such orders and inspections shall be
    maintained in the project field office or, if there is no field office, kept by the project engineer.
    The use of no-payment “Erosion Control Corrective Actions” is limited to situations where:
              1. The order is to perform corrective action, such as correcting items not properly installed, installing
                 items not installed as previously ordered, or repairing damaged items.
              2. The work is required because the contractor is out of compliance with the project erosion control plan
                 or ECIP, per Trans 401.
              3. The work is part of normal maintenance covered and paid under a previously-installed bid item.
    This guidance is included in the May 2011 CMM release.
    Contact Al Nemec, Bureau of Project Development, 608-267-0306, or Michelle Reynolds, Bureau of Equity and
    Environmental Services, 608-264-8417 for more information regarding this note.




May 2011                                                                                                                  Page 19
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    CMM 1.55 Construction Site Crashes

                                                                                  Wisconsin Department of Transportation
                Construction and Materials Manual
                    Chapter 1      General Provisions
                    Section 55     Construction Site Crashes

    To the extent necessary and practicable, the engineer is to contact local law enforcement officials to solicit their
    assistance in evaluating the effectiveness of the traffic control operations, and to obtain written and verbal
    reports of crashes occurring in the work zone and immediate project vicinity.
    In addition to implementing any necessary corrective actions consistent with the duties and responsibilities
    associated with the position, the engineer will provide the crash reports to the area supervisor on a weekly
    basis. Then as deemed necessary, on an individual project basis, the project’s crash situation will be reviewed
    by representatives of the region’s construction, design, maintenance, and traffic sections (as appropriate), in
    cooperation with the statewide bureau traffic section and central office oversight engineer (as appropriate). This
    will be done for the purpose of evaluating the crash frequency and/or severity occurring on the project, and for
    determining appropriate improvements.
    Findings of the reviews will be documented by the region, with copies of the documentation furnished to
    appropriate statewide bureau sections, enabling implementation of improvements on future projects. The
    following steps identify immediate actions that should be followed by the department's field representatives to
    promote safety and help manage WisDOT's risk in construction work zones.
           1. If emergency responders have not arrived, call 911 as soon as possible to report the crash.
           2. Notify the project manager or the supervisor that a crash has occurred.
           3. If the project supervisor deems necessary, notify Janet Huggins (Risk and Safety supervisor of
              WisDOT's Risk Management Unit janet.huggins@dot.wi.gov ) that a crash has occurred.
           4. When possible, document the crash site area with photos and sketches as appropriate.
           5. When available, obtain the crash report from law enforcement.
    1.55.1 INVESTIGATION CHECKLIST
    Form DT2044, The Investigation Checklist, is to be used as a guideline only to assist the engineer in gathering
    potential evidence and documentation that may be requested in the defense of a claim against a state employee
    or contractor. Each claim is unique and may require additional information not listed on this checklist.
    Information gathering should begin as soon as the engineer determines that a significant event may result in the
    filing of a claim.
    Information gathered using this checklist may be considered confidential attorney-client communication. The
    Risk Management unit should be contacted before releasing any information.
    1.55.2 TRAFFIC DAMAGE CLAIMS
    It is the policy of the department to bill contractors for damages caused by their construction operations to signs
    and other traffic control device installations. Any time a contractor removes signs and fails to reinstall them
    properly, or any time damages to signs or other traffic control devices are incurred as a result of operations by a
    contractor, those costs should be billed to the contractor under a damage claim. Accordingly, the project
    manager should record all pertinent information relative to such damages or incurred costs. This information
    should be given to the region office.




May 2011                                                                                                                   Page 1
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    CMM 2.00 Chapter 2 Table of Contents

                                                                           Wisconsin Department of Transportation
               Construction and Materials Manual
                   Chapter 2     Contract Administration
           2.10..... Contracts and Agreements 

           2.14..... Federal Aid Local Road Projects

           2.15..... Transparency Efforts for Projects

           2.16..... Consultant Contracts for Construction Services 

           2.18..... Project Relationships and Communication 

           2.19..... Construction Services by Local Units of Government

           2.20..... Public Relations 

           2.22..... Notice to Proceed 

           2.24..... Labor Compliance 

           2.26..... Preconstruction Meeting 

           2.28..... Laws and Standards 

           2.30..... Right-of-Way

           2.32..... Measurement and Payment 

           2.34..... Site Time - Damages and Incentives 

           2.36..... Intermediate/Tentative/Final Estimates 

           2.38..... Administrative Items 

           2.40..... Prompt Payment 

           2.42..... Contract Modifications 

           2.44..... Cost Reduction Incentive 

           2.46..... Force Accounts 

           2.48..... Suspension of Work 

           2.50..... Project Acceptance 

           2.52..... Bonds and Warranties 

           2.54..... Contract Claims 

           2.56..... Utilities 

           2.58..... Railroad Agreement

           2.60..... Subcontracting 





May 2011                                                                                                            Page 1
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     CMM 2.15 Transparency Efforts for Projects

                                                                                  Wisconsin Department of Transportation
                  Construction and Materials Manual
                      Chapter 2      Contract Management
                     

                      Section 15     Transparency Efforts for Projects
 


     The Transparency Effort is a concept where state or local design services contracts may sometimes include
     providing consulting services to consultant construction project leaders during construction of highway projects.
     The intent is to provide a way of improving construction communications on consultant managed construction
     projects so that project leaders can make timely project decisions.
     The full process for Transparency Effort is described in FDM 8-1-10. Here are a few of the highlights of that
     process.
              -	 Since most of the questions from the field staff are discovered during review of the plans and contract
                 documents in preparation for starting field work, the Transparency contract or work order is expected
                 to be in place well before the project Preconstruction Meeting to ensure that the consultant designer is
                 available to address design related questions.
              -	 Transparency Projects will use the Design Information Notice (DIN) WS2503 to document questions
                 going to the design consulting firm so that there is no confusion with questions that may come from the
                 contractor to the consultant construction Project Leader. The construction Project Leader must
                 approve the DIN before the design consultant may begin work.
              -	 Construction project personnel, including contractors, should be informed that the design consulting
                 firm is under contract to provide answers to design questions to the construction project leader and
                 that they are encouraged to use the program when needed. They should also be informed that the
                 construction Project Leader must approve the DIN before the design consultant may begin work.




May 2011	 	                                                                                                                Page 1
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    CMM 2.60 Subcontracting

                                                                                     Wisconsin Department of Transportation
                 Construction and Materials Manual
                     Chapter 2      Contract Management
                     Section 60     Subcontracting

    2.60.1 SUBLETTING THE CONTRACT
    Standard spec 108.1.1 requires that before the prime contractor may sublet, sell, transfer, or assign any contract
    work, or otherwise dispose of the contract, a portion of the contract, or a right, title, or interest in the contract, the
    written consent of the engineer must first be obtained. Before subletting or subcontracting any portion of the
    contract work, the contractor must submit form DT1925, Sublet Request and DBE Sublet Purchase Report.
    Figure 1 provides an example. A separate form must be submitted for each proposed subcontract. The form
    must be completely filled in and signed by the contractor or the contractor's authorized agent. If the prospective
    subcontractor is not pre-qualified with the department, evidence of competency to perform the work must be
    attached.
    The engineer will not permit contract work to be performed by a subcontractor until the request for permission to
    sublet the work has been approved. A subcontract is a direct contractual relationship between the prime
    contractor and another company where the company operates independently to perform a defined portion of the
    contract. These contractual relationships are often referred to as first tier subcontracts. The authority to approve
    or disapprove will reside in the regions within these guidelines.
    Occasionally, a question will arise as to whether a contractual relationship between a prime contractor and
    another company is a subcontract or an employee lease arrangement. FHWA has addressed this question in
    their Contract Administration Core Curriculum Participant's Manual and Reference Guide. In this manual, FHWA
    states that employee lease arrangements are acceptable for federal-aid projects if the leased employees are
    under the direct supervision and control of the contractor's superintendent or supervisor. Leased employees
    may be considered to be part of the prime's own organization if:
            -	 The prime contractor maintains control over the supervision of the day-to-day activities of the leased
               employees.
            -	 The prime contractor remains responsible for the quality of the work of the leased employees.
            -	 The prime contractor retains all power to accept or exclude individual employees from work on the
               project.
            -	 The prime contractor remains ultimately responsible for the payment of predetermined minimum
               wages, the submission of payrolls, statements of compliance, and all other federal regulatory
               requirements.
    The key issue is supervision and control of any leased personnel. If the leased personnel are treated as
    employees of the prime contractor, and would be considered as such but for their actual employment by a
    leasing agency, then for purposes of 23 CFR Section 635.116(a) they should be considered employees of the
    prime contractor's organization.
    If the above conditions are met, the contractual relationship is an employee lease arrangement, not a
    subcontract. An employee lease arrangement is not subject to the 30% rule discussed later in this section, and a
    request to sublet is not required.
    Note that DT1925 is also to be used for reporting DBE/WBE work, which may not be an official subcontract, and
    also for reporting materials or supplies furnished by a DBE/WBE.




May 2011	                                                                                                                     Page 1
CMM 2.60 Subcontracting




                          Figure 1: Example Sublet Request and DBE Sublet Purchase Report

    In addition to obtaining department approval for all first tier subcontractors, standard spec 108.1.1 requires the
    prime contractor to notify the department of all lower tier subcontractors and all other parties working on the
    contract.
    This notification is important so the department is aware of all the parties working at the project site, and can
    properly administer labor compliance regulations.
    2.60.2 PRIME CONTRACTOR PARTICIPATION
    Standard spec 108.1.2 includes the federal requirement that the prime contractor perform at least 30% of the
    original contract work with the prime contractor's own organization. The purpose of this requirement is to prevent
    brokering. Brokering occurs when the company under contract with the owner sublets all or virtually all of the
    work to other companies.
    The prime contractor's own organization is defined as workers the contractor employs and pays directly as well
    as equipment the contractor owns or rents, either with or without operators.
    Occasionally, due to a wide variety of work within a single contract, FHWA may approve a reduction in the level

May 2011                                                                                                                 Page 2
CMM 2.60 Subcontracting



    of prime contractor participation before the contract is let. If a reduction is approved, it will be identified in the
    contract special provisions.
    The department administers the 30% rule by:
            -	 Reviewing the prime contractor's initial submittal identifying the work they will perform.
            -	 Monitoring the total amount of work the prime contractor is proposing to sublet as shown on the
               department form DT1925,Sublet Request and DBE Sublet Purchase Report.
    2.60.2.1 Prime Contractor's Initial Submittal
    As referred to in standard spec 108.1.2, standard spec 103.6 requires the prime contractor to submit
    documentation regarding the 30% rule during the same 10 business day time period the prime submits a signed
    contract, the contract bonds, and other department required forms. The prime contractor must demonstrate
    compliance with the 30% rule as a condition of contract execution.
    The prime contractor is required to submit its 30% rule documentation on WS1081, Prime Contractor
    Participation. Submit WS1081 using the automated process described below. The submittal must contain the
    prime contractor's best information, at the time of the letting, concerning the work the prime contractor intends to
    do.
    The department recognizes the information on the prime contractor participation worksheet is subject to change
    as work proceeds on the contract. The prime contractor is not obligated to perform the work as shown on the
    initial submittal. At its discretion, the prime contractor may decide to complete the work differently provided it
    complies with standard spec 108.1.
    The department will further monitor compliance of the 30% rule during the course of the contract by reviewing
    the total amount of work the prime contractor is proposing to sublet as shown on DT1925.
    2.60.2.2 Installing the Prime Contractor Participation Worksheet
    Users of WS1081 will need to save the worksheet template on their hard drive before using it the first time, by
    following these steps:
            -	   Create a C:\ws1081 folder.
            -	   Click on the WS1081 download link.
            -	   If the Macros prompt comes up click Enable Macros.
            -	   A box will come up saying "Do you want to open or save this file" Click Open.
            -	   A box will come up saying, "Enter the prime contractor name". Click OK.
            -	   Go to File -> Save As.
            -	   Under the "Save as type:" pulldown choose Template (*.xlt)
            -	   Under the "Save In:" pulldown navigate to the C:\ws1081 folder
            -	   Under the "filename" pulldown make sure it says ws1081.xlt
            -    Hit Save.
    2.60.2.3 Instructions for Completing the Prime Contractor Participation Worksheet
    The following set of instructions will detail how to download a file of contract items and unit prices, import the
    items into the prime contractor participation worksheet, complete the worksheet, and send it to the department.
    The instructions assume that you are logged on to the WisDOT extranet site where you will begin by
    downloading the list of contract items. This process can be used for a single contract or multiple contracts. For
    multiple contracts you will need to repeat Steps 2 - 12 for each contract.
    2.60.2.3.1 Download Contract Item File
      Step 1: Go to the Construction Contract Payment Viewing System at the following link:
                                         https://trust.dot.state.wi.us/ccpvs/default.jsp
                  You will need to logon to the WisDOT Extranet web site.




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CMM 2.60 Subcontracting



      Step 2: Select the By Contract Id radio button and enter the contract number in the box provided and click
              Continue.




      Step 3: Select voucher 000.




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CMM 2.60 Subcontracting



      Step 4: Right-click on CSV Export, then go to Save Target As...




      Step 5: Select the C: drive; double click on the ws1081 folder.
      Step 6: Click Save.




               Please do not change the folder location or the file name. The csv file must be saved to the
               C:\ws1081 folder and the file name must be “voucher_details.csv”. If you change either one, the
               worksheet will not import the 0000 voucher data.



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CMM 2.60 Subcontracting



       Step 7: When the dialog box shown appears on your screen, click on the Yes button and the download
               process will start.




                This dialog box will not appear the first time you perform Step 7, but will appear each subsequent
                time. If you have multiple contracts, continue through Step 12 before beginning to download data for
                the next contract.
       Step 8:	 	After the downloading is completed the following message box will appear. Click on Close to exit.




     2.60.2.3.2 Import Contract Item File
       Step 9:	 Close excel and all active spreadsheets. Open ws1081.xlt, the Prime Contractor Percentage
                 	
                worksheet template that you installed in the C:\ws1081 folder.
      Step 10: When you open ws1081.xlt the following dialog box will appear. Click on Enable Macros.




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CMM 2.60 Subcontracting



     Step 11: Opening ws1081.xlt will create an empty worksheet. You will be prompted to enter the prime
              contractor name. Click OK.




               Enter the prime's name in the yellow highlighted box labeled (The Contractor).




               By completing the worksheet the contractor agrees to the terms of the Contractor Certification
               Statement contained in the worksheet header.




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CMM 2.60 Subcontracting



      Step 12: Click Import Data to populate the worksheet with the contract bid items.




                The data from the voucher_details.csv previously saved in Step 6 will be imported into the blank
                WS1081 worksheet file and will be automatically saved as the PCS"contractID".xls file in the
                C:\ws1081 folder. The "contractID" designation in the file name is the contract ID for the contract
                entered in Step 2. You will see the file name displayed in the top blue bar of the open worksheet, for
                this example Microsoft Excel - PCS20050510007.xls as displayed in the above screen shot.

      Step 13:	 	If you want to continue filling out the worksheet, first close the Construction Contract Payment
                 Viewing System and go to Step 14. If you have multiple contracts to download, follow Steps 2 -12 for
                 each contract. Click "Return to Initial Selection Page" to return to the screen described in Step 2.
                Remember to open a new ws1081.xlt worksheet file in Step 9 from your C:\ws1081 folder for each
                new contract ID.




May 2011	 	                                                                                                          Page 8
CMM 2.60 Subcontracting




     2.60.2.3.3 Complete Worksheet to Determine Prime Contractor's Share
                Please see standard spec 108.1.2 for a complete description of the prime contractor's share formula
                shown on the upper right. The prime’s share is automatically calculated as the contract amounts for
                each bid item are placed in the desired columns.
                As long as the prime’s share is less than 30%, a note in red appears indicating such.
                You can copy blocks of item “Contract Amounts” to the other columns using standard MS Excel copy
                and paste features.
      Step 14:	 	With desired contract worksheet open, as illustrated in Step 12, fill in the “Prime Contractor Amount”
                 (P) column for each bid item as follows: 

                 -	 Use let cost information. 

                 -	 Indicate the dollar amount of work the prime contractor intends to perform, including materials the 

                    prime contractor purchases and installs.
                 -	 The prime contractor can indicate if it is performing the entire bid item or just a portion of it.
                 -	 Prime contractors can include in the (P) column any materials the prime contractor purchases for
                    others to install, and can include the cost of trucking that the prime contractor pays for directly.
                 -	 For the mobilization bid item, the prime contractor should only include its mobilization costs in the
                    (P) column.
      Step15:	 	Next, you have the option of filling in the "Specialty Subcontractor Amount" (S) column; however this
                is not required. Identifying specialty subcontractor work will make it easier for the prime to achieve
                the required 30%.
                Please note that the (S) column is not for identifying all subcontractor work, but is only for specialty 

                subcontractor work. If you decide to fill in the optional (S) column, use let cost information to indicate 

                the dollar amounts of work specialty subcontractors will perform. 

                Standard spec 108.1.2 describes specialty work as follows: 

                - Work that is subcontracted.
 

                - Sanitary sewer system work and water main system work.
 

                -	 Standard specification bid items eligible as specialty items. 

                -	 XXX.XXXX.S and SPV bid items similar to the identified standard specification bid items. 

                Standard specification bid items and XXX.XXXX.S bid items that are not eligible as a specialty item 

                have been grayed out on the worksheet, and you will not be allowed to enter a dollar amount. None 


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CMM 2.60 Subcontracting



                of the SPV bid items have been grayed out on the worksheet, but they are not all eligible as specialty
                items.
                A bid item should not be included in the (S) column unless it is subcontracted. If the prime contractor
                is performing the work on an eligible specialty bid item, it should be included in the (P) column.
      Step 16:	 	When you have completed some or all of the worksheet you can save the worksheet by selecting
                 File/Save from the MS Excel toolbar.




May 2011	 	                                                                                                         Page 10
CMM 2.60 Subcontracting



      Step 17: If you make an entry error, the items that require correction will be shown in red strikethrough. A note
               in red appears indicating error, and the prime contractor’s share percentage is not shown.
                Errors include filling in a dollar amount that exceeds the contract amount for the item, or copying a
                block of dollar amounts into the wrong cells resulting in dollar amounts exceeding the contract
                amount for the item.




      Step 18: Most of the cells in the worksheet are protected and are not available for entry or editing. If you
               attempt to make an entry in a protected cell the following warning message will be displayed.




      Step 19: To print the worksheet select File/Print from the MS Excel toolbar.




     2.60.2.3.4 Send Completed Worksheet to the Department
      Step 20:	 	Send the worksheet(s) to the department by attaching them to an email message. Each completed
                 worksheet must be sent by a separate email message. To send, use one of the following two

May 2011	 	                                                                                                             Page 11
CMM 2.60 Subcontracting



                  methods.
           2.60.2.3.4.1 Method 1: (for Outlook email users only)
                  With the worksheet open, select File/Send To/Mail Recipient (as Attachment...).




                  The email message will be automatically created, with the subject already filled in and formatted, and
                  the worksheet attached. Provide contact information including name and phone number. Enter the
                  following email address in the "To..." field:
                                                  DOTWS1081@dot.wi.gov
                  Click on Send to send the email to the department.




May 2011                                                                                                             Page 12
CMM 2.60 Subcontracting




           2.60.2.3.4.2 Method 2: (for all other email types)
                  Open your email application and create a new message and format the message as shown in above
                  for method 1. Send to the following email address: DOTWS1081@dot.wi.gov. The subject line
                  should be formatted PCS"xxxxxxxxxxx".xls where ”xxxxxxxxxxx” is the contract id. Attach your
                  worksheet, provide contact information including name and phone number, and send to the
                  department.
    2.60.2.4 Region Access to and Use of Contractor's Initial Submittal
    As described above, the prime contractor makes their initial submittal to the Bureau of Project Development.
    Following their review, the Bureau of Project Development will place the contractor's initial submittal on the
    following shared drive for access by the regions:
                                        N:\Bhc\30% Rule Post-Letting Submittals
    Regions can access the contractor's initial submittal; which again, is the prime contractor's best information at
    the time of the letting as to which bid items and what overall percentage of the work it will perform. This
    information can be particularly useful to the regions before the contractor submits a sublet request, and may
    also be of some value during the region's approval of sublet requests.
    However, as noted earlier in this procedure, the prime contractor is not obligated to perform the work as shown
    on the initial submittal. At its discretion, the prime contractor may decide to complete the work differently,
    provided it complies with standard spec 108.1. In situations where the prime contractor is performing
    significantly more than 30 % of the work, there is little need for the regions to do detailed crosschecks between
    the contractor's initial submittal and subsequent sublet requests. Conversely, when prime contractor's work is
    only slightly greater than 30%, regions are more likely to compare the contractor's sublet requests to its initial
    submittal. If they are quite different, regions may question the contractor on how it intends to maintain
    compliance with the 30% rule.
    2.60.3 PUBLIC IMPROVEMENT LIENS
    Information on filing a claim for a person providing services or materials to a prime contractor performing work
    for the department can be found at:
                                www.dot.wisconsin.gov/business/engrserv/constrlien.htm




May 2011                                                                                                                Page 13
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    CMM 4.21 Concrete Pavement Joints

                                                                                    Wisconsin Department of Transportation
                 Construction and Materials Manual
                    Chapter 4       Pavements
                    Section 21      Pavement Joints

    4.21.1 GENERAL
    Saw cuts should be straight, clean, and vertical. If the surface is being torn or chipped, the slab is either too
    "green," the saw is dull, or is turning too slowly, or is traveling ahead too rapidly. Sawing may be done dry or
    with water. Be sure the water doesn't have oil in it from a leak in the equipment. If sawing is being done next to a
    traffic lane, be sure dust or water is not causing problems for vehicles.
    4.21.2 SAWED CONTRACTION JOINTS
    The sawing of joints is one method used to control random cracking in concrete pavements. Joint sawing should
    conform to the depth and width shown on the plans. Concrete joints should be laid out according to SDD 13C
    18.
    A crack is induced at selected locations where planes of weakness or "joints" are created by sawing. As the time
    of sawing is important, it is helpful to keep in mind the behavior of concrete slabs and the changes that occur
    under varying temperature conditions.
    Under normal summer conditions, pavements placed early in the day are subjected for a longer period to the
    higher daytime temperatures, which augment the internal heat generated in the concrete by the hydration
    process. The maximum temperature is reached in six to eight hours, after which it begins to drop, and
    contraction stresses are set up. These are the stresses that cause pavements to crack. The maximum
    temperatures of pavements placed at later hours become lower and the contraction stresses gradually diminish,
    thus reducing the tendency to crack.
    It is necessary to saw transverse joints as soon as it can be done without excessive tearing. Sawing should be
    completed by midnight unless the condition of the pavement prevents it. If sawing must be deferred until the
    following day, it should not be resumed until the air temperature is quite warm and contraction stresses have
    diminished.
    Early morning is an ideal time to examine un-sawed pavement for cracks that may have occurred adjacent to a
    proposed joint location. If a crack has developed, sawing should be omitted at the joint location.
    Joints must be sawed in a double-phase operation if the joint is to be sealed. The initial cut is made as soon as
    the saw can be operated without damage to the pavement. After the curing period has expired, the second cut is
    made coincident with the first to the required dimensions.
    It may be desirable to employ the "skip" method of sawing to relieve stresses in the pavement. In this method,
    the initial cut of every third joint is made as soon as possible, and the initial cuts of the remaining joints are then
    done as soon as practicable.
    4.21.3 TRANSVERSE CONSTRUCTION JOINTS
    Construction joints are formed at the end of the day's run or whenever paving is discontinued for a period of time
    in which the concrete would attain its initial set. A header board that conforms to the true cross section of the
    pavement should be used to form the end of the slab. Holes should be drilled in the header for the insertion of
    tie bars at their proper locations. An alternative method is to use a "split header" consisting of two boards with a
    gap between, through which the tie bars are hand inserted into the fresh concrete.
    Only concrete of good quality should be placed against the header, and it must be thoroughly vibrated with hand
    vibrators. Mortar and laitance and segregated concrete brought ahead by the finishing equipment should be
    wasted over the forms. Header boards for continuously reinforced pavement must be constructed to permit easy
    disassembly, and steel reinforcement extending beyond the header must be supported and secured to preclude
    movement.
    Construction joints are to be edged to a radius of 1/4 inch or less.
    4.21.3.1 Placing Construction Joints
    In addition to the "tied" construction joint shown on SDD 13C 11 and 13, contractors will be allowed the option of
    placing construction joints in the following manner:
    4.21.3.1.1 End of a Day's Paving Run
           1. Run the paver out of concrete and allow the concrete to set.

May 2011                                                                                                                     Page 1
CMM 4.21 Pavement Joints



           2. Make a full depth transverse saw cut, "normal" to the centerline, at a point along the slab that will
              provide the desired transverse and longitudinal profile, as well as the minimum distance specified on
              the standard detail drawing from the last contraction joint. Sawing of the concrete to create the
              construction joint should be done in conjunction with routine transverse joint sawing operations. If
              damage to the slab occurs as a result of sawing, sawing must cease until such time as it can be
              completed without further damage.
           3. The following morning (minimum of 10 hours after conclusion of the previous day's paving), remove
              the concrete to be wasted and drill holes in the vertical face of the construction joint. If damage to the
              slab occurs as a result of drilling, drilling must cease until such time as it can be completed without
              further damage. In the event of severe damage to the slab as a result of drilling or any other
              circumstances, the engineer may require that a new construction joint be sawed beyond the damaged
              concrete, or in extreme cases, removal of the concrete to the nearest contraction joint.
           4. Drilled holes in the face of the construction joint must conform to the following dimensions:
               - Mid-depth of slab.
               - 12 inches center-to-center, starting 6 inches from the edge of slab.
               - 9 inches deep.
               - Hole diameter = diameter of the dowel +1/8 inch.
           5. After completion of the drilling operation a non-shrinking high strength epoxy mortar must be injected
              into the back of each hole and dowel bars must be inserted in the holes in accordance with standard
              spec 416.3.7.
           6. 1- 1/4 inch x 18 inches dowel bars must be inserted in the holes to one-half their length and be parallel
              with the centerline and grade. If the pavement is 9 inches or greater in thickness, dowel bars should
              be 1-1/2 inch diameter.
           7. Construction joints must be saw cut in conjunction with the second stage sawing of adjacent
              contraction joints if the joints are to be sealed.
    4.21.3.1.2 Planned Concrete Pavement Gaps
           1. The two construction joints resulting from planned gaps must be constructed by applying the rules set
              forth above for construction joints at the end of a day's run.
           2. Since there is no urgency for early drilling of holes in the vertical face of the construction joints, this
              operation should be delayed closer to the time when paving of the temporary gap is expected.
           3. Since gaps can have a wide variation as to length, great care should be exercised in planning their
              location. This applies to locating the construction joints both in relation to transverse contraction joints
              outside the gap limits, as well as any required contraction joints between the construction joints when
              the gap is poured.
           4. Dowel basket assemblies should be placed at all contraction joints required between construction
              joints in gap areas.
    4.21.3.1.3 When Paving Away From the Construction Joint
           1. Remove the header, if applicable.
           2. Uncover the tie bars, if applicable.
           3. Grease the dowel bars lightly, if applicable.
           4. Pre-wet the base.
           5. Place concrete against the header or saw-cut slab end. Consolidate with hand-held vibrators, with
              particular attention paid to the area around dowels or tie bars.
           6. Position the paver next to the slab end. Be sure no part touches the tie bars, dowels, or hardened
              concrete.
           7. Use the paver to place, consolidate, and finish concrete, proceeding away from the joint.
           8. Hand finish the fresh concrete at the joint to plan elevation and typical section. Check the evenness
              with a straightedge per standard spec 415.3.11.5.
    4.21.4 LONGITUDINAL CONSTRUCTION JOINTS
    A longitudinal construction joint is formed when a pavement is placed to partial width, and the first lane of
    pavement acts as a form for the concrete in the second lane. Because finishing defects at the edge of the

May 2011                                                                                                                    Page 2
CMM 4.21 Pavement Joints



    original lane will be reflected into the second lane, careful attention should be directed to the finishing in both
    lanes to prevent an uneven surface across the joint which will cause poor riding qualities or create obstructions
    to surface drainage.
    Tie bars across the joint should be carefully installed at the correct spacing and skew as shown on the detail
    drawing. Bar shields, when used, should be placed and maintained tightly against the forms so the second half
    of the bar is completely exposed when the forms are removed.
    Standard spec 415.3.1.2 of the standard specifications provides that the slip-form paver must be equipped with
    a suitable mechanical device that can accurately and positively space and position tie bars and will permit
    satisfactory insertion by mechanical or manual means. It is essential the contractor's equipment and methods
    are reviewed to ensure that adequate bond and true, non-slumping pavement edges will result.
    Positioning of the tie bars should be checked during placement to ensure they are being inserted level and at
    the correct depth, spacing and skew.
    Edge slump is limited to 1/10 inch. If edge slump is in excess of this requirement, correction should be made at
    once.
    4.21.5 EXPANSION JOINTS
    Expansion joints may be formed at bridge approaches and where specified in urban construction to absorb the
    pressure exerted by pavement through temperature expansion and "growth." The performed filler should
    conform to the cross section of the pavement and have its top edge ½ inch below the pavement surface.
    Concrete at the face of the joint must be thoroughly consolidated by spud vibrators.
    The joint must be edged to a ¼ inch radius, or less. Refer to standard spec 415.3.11.7.
    4.21.6 CLEANING AND SEALING JOINTS
    The following discussion applies only to projects on local highways where joint sealing has been requested by
    the local government and approved by WisDOT. WisDOT no longer allows the curing, sealing, or filling of joints
    in concrete pavement on highways under their jurisdiction. Local streets and roads for which WisDOT has
    project administration responsibility only (no project financing) may have joints sealed if the local government
    has expressed a preference for sealing and WisDOT has concurred.
    Proper cleaning of the joints is essential if a long lasting seal is to be obtained. In all cases, the cut should be
    blown clear of dirt and should be dry before sealing. The saw cut is cleaned with compressed air or pressurized
    water. Be sure there is no oil in the air or water as a result of equipment leaks. The saw cut must be absolutely
    clean if the joint sealer is to adhere to the side walls of the cut.
    A backer rod will then be inserted into the clean saw cut and pushed down to the correct depth. This forms the
    base for the joint sealer. The backer rod should be tight against the sides of the cut; be sure the right size of rod
    is used.
    When cold-poured silicone joint material is used, the joint must be completely dry. If there is any moisture
    present in the joint at the time of sealing, a skin will form on the sides of the sealant, preventing adhesion to the
    concrete. Following a rain or damp weather, all of the moisture must be removed from the joint before sealing.
    The contract special provisions will specify which type sealant is to be used. The plan may also contain a
    special detail drawing.
    Cold-poured silicone is most frequently used. Although cold-poured silicone is an improvement over the old hot­
    poured sealers, frequent failures are experienced. Most of these failures can be attributed to inadequate
    cleaning and drying of the joint, or faulty installation procedures. A check of many joints sealed with cold-poured
    silicone indicates the sealant has adhered to only the upper edge of the joint and not to the sides. Dirt or
    moisture on the sides of the joint prevents adhesion. Also, it is likely that insufficient pressure was used during
    the extrusion of the sealant into the joint to ensure full contact with the sides of the joint. To ensure positive
    contact the joint must also be carefully "tooled" after extrusion. The surface of the sealant after tooling must be
    concave upward, and lie about ¼ inch below the pavement surface.
    If the joint sealer is of the solid pre-formed elastomeric compression seal type, it will be necessary to lubricate
    the seal or joint faces before installation. A special tool is used for installation; sharp instruments that may
    puncture the seal must not be used.




May 2011                                                                                                                  Page 3
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    CMM 4.24 Concrete Paving Inspection

                                                                                                   Wisconsin Department of Transportation
                 Construction and Materials Manual
                      Chapter 4         Pavements
               

                      Section 24        Concrete Paving Inspection 


            CMM provisions mobilized by the contract:
                   4.24.6                                       ....... Concrete Transverse Crack Repair cost responsibility.
                   4.24.7 .............................................. Ancillary Concrete cost responsibility for crack repairs.

    4.24.1 RESPONSIBILITIES OF THE PAVING INSPECTOR
    Following are additional duties normally assigned to a paving inspector. These are intended for a non-QMP
    contract when WisDOT is responsible for the inspection. Refer to the contract provisions and the QMP Manual
    for a definition of contractor and WisDOT responsibilities in the case of a contract containing the QMP
    provisions.
           1. Inspection/delivery tickets must be collected from the truckers, initialed, totaled, and turned in each
              day to the engineer.
           2. Reports and records as specified by the engineer must be kept. These may include: 

               - A count of revolutions on ready-mix trucks. 

               - Delivery times for the ready-mix. 

               - Samples taken - where, when, and how. 

               - Tests performed and results. 

               - Cubic yards of mix placed and location. 

               - Weather and working conditions. 

               - Equipment used, and breakdowns and delays. 

               - Contractor's personnel. 

           3. Required reports will have to be filed with the engineer at the specified frequency and in the specified
              number.
           4. Unsafe conditions should be brought to the attention of the contractor for immediate correction. The
              inspector should follow-up to be assured they are corrected. These may include:
                - Inadequate or improper signing and flagging.
                - Unsafe parking of private vehicles. 

                - Unsafe concrete truck delivery and waiting traffic pattern. 

    4.24.2 CHECKING SURFACE CROSS SECTION
    It is essential that careful inspection of the initial pavement slab be performed by checking the crown,
    straightening both transversely and longitudinally, string lining, and using other visual procedures to detect
    improperly adjusted equipment or poor paving procedures.
    Before paving has progressed too far, a check of the surface cross section of the pavement should be made in
    order to determine if the finishing equipment has been properly adjusted to the correct slope and crown of the
    pavement.
    Two blocks of uniform height should be placed on the forms or base on either side of the slab and a fine line
    stretched across them from which measurements are taken to the surface at one-foot intervals. Variations in the
    measurements from the theoretical will indicate if adjustments are required in the screed. When plotted on an
    exaggerated scale any deficiencies are immediately determined and corrections can be made accordingly.
    Periodic checks should be made thereafter as the job progresses.
    If correction is necessary, the contractor must be immediately notified, and any required corrective action must
    be taken before additional pavement can be placed.
    4.24.3 MEASUREMENT AND PAYMENT OF CONCRETE ITEMS
    Concrete pavement, including concrete pavement replacement areas, is measured by the square yard in place.
    Frequently questions will arise concerning the contract items and payment associated with concrete pavement
    repair and concrete pavement. The following should help explain these differences.
    4.24.3.1 Sawing Asphalt and Sawing Concrete
    When specified in connection with pavement removal, this work is measured and paid for by the foot. When this

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CMM 4.24 Concrete Paving Inspection



    work is not specified, but is done for the convenience of the contractor, it is not measured and paid for. The
    measurement of Sawing Concrete, when performed in conjunction with the pavement patching and repair items,
    is further restricted by standard spec 690.4.
    Saw cuts for longitudinal and transverse joints are not measured for payment.
    4.24.3.2 Dowels
    Dowel bars installed in new concrete pavement are not measured for payment. Dowel bars that are installed in
    existing concrete pavements by drilling and epoxying are measured and paid for as Drilled Dowel Bars.
    4.24.3.3 Tie Bars
    Tie bars installed in unhardened concrete pavements are not measured for payment. Tie bars installed to tie
    existing concrete pavement by drilling and then driving or epoxying the bar into new concrete pavement are
    measured for payment as Drilled Tie Bars.
    4.24.3.4 Compressive Strength
    Contracts containing the QMP Concrete Pavement special provision contain an incentive/disincentive pay
    adjustment clause based on 28-day compressive strength. Determine pay adjustments using the Materials
    Reporting System (MRS). The QMP Concrete Structures spec also has strength incentive computed by the
    MRS. The MRS can be found at the following link.
                                           http://www.atwoodsystems.com/mrs
    4.24.3.5 Ride Quality
    If the contract contains the QMP Ride special provision, the contractor must measure ride quality with a
    lightweight inertial profiler. Mainline paving is tested to determine the International Roughness Index (IRI) for
    each wheel path. The QMP Ride special provision contains provisions for incentive/disincentive pay adjustment
    based on the measured IRI. Determine pay adjustments using the department's Materials Reporting System
    (MRS) software available on the department's web site at:
                                           http://www.atwoodsystems.com/mrs


    In addition to the IRI based pay adjustment, the QMP Ride special provision also specifies a pay reduction for
    each area of localized roughness in each wheel path.
    4.24.4 SURFACE SMOOTHNESS
    Under standard spec 415.3.11.8 the department may require the contractor to test the smoothness of the
    hardened pavement surface using a 10-foot straightedge or other engineer-approved device.
    High spots of 1/8 inch in 10 feet or less are acceptable. The engineer may direct that high spots exceeding 1/8
    inch in 10 feet, but less than 1/2 inch in 10 feet be ground down to 1/8 inch in 10 feet or less. The engineer may
    direct that concrete having high spots in excess of 1/2 inch in 10 feet be removed and replaced with no
    additional compensation to the contractor.
    If testing reveals more than an occasional minor infraction of the specified straightedge tolerance, it may
    indicate a malfunction of the paving equipment or improper procedures in the paving process. If this occurs,
    paving should be immediately discontinued until the source of the trouble can be identified and corrected.
    Standard spec 415.3.11.8 requires grinding, when necessary, to correct surface irregularities. The work should
    be accomplished in a manner that does not adversely affect either the ride or the appearance of the ground
    pavement. After the high spot or spots have been ground down, additional light grinding may be necessary to
    leave a neat rectangular area of uniform appearance. Grinding must be done parallel with the roadway
    centerline.
    The grinding should leave grooves comparable to grooves made by tining, but should not damage the
    pavement.
    4.24.5 DEFICIENCIES AND PROBABLE CAUSES
    Table 1 below outlines pavement deficiencies that sometimes show up in the finished pavement. The inspector
    should be aware of these deficiencies and their probable cause. If one or more of these conditions occur, the
    engineer should review region and departmental correspondence and the engineer’s own experience before
    deciding to accept the pavement or to require corrective action by the contractor. If the engineer feels guidance
    is needed in the decision, or if conditions are severe enough to warrant investigation by persons with specialized


May 2011                                                                                                             Page 2
   CMM 4.24 Concrete Paving Inspection



         training, the lab should be notified.
                       Pavement Condition                                              Possible Causes

               1. Spalling                                 - Water content too high
                                                           - Air content too low
                                                           - Excessive finishing

               2. Raveling and sanding                     - Water content too low.
                                                           - Incomplete mixing.
                                                           - Spot repairs to correct surface defects resulting from walking in the
                                                              finished concrete, or to correct low concrete under the paver.
                                                           - Inadequate curing.
                                                           - Air temperature too high or too low.

               3. Random and shrinkage cracking            - Paving in too hot weather.
                                                           - Steel set too low.
                                                           - Late curing or sawing.
                                                           - Water content too high.

               4. Thin slabs                               - Rutted and ridged base.
                                                           - Wrong base elevation (too high).
                                                           - Poor base trimming.
                                                           - Wrong form depth.
                                                           - Sinking forms or track line under the paver train.

               5. Surface pop-outs                         - Chert in the aggregate.
                                                           - Steel set too high.

               6. Slippery pavement                        - Inadequate texturing.
                                                           - Rain damage.

               7. Rough centerline joint                   - Excessive edge slump.

               8. Rough ride                               - Forms settlement; forms not on grade.
                                                           - Soft base under slip-form paver.
                                                           - Stop-and-start paver operation.
                                                           - Dirty finisher wheels.
                                                           - Defective longitudinal controls on slip-form paver.
                                                           - Varying depth of concrete ahead of slip-form paver.
                                                           - Non-uniform concrete slump.

                9. Nonfunctioning Joint                    - Poor sawing technique.

               10. Slab tilt, faulting or subsidence       - Poor base.

                                               Table 1: Pavement Deficiencies and Causes

         4.24.6 CONCRETE TRANSVERSE CRACK REPAIR
Assignments of responsibility of costs for crack repairs, mobilization for traffic control, and traffic control devices prescribed in Table 3 of CMM
4.24.6 are mobilized into the contract per standard spec 415.5.3.

         Standard spec 415.3.19 states that the engineer is responsible for conducting two inspections of the concrete
         pavement and ancillary concrete items. The first should be performed after the pavement reaches opening
         strength as specified in standard spec 415.3.17 but before opening to construction or public service. The second
         is done before opening to public service, or before partial acceptance, as defined by standard spec 105.11;
         whichever comes first.
         If cracking occurs, the engineer, with input from the contractor, is responsible for determining if a repair is
         needed and for assigning the responsibility for the cost of repairs, costs for mobilization for traffic control, and
         costs for traffic control devices. All repairs should be made according to the appropriate standard detail drawing
         or plan detail.
         Table 2 outlines repair options and when it is appropriate to use the type of repair described. These options may

   May 2011                                                                                                                               Page 3
CMM 4.24 Concrete Paving Inspection



    not address all cracking situations. Please contact the WisDOT Bureau of Technical Services - Foundation and
    Pavements Unit regarding situations not covered in the table, or for any questions.

           REPAIR OPTION:                          CONDITION:                           EXAMPLE:
    A. Do Nothing                     A1. Pavement will serve original function         No Example
                                         or purpose.
                                      A2. Crack will not be a local or aesthetic
                                         issue.
                                      A3. Crack will not be a future
                                         maintenance issue.
                                      A4. Pavement has minor vertical or
                                         horizontal displacement.

    B. Seal Only                      B1. Crack has minor spalling or other             No Example
    (Work includes seal with             distresses.
        approved joint filling
        material)

    C. Rout and Seal Cracks Only      C1. Crack has minor spalling or any               No Example
    Un-doweled or Doweled                other distresses.
    (Work includes standard           C2. Joints are sealed because of local
       routing equipment with            preference.
       routing the full length of     C3. Cracked panel is in an intersection,
       crack, sealed with approved       and has irregular geometry.
       joint filling material)

    D. Retrofit Dowel Bar             D1. Crack is in center one-third of panel.
                                      D2. Crack is transverse and less than a
                                         6:1 skew.
                                      D3. Crack is a clean, single crack with
                                         minor spalling or parallel cracks.
                                      D4. Do not use if panel is in more than
                                         two pieces.


    E. Partial Panel Replacement      E1. Mid-panel crack occurs.
                                      E2. Corner crack occurs.
                                      E3. Majority of crack occurs within 3 ft.
                                         of a joint.




    F. Full Panel Replacement         F1. Panel is in 3 or more pieces.
                                      F2. Crack is diagonal and encompasses
                                          a majority of the panel.
                                      F3. Local preference or aesthetic
                                          reasons.




                                        Table 2: Transverse Crack Repair Options

    A panel is defined as the limits between two adjacent transverse joints and two adjacent longitudinal joints or
    pavement edge, as shown below in Figure 1.




May 2011                                                                                                              Page 4
CMM 4.24 Concrete Paving Inspection




                                               Figure 1: Definition of Panel

    The department will allocate responsibility for costs as specified in Table 3. If the cause is unknown the
    department and contractor will share the cost of repair and calculate the applicable contractor-shared
    reimbursement as described in the contract specifications.
    Investigation of the cause will help determine the responsibility for costs of the crack repair. Suggested causes
    for cracking are listed below but are not intended to be a complete list.
            -   A pavement/subgrade not built in compliance with plans & specifications.
            -   Differential subgrade layers and cross section.
            -   Improper sawing methods (e.g. location, timing, mix type).
            -   Improper joint layout.
            -   Interface between different mixes.
            -   Utility work and trenching.




May 2011                                                                                                                Page 5
                                                                                                                                                         Cost of
                                                                                                                                       Cost of                                    Cost of Traffic
   Cracking Occurs              Responsibility                   Location of Crack                     Repair Options                                 Mobilization for
                                                                                                                                       Repair                                    Control Devices
                                                                                                                                                      Traffic Control

 1. Crack occurs BEFORE         Contractor              A. Crack occurs within 3 feet of a              Use partial or full     100% contractor           100% contractor         100% contractor
     opening to service as                                  transverse pavement joint.                 panel replacement
     defined by standard
     spec 415.3.17.             Contractor/             B. Crack occurs beyond 3 feet of a                See Table 2                See standard         100% contractor       100% department at
                                   department               transverse pavement joint and                                            spec 415.5.3                                contract unit prices
                                   (cause                   pavement is constructed in
                                   unknown)                 compliance with specs.

                                Contractor              C. Crack occurs beyond 3 feet of a                See Table 2           100% contractor           100% contractor         100% contractor
                                                           transverse pavement joint and
                                                           pavement is NOT constructed in
                                                           compliance with specs.

                                Department              D. Crack occurs beyond 3 feet of a                See Table 2                See standard     100% department           100% department at
                                   (cause by               transverse pavement joint and                                             spec 415.5.3                               contract unit prices*
                                   others, utility,        pavement is constructed in
                                   or public)              compliance with specs.

 2. Crack occurs AFTER          Contractor/             A. Crack occurs at any location from              See Table 2                See standard         100% contractor       100% department at
     opening to service as         department               a transverse pavement joint and                                          spec 415.5.3                               contract unit prices**
     defined by standard           (cause                   pavement is constructed in
     spec 415.3.17.                unknown)                 compliance with specs.

                                Contractor              B. Crack occurs at any location from              See Table 2           100% contractor           100% contractor         100% contractor
                                                            a transverse pavement joint and
                                                            pavement is NOT constructed in
                                                            compliance with specs.

                                Department              C. Crack occurs at any location from              See Table 2                See standard     100% department           100% department at
                                   (cause by               a transverse pavement joint and                                           spec 415.5.3                               contract unit prices*
                                   others, utility,        pavement is constructed in
                                   public)                 compliance with specs.

        * When utility is responsible for cracking, WisDOT will pay for concrete repair and pursue reimbursement from the utility.
        **This cost is 100% contractor if crack occurs before opening to service and contractor chooses to make repair after opening and project engineer determines it is feasible to have done
              before opening to traffic.

                                                           Table 3: Transverse Cracking Policy for New PCC Pavements




May 2011                                                                                                                                         Page 6
         4.24.7 ANCILLARY CONCRETE
 

Assignments of responsibility of costs for crack repairs, mobilization for traffic control, and traffic control devices prescribed in Table 4 of CMM
4.24.7 are mobilized into the contract per standard spec 416.5.2.

         Ancillary Concrete is defined as curb and gutter (separate or integrally placed), curb, gutter, medians, raised
         medians, sidewalks, driveways, loading zones, safety islands, and steps. The engineer should allocate
         responsibility for costs, repairs, and traffic control according to Table 4.
         Cracks resulting from the following will be considered contractor-caused:
                 -   Mismatched joints from pavement to curb to driveway/sidewalk etc.
                 -   Inconsistent or no attention paid to expansion.
                 -   Damage by public/business traffic due to non-protection of work.
                 -   Damage by contractor operations (prime or subcontractor).
                 -   Joint layout.
         Cracks resulting from the following will be considered department-caused:
                 - Poor design.
                 - Damage by public/business traffic.
         When a utility is found to have caused the crack, WisDOT will pay for concrete repair and pursue
         reimbursement from the utility. 

         If the cause of a crack is unknown, the contractor and department will share the responsibility.
 





   May 2011                                                                                                                               Page 7
       Responsibility                 Location of Crack            Required Repair         Cost of Repair        Cost of Mobilization    Cost of Traffic Control
                                                                                                                  for Traffic Control           Devices

    Contractor/Department        A. Crack occurs at any location   A1. Remove and        A1. See standard spec   A1. 100% contractor    A1. 100% department
    (Cause Unknown.)                 and is constructed in              replace.            416.5.2
                                     compliance with plans and
                                     specifications and cannot     A2. Leave in place.   A2. No cost             A2. No cost            A2. No cost
                                     be attributed to the
                                     contractor operations.
                                                                   A3. Saw only (for     A3. 100% contractor     A3. 100% contractor    A3. 100% department
                                                                        C&G only).

    Contractor                   B. Crack occurs at any location   B1. Remove and        B1. 100% contractor     B1. 100% contractor    B1. 100% contractor
                                     and is NOT constructed in          replace.
                                     compliance with plans and
                                     specifications.               B2. Leave in place.   B2. No cost             B2. No cost            B2. No cost

                                                                   B3. Saw only (for     B3. 100% contractor     B3. 100% contractor    B3. 100% contractor
                                                                        C&G only)

    Department                   C. Crack occurs at any location   C1. Remove and        C1. See standard spec   C1. 100% department    C1. 100% department
    (Cause by others, utility,      and is constructed in              replace.             416.5.2
    public.)                        compliance with plans and
                                    specification and cannot be    C2. Leave in place.   C2. No cost             C2. No cost            C2. No cost
                                    attributed to the contractor
                                    operations.                    C3. Saw only (for     C3. 100% contractor     C3. 100% contractor    C3. 100% department
                                                                       C&G only).

                                                            Table 4: Cracking Policy for Ancillary Concrete




May 2011                                                                                                                 Page 8
    4.24.8 RAIN-DAMAGED PAVEMENT
    Areas damaged by rain may be re-dragged and/or re-tined if the concrete is still plastic. It is even better, if
    rain is suspected or forecast, to have plastic ready for covering the pavement and to halt paving
    operations if rain is prolonged. If all else fails, the damaged area must be ground by machine to avoid
    accidents caused by slick pavement. Grinding should be parallel to the centerline, and the finished areas
    should be rectangular, neat and not distracting to motorists.
    4.24.9 CONCRETE PAVEMENT REPAIR AND REPLACEMENT
    Concrete Pavement Repair and Replacement, and Special High Early Strength Concrete Pavement
    Repair and Replacement are defined in standard spec 416 and detailed in Standard Detail Drawing 13C9.
    Repair lengths of 15 feet or less are constructed, measured, and paid for under the provisions of standard
    spec 416. Repair sections between 15 and 100 feet in length should be paid as Concrete Pavement
    Replacement. Repair sections 100 feet or longer should be paid as Concrete Pavement, as provided in
    standard spec 415.
    All concrete pavement repair and replacement items are measured by the square yard in place. Saw cuts,
    tie bars, and dowel bars installed in existing concrete pavements are paid separately. For concrete
    pavement items, tie bars and dowel bar assemblies at contraction joints are included in the contract price.
    The plan will show a breakdown in the miscellaneous quantities of areas designated as repair or
    replacement. The length of 15 feet was chosen as the distinction between repair and replacement, based
    on the maximum joint spacing. A “repair” section will not contain contraction joints, dowel assemblies, or
    tie bars.
    The item of Special High Early Strength Concrete Pavement Repair is used when same day opening to
    traffic is necessary. Frequently the sawing is done one or more days before the removal and replacement
    operation.
    The major differences between the repair and replacement items are outlined below:
             1. Measurement and payment.
                 -	 Pavement repair items include removing pavements and repairing shoulders, while saw
                    cuts, tie bars, and dowel bars installed in existing concrete pavements are paid separately.
                 -	 For pavement replacement, concrete pavement is measured by the square yard, and
                    removing pavement and shoulder repair are paid separately.
             2. Concrete mixes.
                 -	 Grade C mixes are specified for concrete pavement repair and a special 8-hour concrete
                    mix is specified for special high early strength concrete pavement repair.
                 -	 Concrete pavement may be constructed with Grade A concrete.
             3. Opening to traffic.
                 -	 Repair areas must be opened to traffic based on cylinder tests of 3,000 psi.
                 -	 Special high early strength concrete pavement repair areas must be opened to traffic by
                    sunset on the same day the old pavement is removed.
                 -	 Concrete pavement may be opened to traffic based on either test cylinders or minimum
                    time periods related to atmospheric temperatures.
    4.24.10 OPENING TO SERVICE
    Refer to standard spec 502.3.10 for strength requirements for opening to service.




May 2011 	                                                                                                            Page 9
test
        CMM 5.25 Bridge Decks

                                                                                                              Wisconsin Department of Transportation
                      Construction and Materials Manual
                           Chapter 5           Structures
                           Section 25          Bridge Decks

                 CMM provisions mobilized by the contract:
                        5.25.1 Figure 1 ................................................................................ evaporation nomograph

        5.25.1 PLACING, FINISHING, AND CURING BRIDGE DECKS
 

The evaporation nomograph in Figure 1 of CMM 5.25.1 is mobilized into the contract per standard spec 501.3.8.2.2.

        5.25.1.1 General
        The placing, finishing, and curing of concrete bridge decks is the most critical aspect of bridge construction. Not
        only is it critical from the standpoint of the finished surface, since the traveling public judges a bridge by its riding
        qualities, but the quality and durability of the concrete are critical because bridge decks are probably subjected
        to more severe conditions conducive to scaling and deterioration than any other highway element. Since bridge
        decks are subject to becoming frosty and slippery, chemical de-icing and abrasive agents are frequently applied,
        which may remain in contact with portions of the bridge deck for extended periods.
        Some of the measures necessary to obtain smooth riding bridge decks are setting of grades to allow for
        anticipated deflections, adequate falsework and supports, including banding and bracing of outside girders as
        needed, the use of adjustable screed guides, constant observation of actual deflections during the placement of
        the deck concrete, and the correction of any indicated deficiencies. Generally, it might be said that the same
        principles, methods, and skills are required to produce smooth bridge decks as are employed in constructing
        smooth pavements. The important difference in the two procedures is the technique of working in the limited
        space usually available on a bridge deck.
        One of the essential ingredients of a smooth bridge deck, after the forms and screed guides are accurately set
        and firmly supported, is a properly proportioned, uniform concrete mix. It is impossible to get optimum results
        with concrete of varying consistency, since areas of stiffer concrete will finish a little higher than those placed
        with wetter concrete, and the wet concrete will shrink more when drying. However, a good mix is of little value
        unless it can be delivered to the bridge deck at an adequate and constant rate to permit uninterrupted
        placement and finishing of the deck surface. Another essential element is adequate equipment and manpower
        to place, strike-off, finish, and start curing the concrete.
        5.25.1.2 Setting Grades
        The structure plans will generally include a diagram showing the amount of deflection expected in any span due
        to the mass of the span itself (dead load). For non-prestressed cast in place structures, there will be an
        additional allowance for deflection due to future creep. Creep is the tendency for concrete under stress to
        deform, at a decreasing rate for a period of time, perhaps several years. The grade to which the forms, screed
        guides, or rails are set will depend on several considerations. As mentioned in the discussion of falsework, the
        grade to which the forms are built must provide sufficient camber to offset anticipated deflections due to dead
        load and future creep, plus an allowance for settlement or compression that will take place within the falsework.
        Theoretical finished grades at the centerline and edge of slab at required intervals are supplied to the region by
        the structural design section. For spans utilizing steel beams or prestressed concrete members, WisDOT should
        determine a profile for each stringer after steel erection by taking elevations at frequent intervals. The theoretical
        deck grade, adjusted to allow for the anticipated dead load deflection, is then compared with the stringer profile
        and modified, if necessary, due to excessive camber in any stringer, to provide the minimum deck thickness and
        haunch as specified on the plans. After the forms, screed guides, or rails are set by the contractor to the grade
        established by WisDOT, they should be "sighted in" to remove any irregularities.
        Attention must be paid to deflection allowances when screed rails are placed on overhangs. Falsework supports
        or placing of outer beams may be necessary to prevent settlement of the overhang or other areas of the deck
        forms.
        The contractor should set the rails or tracks upon which the machine finisher operates to the required elevation.
        For all but the shortest spans, the screed guides or rails on which the strike-off apparatus rides should be readily
        adjustable, so that if excessive settlement or deflection takes place under load, appropriate adjustments can be
        made at once and the surface refinished to the correct grade.
        Rails or tracks upon which heavy machine finishers operate should be rigid enough and supported at frequent
        intervals so that deflection of the rail will be minimized, and preferably the supports on one side of the bridge

   May 2011                                                                                                                                            Page 1
CMM 5.25 Bridge Decks



    should not be directly opposite those on the other side.
    The rails or tracks should be extended to permit the finishing machine to be run clear of the floor at both ends.
    Hand finishing at the ends of the bridge floor can be eliminated, and the quality of the ride improved under this
    procedure.
    5.25.1.3 Prepour Preparations
           1. Initial inspection.
              Before placing the deck concrete, a thorough inspection of the falsework should be made, including
              the following: 

                - Footings and the forms. 

                - Reinforcement. 

                - Finishing equipment. 

                - Guides or rails. 

                - Delivery system. 

                - Transit mix trucks or other mixers. 

                - Batch plant including admixtures, aggregates, and cement. 

                - Fogging and curing systems. 

                - Tell tale devices. 

              Any deficiencies should be corrected before deck placement. Before scheduling the pour, a dry run of
              the finishing machine over the placed reinforcement bars must be made and periodic measurements
              of total deck thickness and clearance to the reinforcement taken and recorded. The fogging equipment
              must also be tried to see that it functions as intended and will not cause damage to the surface.
           2. Prepour meeting.
              Before every deck pour a prepour meeting should be held with the contractor at which time every
              aspect of the pour should be discussed and any differences resolved. Items to be discussed should
              include:
                - Time of starting the pour.
                - Anticipated weather conditions.
                - Rate of delivery of the concrete to ensure completion within a reasonable time.
                - An adequate number of approved delivery vehicles available exclusively for the pour.
                - Method of placement.
                - Consolidation and finishing of the concrete.
                - Number of finishers and their duties.
                - Finishing tools and equipment available
                - Application of the surface texture.
                - Timing of fogging and final curing.
                - Emergency covering materials available in case of inclement weather.
                - Any other appropriate subjects.
              Consideration should be given to delaying the pour if the rate of concrete surface moisture
              evaporation exceeds 0.2 lb/sq ft per hour as shown in Figure 1 below.




May 2011                                                                                                                Page 2
CMM 5.25 Bridge Decks




                         Figure 1: Rate of Evaporation of Surface Moisture from Concrete

    5.25.1.4 Placing Concrete
    The concrete should be spread to approximate grade, then consolidated by vibration. The strike-off for the
    screeding equipment should be capable of striking-off low slump concrete to the desired grade and cross-
    section, moving forward at a uniform rate, and accomplishing its objective without requiring an excessive
    number of passes. It should be operated with a uniform amount of concrete ahead of the screed at all times, and
    for the full width of the screed. Walking in the concrete should be prohibited after the screeding operation.
    Placement of concrete on the overhang should not be completed before placement of concrete on the adjacent


May 2011                                                                                                         Page 3
CMM 5.25 Bridge Decks



    bay or lane; otherwise the steel reinforcement on the overhang may deflect and raise the steel on the adjacent
    bay, reducing minimum clearance.
    It is recommended that where feasible and practical, concrete placement proceed from the lowest elevation to
    the highest elevation to minimize finishing problems caused by flow of rainwater or moisture from fogging into
    the area where finishing operations are proceeding. Also, concrete placed in longer steel girder structures has a
    tendency to walk downgrade, especially if concrete placement is started at the highest elevations.
    Field reviews have indicated that slump of vibrated concrete has frequently exceeded the maximum of 4 inches.
    Standard spec 105.3 requires that slump test results should fall substantially within the specified range and only
    occasionally be of borderline quality. Concrete having a uniform, proper slump is essential in obtaining a strong,
    durable deck, and the contractor should be required to regulate and control concrete production to ensure
    compliance with the slump requirements of standard spec 501.3.7.1.
    Checks for deflections at form or rail supports need to be made during the deck pour. Depth of embedment and
    total slab depth must also be frequently checked during the placement operation, and any appropriate
    adjustments made in the rails or finisher screeds. The method used may be dictated to some extent by job
    conditions. A device for stabbing the deck for cover or thickness has been made available to each region for use
    in the field.
    Decks that have turned out to be less than specified thickness could have easily been detected early enough by
    timely probing to make corrections. On the other hand, another deck pour that could have been a disaster was
    detected early by alert inspection, and the paving rails were adjusted to make the necessary correction. It is not
    sufficient to assume everything will turn out all right because the dry run with the machine showed proper cover
    and thickness. We have numerous examples where these measurements have changed substantially without
    satisfactory explanation. The only defense is to be constantly aware of what is happening and have a
    contingency plan for correcting it when something starts to go amiss. The inspector should also be constantly
    checking for settlement or deflection during a floor pour by sighting along the forms or rails, taking elevations of
    the same at frequent intervals, or by the use of telltale devices previously installed.
    The standard specs require that concrete in decks must be consolidated by mechanical vibration. Gang
    vibrators mounted on the paving machine are preferred. An adequate number of vibrators should be provided.
    Special care must be taken to ensure the entire deck pour is completely and uniformly vibrated to achieve
    thorough consolidation without over vibration of local areas. Vibration must not be applied through reinforcement
    to partially hardened areas of the deck. Vibrators must be capable of transmitting at least 4,500 impulses per
    minute to the fresh concrete. This frequency can be checked by means of a vibrating reed tachometer available
    through the region. The tachometer reading shown in revolutions per minute is equivalent to impulses per
    minute.
    5.25.1.4.1 Evaporation Retarders
    The use of commercial liquid evaporation retarders is only permissible with approval of the engineer in
    emergency situations such as an equipment breakdown during the deck placement process. If used,
    evaporation retarder must be applied in an even, fine mist by a hand-held pressurized sprayer. Application of
    evaporation retarder that results in any puddling or runoff is considered excessive, and will be prohibited.
    5.25.1.5 Finishing Concrete
    Standard spec 502.3.7.8 provides that all concrete bridge floors must, unless otherwise specified, be finished by
    self-propelled machine finishers.
    Placement of the concrete should never be allowed to progress faster than the hand finishers or machine
    finishers can satisfactorily complete the finishing of the concrete. The skill and experience of the contractor's
    crew will have a great effect on the final finishing operations. Where a satisfactory finish has been obtained by
    the self-propelled finishing machine, float finishing will not be required. Float finishing, when required, should be
    closely observed by the inspector to detect and correct waves or dips due to faulty operation of the strike-off,
    failure to properly adjust screed guides, deflections of forms or screed guides, uneven consolidation of the
    concrete, or failure to properly meet expansion joints or construction joint headers. The screed or screeds
    should be so adjusted and operated as to finish the concrete to the required crown and grade and to produce a
    surface within specified tolerances.
    Straight edging should be done while the concrete is still in a condition that corrections can be made, but
    delayed as much as possible to take advantage of the final slumping of the concrete. The inspector should
    closely observe the straight edging operations by the contractor, or may elect to independently check the
    surface with a testing straightedge. Any irregularities disclosed by the straight edging should be immediately
    corrected. Special attention should be paid to the finishing of gutter lines to maintain longitudinal drainage on the

May 2011                                                                                                                Page 4
CMM 5.25 Bridge Decks



    bridge floor. With structures on very flat grades or on the crest of vertical curves, it is sometimes necessary to
    warp the flow line of the gutter in order to maintain drainage to the ends of the structure or to the floor drains as
    the case may be. This warping can be accomplished in the outer three feet of the surface, and need not be
    detrimental to the overall riding quality of the deck. A carpenter's or mason's level is helpful to the finishers
    working in these areas.
    The final operation in finishing the bridge floor is the application of the surface texture. This is intended to give
    the floor a uniform, pleasing appearance and a skid-resistant surface. The timing of this operation must coincide
    with the proper degree of setting of the concrete if optimum results are to be obtained.
    Decks having approach pavements with design speeds of 40 mph or greater must receive either an artificial turf
    drag finish or a broom finish, followed by a tined finish. The tined finish is similar to that used on rural pavements
    except that the depth is only about 1/8". The tining must not be applied within 1 foot of the gutters, and may be
    applied manually. On bridge decks having skew angles of 20 degrees or greater, tining must be applied within
    20 degrees of the centerline of bearing of the substructure units.
    Decks having approach pavements with design speeds less than 40 mph must receive either an artificial turf
    drag finish or a broom finish, with no tining.
    Brooms for a broomed surface should have fairly stiff, medium coarse bristles, and the pressure on the broom
    should be regulated to prevent tearing of the surface yet produce a satisfactory skid resistant surface.
    5.25.1.6 Curing Concrete
    Curing of the concrete is extremely important in the production of strong, durable concrete. Included in the
    curing process is the protection of the concrete from either excessively high or low temperatures. It is very
    important that before the water sheen disappears from the surface of the bridge floor a fog or fine water spray
    be applied until the concrete is sufficiently hardened to support the curing procedure used for these surfaces.
    The object of fog curing is to provide the necessary concrete cure after the deck slab loses its surface moisture
    and before it is sufficiently hardened to permit placement of the burlap or fabric. The amount of mist and number
    of applications necessary may vary from bridge to bridge depending on weather, concrete consistency, and
    finishing methods. The engineer should review with the contractor the proposed method for applying the fog
    cure at the prepour meeting and before the day of the deck pour. Fogging should be accomplished by nozzle
    arrangements allowing the discharge of a constant uniform mist without washing of the fresh concrete. Fogging
    should be accomplished as a separate and distinct part of the deck curing operation.
    After the concrete has sufficiently hardened the deck should be cured with a double thickness of wet burlap for
    not less than seven days. Keeping the deck continuously wet and covered is very important to maximize future
    strength and durability and minimize the potential for cracking. Decks on structures less than 100 feet in length
    may be cured for a period of seven days with polyethylene-coated burlap or other coated material meeting the
    requirements of the standard specs. Curing with liquid membrane curing compound is not permitted on the
    bridge deck.
    Refer to Figure 1 for rates of evaporation of moisture from concrete. Refer to standard spec 502.3.8 for detailed
    curing requirements.
    5.25.1.7 Durability of Bridge Decks
    Probably the most significant factor in the resistance of concrete to scaling is adequate air-entrainment. Many
    variables affect the percentage of air that a given concrete mixture will entrain. The inspector should make
    sufficient air tests on the concrete going into structures to ensure an air content well above the lower limit of the
    specification range. Later operations of placing and finishing the concrete should be closely controlled, since
    excessive manipulation and vibration of the concrete may decrease the air content. Research indicates a loss of
    0.5% to 1.0% of air occurs at the surface of the concrete due to over vibration. Also, over vibration tends to bring
    the lighter, unsound aggregate particles to the surface where freeze-thaw action may cause deterioration, pop-
    outs, and scaling.
    Another practice to be strenuously avoided in the finishing of concrete is the persisting tendency of some
    finishers to sprinkle water on the surface in an attempt to gain workability. The resulting high-water content in
    the surface mortar can result in a reduction of up to 25% in the strength of concrete at the surface, and is an
    invitation to the development of surface scaling.
    5.25.2 MISCELLANEOUS
    5.25.2.1 Set Retarding and Water Reducing Admixtures
    The use of retarding agents to delay the setting of concrete in bridge floors, especially in hot weather, offers the
    advantage of providing sufficient time for proper finishing of the concrete, including any corrections of high or

May 2011                                                                                                                Page 5
CMM 5.25 Bridge Decks



    low spots disclosed by the final straight edging, and generally permits the use of a lower water content, which is
    conducive to a stronger, more durable concrete.
    5.25.2.2 Rust Stains
    Rust stains may be removed from the concrete by mopping with a solution containing 1 lb of oxalic acid powder
    per gallon of water. After two to three hours, rinse with clear water and scrub with a stiff brush. Rust staining of
    substructure concrete where reinforcing steel extends through a construction joint and will be exposed for some
    considerable time can be prevented by painting the steel with a thin coat of cement grout. The grout must be
    entirely removed before the remainder of the concrete is poured.
    5.25.2.3 As-Built Plans
    Refer to CMM 1.65 for requirements relating to the supplying of as-built structure detail sheets to Bureau of
    Structures, Structures Development section.
    5.25.2.4 Inventory Inspection
    An inventory inspection is the inspection of a new bridge as it becomes a part of the bridge inventory. An
    inventory inspection could also apply where a substantial change has been made to the existing structure such
    as widenings, lengthenings, supplemental bents or piers, deck replacements, superstructure replacement,
    concrete or asphalt overlay, changing pin and hangers, or replacing or changing joints, bearings, etc. The
    inventory inspection required here may only have to include the changes made.
    The inventory inspection is a fully documented investigation performed by persons meeting the required
    qualifications for inspection personnel. An analytical determination of load capacity may be required. An
    underwater or other specialized inspection may be part of the inventory inspection.
    The purpose of this inspection is twofold:
             -	 It will be used to determine all structure inventory and appraisal data required by the Federal Highway
                Administration and other relevant information required by Wisconsin Department of Transportation to
                maintain an up-to-date bridge file.
             -	 It will be used to determine baseline structural conditions and identify and list any existing problems or
                locations that may have potential problems. With this information recorded, these areas can be
                checked at the next inspection for a comparison to see what is developing. Aided by a prior detailed
                review of plans, it is during this inspection that any fracture critical members (or details) are noted for
                subsequent focus, and assessments are made of other conditions that may later warrant special
                attention.
    On any new bridge or rehabilitated bridge where the construction inspection was accomplished with state funds
    by state forces or consultant forces, the engineer must notify the bridge maintenance supervisor and the
    maintaining authority that the structure is ready for an inventory inspection. This applies to either a state-
    maintained bridge or a local government-maintained bridge.
    The inventory inspection should be accomplished after the bridgework is complete, but before the contractor
    leaves the job site.
    All data required to update the bridge file must be submitted to the proper region. The region should submit the
    data to the structural development section of the Bureau of Structures. This data should be submitted as soon
    as possible, preferably before the bridge is open to traffic.
    Data to be submitted may include the inventory inspection, Bridge Inspection Report (form EM30), Bridge
    Inventory Report (short form EB575-186) and a set of bridge plans. The data required depends on the work
    done, plans available, if the state has a set of plans, etc.
    5.25.2.5 Opening to Service
    Refer to standard spec 502.3.10 for strength requirements for opening to service.
    5.25.2.6 (Vacant)
    5.25.2.7 Grooving Preformed Plastic Tape on Bridge Decks
    Preformed Plastic Tape placed in a grooved 100 mils slot on a bridge deck or concrete overlay will not cause
    structural problems, or affect the service life of the concrete. Whenever an anti-ice overlay and preformed plastic
    tape are called out on a project, the warranties of both products will not be invalidated as long as both the
    overlay and marking vendor are in agreement with the installation procedures.




May 2011 	                                                                                                                Page 6
CMM 5.25 Bridge Decks



    5.25.3 CRACK SURVEY AND SEALING
    Sealing cracks on bridge decks has great potential to extend service life of structures. Concentrated chloride
    solution can leach through cracks as a direct conduit all the way through decks within the first winter season.
    Defects in epoxy coating on embedded rebar in the vicinity of the cracks can allow corrosion to begin
    immediately. To prevent chlorides from leaching into cracks, standard spec 502.3.13 requires application of low
    viscosity crack sealer to all cracks visible in dry weather conditions.
    5.25.3.1 Crack Survey
    The initial crack survey is to be performed within 7 days following the end of the required wet-cure period. The
    deck surface should be thoroughly dry at the time of the initial crack survey. The initial crack survey should be
    completed before opening the deck to public traffic. Falsework does not have to be released before the initial
    crack survey. Cracks to be sealed should be visible to the naked eye from a standing position. The initial crack
    survey must include the bridge deck surface only, not other items such as medians, sidewalks, or parapets.
    When conducting the initial crack survey, identify the endpoints of each crack with a small, discreet mark. Use of
    a black felt-tip permanent marker is recommended. Please do not mark along the length of the cracks with
    fluorescent paint or any other marking that would prevent penetration or bond of the crack sealer, or appear
    obnoxious to the public after the structure is open to traffic.
    At the conclusion of the initial crack survey, determine the total linear footage of cracking that has been
    identified to be sealed. This is the upper limit of cracking for which the contractor will be responsible for sealing
    on an incidental basis to the Concrete Masonry Bridges bid item.
    5.25.3.2 Crack Sealing
    The initial crack sealing should be completed at least 7 days following the end of the wet cure period at the
    earliest, but before opening the deck to public traffic. High pressure water-blasting should be used to clean the
    deck surface in the immediate vicinity of the cracks to be sealed. Do not sandblast, as this will deface the
    appearance of the deck.
    The deck surface should be allowed to air dry for at least 48 hours before crack sealing. The sealer must be
    selected from the department's approved product list. It is satisfactory for the sealer to be applied after only 7
    days following the end of the wet cure period, which will take precedence over the longer dry curing periods
    recommended by the sealer manufacturers. The department recognizes the time pressure to construct and
    open projects quickly, and is willing to forego the benefits of dry curing for 21 to 28 days as recommended by
    the sealer manufacturers.
    Initial crack sealing is incidental to the concrete masonry bid item. However, it is recognized by the department
    that a majority of later cracking can be due to design and deflection influences that are beyond the control of the
    contractor. The department will be responsible for the cost (including traffic control) of sealing any additional
    cracking that develops at a later date following the initial crack survey. The contractor should be paid for any
    additional crack sealing as additional work. To enhance the durability of the structure, it is recommended that
    wherever practicable, the department should pay for sealing any additional cracks that have developed just
    before final opening of the completed structure to public traffic.
    In the event of a late season deck pour, when there is no opportunity to perform the crack sealing promptly due
    to cold or wet weather and improper curing conditions, the contractor may perform the crack sealing the
    following spring when weather conditions permit. Traffic control, if needed, will be paid for by the department.
    5.25.3.3 Protective Surface Treatment
    After deck crack sealing, new bridge decks must be sealed with protective surface treatment. Protective surface
    treatments significantly reduce the penetration of de-icing chemicals into the concrete, which reduces the rate of
    chemical attack on the concrete and chloride attack on the reinforcing steel and minimizes the effects of
    corrosion and freeze-thaw cycles.
    The contractor must use products from the approved products list, and apply the treatments according to
    manufacturer's recommendations. Application requirements can be found in standard spec 502.3.13.2.
    5.25.4 SLAB SPAN BRIDGES
    Slab bridges are cambered (normally up) during construction in order to counteract the long-term creep of the
    concrete over the next several years. This camber is normally three times the dead load deflection. This camber
    will cause a temporary "bump" in the grade line until the creep deflection slowly takes place over the next
    several years. This is an expected condition and part of the process in using concrete slabs. The finishing
    machine rails should be set to reflect this camber condition. Normally the high points will be at the mid span


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CMM 5.25 Bridge Decks



    locations of the bridge. The bridge surface should not be ground after casting as the bump is expected and will
    disappear over time. If the bump is corrected when the bridge is opened there will be a depression at mid span
    a few years later. Any questions related to this issue should be directed to the Bureau of Structures, Structures
    Design Section.




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        CMM 6.45 Erosion Control

                                                                                              Wisconsin Department of Transportation
                      Construction and Materials Manual
                          Chapter 6       Miscellaneous Construction
                          Section 45      Erosion Control

                 CMM provisions mobilized by the contract:
                        6.45.2 ...................... Erosion Control and Implementation (ECIP) preparation and submittal

        The department emphasizes practical roadside erosion control to reduce water pollution, soil erosion, and
        siltation of watercourses and adjacent lands. Environmental concerns necessitate advance planning, increased
        use of erosion control materials, and installation concurrently with grading operations, rather than as a final
        operation before acceptance of the work.
        The department is committed to lessening adverse environmental impacts resulting from our projects. WisDOT
        policy is to construct projects according to standards that will minimize or negate erosion and/or sediment
        damage to the highway and adjacent properties, prevent surface water pollution, and prevent ground water
        contamination.
        Standard spec 107.20 requires that continuous erosion control be practiced during and after construction using
        temporary or permanent measures such as seeding and mulching as shown on the plans or determined by the
        engineer. Temporary and permanent erosion control will be measured and paid as provided for the contract or
        as extra work, unless the need for temporary erosion measures stems from the contractor’s negligence. The
        specification is designed to prevent damage to the environment caused by the construction or reconstruction of
        a publicly owned transportation facility.
        6.45.1 MEASURES TAKEN BEFORE CONSTRUCTION
        According to Chapter Trans. 401 of the Wisconsin Administrative Code and standard spec 107.20 the contractor
        is required to prepare and submit a detailed erosion control implementation plan (ECIP) for the project, including
        borrow sites and material disposal sites. Special provisions may also require removal plans and/or clean-up
        contingency plans for removals over waterways.
        Temporary and permanent erosion control measures proposed in the contractor’s ECIP and schedule are
        discussed at the preconstruction conference. Refer to CMM 2.26.
        Before the preconstruction conference, the engineer reviews the project plan, ECIP, and schedule, plus the
        environmental documents, to become fully aware of areas of environmental sensitivity and concern.
        Environmental commitments and permit requirements should be noted for compliance and implementation by
        WisDOT and/or the contractor.
        Before construction begins, the engineer should discuss contract-required erosion control measures with the
        prime contractor. The prime contractor should be aware of the requirements of any erosion control items
        performed by the subcontractors, and the prime contractor’s ultimate responsibility for all subcontractor actions.
        The prime contractor should also be made aware that the department will pay for all reseeding and refertilizing
        made necessary by factors beyond the contractor’s control.
        The Wisconsin department of natural resources (DNR) must receive a copy of the ECIP developed by the
        contractor 14 days before the preconstruction conference. The DNR should be consulted on the erosion control
        needs and the measures proposed to be taken.
        6.45.2 EROSION CONTROL IMPLEMENTATION PLAN (ECIP)
Requirements for preparation and submittal of the Erosion Control Implementation Plan (ECIP) as prescribed in CMM 6.45.2 are mobilized into
the contract per standard spec 107.20.

        Standard spec 107.20 and Chapter TRANS 401.08 Wisconsin Administrative Code require the prime contractor
        to prepare and submit an ECIP for a project. The prime contractor must submit the ECIP to the appropriate
        region office of the department and to the region liaison at the appropriate region office of the DNR. The ECIP
        must be submitted at least 14 days before the pre-construction conference, or at a time otherwise agreed upon
        by the DOT, DNR and prime contractor. It is to contain project implementation details that indicate the timing of
        project activities related to erosion control, such as staging and the placement of erosion control practices.
        An ECIP is required for any WisDOT-administered project that contains an erosion control bid item or a structure
        removal over a waterway special provision. However, the details and contents of the ECIP depend on the
        project type. WisDOT- administered projects that do not contain erosion control bid items do not require the
        submittal of an ECIP, unless specified otherwise by the department. The ECIP may be completed in stages, if

   May 2011                                                                                                                            Page 1
CMM 6.45 Erosion Control



    approved by the department. For example, if borrow and material disposal sites are not known at the time of the
    ECIP submittal, a staged ECIP will likely be approved. The initial ECIP for the project should indicate that other
    stages would be submitted later. The engineer must consult with DNR before approving staged ECIP submittals.
    The region reviews the ECIP for conformity with TRANS 401 requirements. The DNR also reviews the ECIP and
    sends comments to the region before the date scheduled for the preconstruction conference. If the DNR has not
    sent comments by that date, assume that the DNR concurs and construction can proceed. The ECIP must
    receive region approval before the contractor can start construction. Keep a copy of the approved ECIP in the
    field office. The engineer must monitor compliance with the approved ECIP during construction.
    The contractor should consider the erosive effects of its planned operations and provide an ECIP that will
    mitigate and control erosive action. Permanent erosion control required in the contract plans can be used as a
    guide and basis in planning complementary interim erosion control measures. Measures necessary to control
    erosion based on the contractor’s particular schedule or sequence of operations should be addressed. Items
    that should be provided for in the ECIP include but are not limited to the following:
           1. Provide a schedule of grading operations showing the grading segments and sequences necessary to
              conform to or satisfy the intent of the number of erosion control mobilizations provided in the contract
              plans. A variation in the number of mobilizations can be submitted for the engineer's approval.
           2. Show on the erosion control or plan and profile sheets the specific erosion control measures that must
              be in place before grading operations begin, if they are not indicated in the contract.
           3. Show interim treatment between sequences or operation, noting specific erosion control device type
              and location using plan sheets. In particular, address protection for sensitive areas, including streams,
              lakes, uplands, and woodlands. Include provisions for topsoil storage locations and dewatering sites
              when applicable. Address stream diversion methods in detail.
           4. For borrow and material disposal sites (selected sites), provide a complete erosion control plan and an
              ECIP, including the appropriate calculations to demonstrate that the proper erosion control measures
              are being used.
           5. Designate the person on the contractor’s staff responsible for erosion control administration, and
              include mobile telephone numbers. Responsibilities include consideration and mitigation of soil erosion
              in planning grading activities, mobilization of materials and work force to meet erosion control needs,
              monitoring of the project site for necessary revisions to the erosion control effort, and monitoring and
              maintenance of the in-place erosion control devices.
           6. Hydrologic and hydraulic calculations for selected sites that would be severely impacted by off-site
              erosion because of the proposed excavation as fill.
           7. Give details of either a structure removal plan or a structure removal and clean-up plan depending on
              the environmental sensitivity of the affected waterway and the feasibility of various strategies the
              contractor might employ to protect the waterway.
    Other items to be considered in the plan may include:
           1. Access to site (causeway, temporary roads).
           2. Topsoil (removal, storage and placement).
           3. Special ditches and intercepting embankments.
           4. Embankment (cuts and fills).
           5. New structures over waterways (abutment fills, excavation, temporary crossings).
    In development of the plan and during prosecution of the erosion control measures, the contractor should:
           1. Use innovative ideas and techniques. Be specific in schedule and detail.
           2. Maintain flexibility. Be ready for adjustments and alterations.
           3. Rethink past practices.
           4. Have necessary materials on the job site for timely installation. Preplan implementation of erosion
              control measures.
           5. Be prepared to correct, augment or add measures during and after periods of runoff.
           6. Revise ECIP should planned operations significantly change.
    During review of the plan and during the work operations, the engineer or responsible WisDOT agent should:

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CMM 6.45 Erosion Control



           1. Thoroughly review the plan, analyze measures in detail for shortcomings and discuss details.
           2. Be generous in application without extravagance.
           3. Adjust methods and limits as needed.
           4. Maintain continuing inspection and surveillance to assure adequacy and performance. Suggest
              corrective measures where and when needed. Inspections are required weekly, after each 0.5-inch
              rainfall, at the beginning and ending of each stage, and at the completion of the project. The inspector
              must use department form WS1072, Erosion Control Diary. The inspection documentation should be
              maintained in project files with the approved ECIP.
           5. Require amendments to the ECIP from the contractor when construction practices no longer conform
              to those described in the ECIP.
           6. Review and approve the ECIP amendments.
           7. Inform DNR of significant changes to the initial ECIP.
    Adjustments and alterations may be necessary after plan review and during construction. The contract should
    provide quantities for the common erosion control items encountered on a project. A list of approved erosion
    mats is available in the department product acceptability lists (PAL)
    http://www.dot.wisconsin.gov/business/engrserv/pal.htm. The approved mats are designed for specific
    applications and should be used accordingly. Follow the procedures of the WisDOT FDM Chapter 10 for the
    proper design of erosion mat application. It is helpful to discuss changes with the design engineer for their input
    on the original design intent.
    For the detailed ECIP requirements refer to TRANS 401.08 Wisconsin Administrative Code. Copies of Chapter
    TRANS 401 Wisconsin Administrative Code are available for reviewing at transportation region offices. As part
    of the awarded contract package the department provides the prime contractor department form WS1073
    "Erosion Control Implementation Plan Worksheet," a worksheet for completing the ECIP.
    The worksheet also describes what is required for selected (borrow and material disposal) sites. The contractor
    must fill out Section B – Erosion Control Implementation Plan – Selected Sites for each selected site for the
    project.
    6.45.3 MEASURES TAKEN DURING CONSTRUCTION
    The planned location of erosion installations should be reviewed and the final location adjusted to fit field
    conditions. Substitution of materials may be necessary. As an example, sodding may not always be adequate to
    prevent erosion and formation of gullies on areas subject to concentrated flow of water at a relatively high
    velocity, and in such cases erosion control may require the use of pipe down drains, riprap, or other appropriate
    means.
    Sound erosion control practices include reasonable restrictions on grading; maintaining drainage and
    consolidating and trimming the subgrade daily to aid drainage and protect against erosion; vehicle access and
    parking; materials delivery and storage sites; constructing and maintaining temporary silt fences; stabilizing bare
    soil as soon as possible by seeding, sodding, mulching, using soil stabilizer or erosion mats; and installing plant
    materials at the earliest opportunity. The best way to ensure the success of these endeavors is through
    engineer-contractor cooperation during the entire life of the contract. It is essential that along with the
    requirements the contractor must strive to maintain an erosion-free project. WisDOT provides the assurance the
    contractor will be paid for the restoration of damaged areas to the extent previously mentioned in background
    above.
    The contractor is expected to ensure the work does not encroach on or directly affect wetlands, streams, or
    other waters of the state abutting highway right of way. The engineer should be alert to such situations, and if
    they occur, order the contractor to cease the work operation, remove all encroachments, and restore the area to
    its prior condition as nearly as practicable. No work shall be performed in waters of the state without prior
    concurrence of DNR and the U.S. Army Corps of Engineers, except in an emergency.
    Temporary and permanent erosion control measures specified in the contract should be installed in a timely
    fashion. The engineer should be alert for situations requiring further erosion control measures not foreseen in
    the plan and schedule, and order the proper erosion control devices to be installed where needed to prevent
    degradation of the highway and surrounding lands.
    The best solution to erosion-related damage is anticipating or identifying possible problems and taking
    preventive measures. Early erosion control practices are far less expensive than damage repair when all
    impacts are considered. Timely installation is essential. The prime contractor or the subcontractor charged with


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CMM 6.45 Erosion Control



    erosion control must take all necessary steps to install the erosion control measures at or before the time they
    are needed. Being busy on another project or another work operation is not an acceptable reason for late
    installation or no installation. A wide range of relatively simple practices is available. Early protective measures
    can include detention basins to trap runoff and sediments, proper procedures and locations for removing and
    storing topsoil, and measures to protect nearby lakes, streams, and woodlands. Other acceptable, proven
    measures are intercepting embankments, berms, dikes, dams, settling basins, ditch checks, riprap, mulches,
    erosion mats, silt fences, seeding, sodding, plantings, and special control installation as called for on the plans
    or ordered by the engineer.
    Erosion control items that have proven effective when correctly installed at suitable sites include:
           1. Rock check-dams, clean concrete ditch checks and mortar rubble masonry ditch checks in ditches
              with step slopes.
           2. Rock lining of ditches, with a geotextile underlayer.
           3. Riprap in ditches at the toe of new slopes and along shorelines.
    Temporary erosion control measures should be coordinated with the permanent measures to secure continuous
    erosion control as economically as possible. However, temporary measures are not to be constructed in lieu of
    permanent measures specified in the contract, since it is the permanent measures that provide the ultimate
    control.
    Permanent and temporary erosion control items that are damaged or lost, or found to be defective should be
    replaced as soon as possible. Replacement necessitated by damage or loss resulting from conditions beyond
    the contractor’s control will be paid for under the standard bid item. Defective materials or installation must be
    replaced at the expense of the contractor.
    Standard spec 107.20 limits the amount of erosive land that can be opened up. The area is not defined in
    square yards but rather is the area that the engineer can approve based on specific conditions affecting the
    area. Contractors must pursue operations in a timely and diligent manner, continuing all construction operations
    methodically, expeditiously, and with adequate forces from the initial topsoil stripping operation through
    subsequent grading operations and ultimate re-topsoiling, seeding, and other associated landscaping
    operations. Standard spec 107.20 extends full authority to the engineer to suspend or limit the contractor’s
    grading operations should the contractor fall behind on erosion control work.
    Occasionally, job conditions may require disturbance of the ground surface beyond the right of way line, such as
    might occur from the storage of topsoil or from grubbing or finishing of the adjacent slopes, especially where
    right of way widths are restricted. Fertilizing, seeding, and mulching of such areas will be measured and paid for
    under the appropriate item, provided such areas are contiguous to the right of way, of a reasonable size, and
    justified by the job conditions.
    The basic work items involved in erosion control are topsoiling, fertilizing, seeding, ditch checks, sodding,
    mulching, erosion mats, sedimentation basins, and silt fence.
    6.45.3.1 EROSION CONTROL ORDER FORM
    The engineer is responsible for inspections on WisDOT administered projects, as detailed under TRANS 401, to
    ensure project compliance with the ECIP. If corrective action of erosion control items is identified, written
    notification must be given to the contractor on department form WS1074, Erosion Control Order. This would be
    for the following cases:
           1. When an Erosion Control Corrective Action is required. The contractor must mobilize within 24 hrs of
              receiving the order. Corrective action is limited to situations where:
                  A. The order is to perform corrective action, such as correcting items not properly installed,
                     installing items not installed as previously ordered, or repairing damaged items
                  B. The work is required because the contractor is out of compliance with the project erosion control
                     plan or ECIP per Trans 401.
                  C. The work is part of normal maintenance covered and paid under a previously installed bid item.
           2. When an Erosion Control Mobilization is required (see CMM 6.45.4). The contractor must mobilize
              within 72 hrs of receiving the order.
           3. When an Emergency Erosion Control Mobilization is required (see CMM 6.45.5). The contractor must
              mobilize within 8 hours of receiving the order.



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CMM 6.45 Erosion Control



    6.45.4 MOBILIZATION OF EROSION CONTROL
    The bid item of Mobilizations, Erosion Control has been established for the purpose of providing payment to the
    contractor for efforts required to marshal labor, equipment, and materials to complete seeding, mulching,
    sodding, and other erosion control measures at planned increments or stages during the life of the project. It is
    intended for use in situations where erosion control mobilization is required per the ECIP or ECIP amendments.
    The contractor is required to mobilize within 72 hours unless otherwise agreed to in writing by the project
    manager, such as for planned future work or work that carries little environmental risk. Payment under this bid
    item will be made for erosion control activity only if all of the following conditions are met:
            1. The erosion control has been preplanned.
                  A. In the original contract plan, or
                  B. In the approved contractor’s ECIP, modifying the contract plan, or
                  C. Ordered in writing by the engineer subsequent to (A) or (B) to respond to changed site
                     conditions or unusually severe weather, but not requiring emergency response of eight hours.
            2. The erosion control requires a substantial move-in of personnel, equipment and materials. Use of on-
               site personnel, equipment and materials is minimal to none.
            3. The erosion control does not constitute normal maintenance of erosion control item installations.
            4. The erosion control does not constitute incomplete	 installation of erosion control items covered by a
               previous mobilization or planned stages, unless required by changed site conditions or unusually
               severe weather and approved by the engineer.
    Amendments to the ECIP not necessitated by the contractor being out of compliance with Trans 401, or
    associated with contractor-selected waste or borrow sites, which result in the landscaper needing to mobilize to
    the project with additional equipment or manpower, will result in one additional mobilization granted per ECIP
    amendment.
    Thus, the contractor and the engineer must plan ahead to ensure that all erosion control measures are
    performed for a completed stage and are provided as required for a following stage. This requires an ongoing
    evaluation of both the permanent and temporary measures required as work progresses. Attention by the
    engineer, prime contractor, and appropriate subcontractors will minimize the potential for “call back” and its
    inherent costs.
    Refer to standard spec 628.5.11, Mobilizations Erosion Control, for payment information and for the deduction to
    be assessed for failure by the contractor to mobilize in a timely manner, following written order by the engineer.
    6.45.5 EMERGENCY MOBILIZATION OF EROSION CONTROL
    The Mobilizations Emergency Erosion Control bid item has been established to provide payment to the
    contractor for efforts required to marshal labor, equipment, and materials to complete seeding, mulching,
    sodding, and other erosion control measures that may be required for emergency situations during the life of the
    project. It is intended for use in emergency situations where erosion control mobilization is required within eight
    hours. Orders issued under this bid item will be made for emergency erosion control activity only if all of the
    following conditions are met:
            1. The erosion control has not been preplanned, such as mobilization included in the ECIP.
            2. The erosion control has been ordered in writing by the engineer.
            3. The erosion control requires a substantial move-in of personnel, equipment and materials beyond
               those already available on-site.
            4. The erosion control does not constitute interim installation of erosion control items between planned
               stages, unless required by changed site conditions or unusually severe weather and has been
               approved by the engineer.
            5. The erosion control work is deemed urgent and necessary to minimize risk of offsite sediment
               discharges. The risk of release may be due to forecasted weather conditions, flooding, change in site
               conditions (such as discovered a spring or breach in adjacent construction), etc.
            6. The required work cannot be installed within 72 hours requirement of “Mobilizations of Erosion
               Control” without substantial environmental risk.
    Refer to standard spec 628.5.12, Mobilizations Emergency Erosion Control for payment information and for the
    deduction to be assessed for failure by the contractor to mobilize in a timely manner, following written order by


May 2011	                                                                                                               Page 5
CMM 6.45 Erosion Control



     the engineer.
     6.45.6 STRUCTURE REMOVALS OVER WATERWAYS
     6.45.6.1 Background
     Structure removals over waterways require special attention. These removals are covered by special provision.
     One of three special provisions will be applicable for each structure removal in the contract. Each special
     provision lists the structure number or a brief description of each applicable structure. All of the special
     provisions require additional information that the contractor must include in the ECIP.
     The removal specials define three levels of care that the contractor must take depending on the sensitivity of the
     waterway and characteristics of the structure to be removed. The baseline level of care requires the contractor
     to minimize debris falling into the waterway. The highest level of care requires a debris capture system to
     prevent virtually all debris from falling into the waterway. The lowest level of care is for situations where there is
     little choice but to drop the structure into the waterway.
     Designers consult with DNR and industry representatives to make sure each structure is included under the
     appropriate special provision. The contractor must describe the precautions they will take to prevent or minimize
     impacts to the waterway. The department must give written approval of the contractor's removal and clean-up
     plans before work covered under that plan begins.
     6.45.6.2 Reviewing the Structure Removal and Clean-up Plans
     Department staff should make sure that the contractor's required removal and clean-up plans are appropriate for
     the level of care required in the special provisions. The following are strategies or techniques that the contractor
     might employ. This is by no means an exhaustive list of appropriate measures, nor is it a set of minimum
     requirements. The contractor is encouraged to develop new and innovative approaches to protect the waterway
     during removal operations. This toolbox is provided to help the contractor put together an effective plan that can
     be customized to the individual project as well as the contractor's available resources. Likewise the toolbox
     should help department evaluate the contractor's plan.
              -    Provide decking attached to the structure. 

              -    Provide barges beneath the structure. 

              -    Build false decks or other temporary structures. 

              -    Provide a crane suspended platform beneath the removal area. 

              -    Provide blasting mats for abutments. 

              -    Provide fencing in the waterway to prevent material from washing downstream. 

              -    Wet-saw the structure into large, manageable sized pieces. 

              -    Use "slab grab" equipment to remove large pieces. 

              -    Provide fencing or side panels on debris collection devices. 

              -    Use fabric or fencing material slung under demolition areas. 

              -    Choose equipment that will minimize the creation of dust and small debris. 

              -    Remove saw slurry, chips, and other potential small debris at the end of each work-day. 

              -    Use vacuum equipment during demolition operations. 

              -    Load and haul away debris immediately as it is created. 

              -    Build temporary work roads. 

              -    Cover accumulated on-site debris to assure containment during windy or rainy conditions. 

              -    Provide boomed equipment with grabber attachments to remove debris from the waterway. 

              -    Remove debris from the waterway by hand. 

     6.45.6.3 Example Removal and Clean-up Plans
         Removing Old Structure Over Waterway: Item 203.0500.S

                  Structure B-XX-XX will be removed in the following manner.
                      1)	 	A crane mounted wrecking ball will be used to break apart the existing structure.
                      2)	 	All rebar will be removed from the waterway.
                      3) All large pieces of concrete will be removed from the waterway using a clam bucket.
                      4)	 	The existing waterway bottom will be restored to approximately original depth. The smaller
                           pieces of concrete remaining will be used to repair the streambed according to the plan. This

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CMM 6.45 Erosion Control



                     work will be done by hand.

                     Alternate Removing Old Structure Over Waterway
                     Item 203.0500.S
                           1) The existing concrete deck will be saw cut into 7'x10' slabs and then removed by a
                              crawler crane.
                           2) Once the slabs are removed the truss will be lightened to a point at which it can be
                              tipped into the stream and then removed in as large sections as the crane can handle.
                           3) The existing pier will be removed by use of a hydraulic breaker to a point 2 feet below
                              existing ground.
                           4) The existing abutments will be excavated to the landward side and removed in that
                              direction by a hydraulic breaker.
                           5) All reinforcing steel and concrete rubble greater than 5" diameter will be removed from
                              the river by use of a clam bucket then trucked off the project site.


         Removing Old Structure Over Waterway With Minimal Debris: Item 203.0600.S

              Structure B-XX-XX will be removed in the following manner.
                  1) A longitudinal saw cut will be made on the “limits of removal” line between Stage I and Stage II.
                     The median side of the bridge deck will be removed in Stage I. Traffic will be operating on the
                     right side of the bridge.
                  2)	 	Transverse saw cuts will extend between the longitudinal saw cut and the curb line.
                  3)	 	A Backhoe mounted breaker will be used to break vertical slot through the parapet and curb
                       parapet at these locations to minimize pieces of broken concrete during removal.
                  4)	 	A backhoe with a “slab grab” attachment will be used to remove and carry the large precut
                       sections of concrete deck to the end of the bridge.
                  5)	 	Removing the bridge deck in large sections in this manner will significantly reduce the amount
                       of small pieces that fall to the ground. Any large pieces of concrete in dimension, all reinforcing
                       steel, and other debris that fall in the water will be picked up using a bucket clam and disposed
                       of at the XYZ quarry.
                  6)	 	Removal operations at the abutments will be completed by excavating behind the abutment and
                       then removing in that direction.

              Bridge Pier Removal
                  1) Turbidity barrier or sheet piling will be installed around piers as defined in the contract.
                  2) The bridge piers will be removed using a wrecking ball.
                  3) Any large pieces of concrete in dimension, all reinforcing steel, and other debris that fall in the
                     water will be picked up using a crane and clam bucket.


                     Alternate Bridge Pier Removal Plan:
                           1) Sheet piling will be installed around the piers.
                           2) Water will be pumped to a settling basin at the location indicated on attachment B.
                           3) A hole will be drilled in the old footing to house a localized charge, the charge will be
                              localized enough to prevent widespread projectile debris.
 

                           4) The debris from the blast will be removed with a clam bucket.
 

                           5) Sheet piling will be removed after the new piers are poured.
 



         Removing Old Structure Over Waterway With Debris Capture System: Item 203.0700.S


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CMM 6.45 Erosion Control



              Structure B-XX-XX will be removed in the following manner.
                   1)	 	A backhoe mounted hydraulic breaker will be used to cut the concrete deck into approximately 6
                        foot x 15 foot sections.
                   2)	 	A backhoe will be used to remove the deck sections.
                   3)	 	For areas of the deck that are over water, a barge will be floated under to catch all debris, or if a
                        barge is not possible, plywood decking will be placed between the existing bridge beams under
                        the areas where the cuts are to be made.
                   4)	 	As the cuts are made to divide the deck into sections, concrete chips will be caught on the
                        barge or the plywood decking.
                   5)	 	After the deck sections are removed, the concrete chips will be removed and taken to the
                        disposal area.
                   6) The girders will then be removed using a crane.
                   7)	 	The bridge abutments will be removed by excavation behind and then removing in that
                        direction.
                   8)	 	The concrete debris from the removal operations will be disposed of in the fill areas of the new
                        roadway as directed by the engineer.
                   9)	 	A flocculent approved by DNR for use in the water and silt screen will be on-site for use incase
                        of a failure to the system.
     6.45.6.4 Monitoring Compliance
     One of the goals in developing these special provisions is to improve the department's ability to administer this
     work and determine if the contractor is removing the structure according to the contract. The basic strategy of
     these specials is:
              -	 The contractor develops a removal plan meeting the requirements of the special provision. 

              -	 The department and DNR approve the contractor's removal plan. 

              -	 The department uses the approved removal plan as the key focus for contract administration. The 

                 department determines contract compliance by holding the contractor accountable to diligently follow
                 the prevention, mitigation, and clean-up measures they identified in the approved plan.
     The special provision language describes requirements for "large" or "small" pieces of debris and "limited
     amounts" without giving measurable definitions for those terms. The language is vague in part because of past
     abuses based on language that required removal of all pieces larger than 5 inches in any dimension. The
     language is also vague to allow some flexibility in the field. Department staff should coordinate with the
     contractor to make sure that both parties understand how these terms will be interpreted under the contract. The
     department's environmental coordinators, erosion control specialists, or DNR liaisons can help field staff
     determine what might be appropriate for their specific set of circumstances. Often times operations required to
     remove debris from the waterway can cause more damage than leaving it in place.
     6.45.7 EROSION CONTROL ITEMS
     6.45.7.1 Erosion Mat
     Erosion mat is placed on seeded areas of the graded roadway to prevent erosion while turf is forming. It is
     important that the mat be placed immediately following completion of the seeding and before a rain occurs.
     All erosion mat products must be pre-qualified by the department before use. Erosion mat products must be
     selected from the erosion control Product Acceptability List (PAL) developed and maintained by the department.
     The PAL identifies pre-qualified erosion mat products by class and type. A copy of the PAL may be obtained at
                                           http://www.atwoodsystems.com/materials
     The specifications for the different classes of erosion mats, and for the biodegradable anchoring devices to be
     used with Class I Type urban mats, are contained within the PAL.
     The required class and type of erosion mat will be shown on the plan or will be specified by the engineer. The
     contractor may furnish any pre-qualified erosion mat product of the class and type shown on the plans or
     specified by the engineer.
     Substitutions within class should not be made without verification being made with the designer. For example
     some of these mats are commonly requested by the DNR liaison or may be needed to meet a certain shear

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CMM 6.45 Erosion Control



    stress requirement. Under no circumstances should products not specifically listed on the PAL be accepted.
    Before installation, the contractor must provide the engineer with one full set of the manufacturer’s literature and
    the recommended installation procedure for each selected product. Installation must be in accordance with the
    procedure recommended by the manufacturer unless otherwise specified in the contract or directed by the
    engineer.
    Class III Type B, Type C, and Type D erosion mats must be covered by a soil stabilizer or erosion control
    revegetative mat as required by standard spec 628.2.1. When a soil stabilizer is used, application must be at the
    rate recommended by the manufacturer of the soil stabilizer, unless otherwise specified by the engineer or
    special provisions.
    The inspector is responsible for determining that the area to be covered is in a suitable condition. The surface of
    the seeded area should be reasonably even, and all stones, clods, sticks, or other objects that would interfere
    with the mat laying completely on the soil should be removed. The inspector should ensure that the following
    procedures are followed:
            -   The mat is placed in a natural smooth position without stretching.
            -   The mat is completely on the soil.
            -   Proper overlaps are made.
            -   Installation of anchor and check slots, when required, are properly made.
            -   The mat is correctly anchored in place.
    Erosion mat placed in channels (ditches) should be placed at a width that will ensure that the outer ends are
    approximately one foot higher than the elevation of the channel bottom.
    Areas of seeding disturbed in making the anchor and check slots should have more seed scattered on them.
    After the fabric is in place, water must be sprayed on the area to moisten the seedbed to a depth of 2" to
    expedite germination.
    Erosion mat designed for lesser flows is typically placed in the upper reaches of a ditch or waterway.
    Subsequent sections through the middle and lower reaches will require mat designed for greater flows, or
    perhaps sod or reinforced sod, dependent upon conditions of runoff.
    6.45.7.2 Erosion Bales
    Erosion bales consist of straw, hay, or other suitable material of the size shown on the plan placed as dikes or
    dams to control runoff from ditches or slopes. These bales are effective in controlling the deposition of
    sediments on adjacent properties, as well as reducing the formation of rivulets and gullies, when placed and
    staked in accordance with plan details.
    Erosion bales should be placed across the full ditch bottom and up the ditch sides to allow water to flow over the
    center bale. This will prevent flow around the ends of the bales. Refer to Standard Detail Drawing 8E8 in FDM
    chapter 16.
    The locations shown on the plan for installation should be considered a guide. Additional bales should be placed
    when and where warranted by field conditions. Also, the locations shown on the plans may require adjustment
    to fit field conditions. After several rains, the bales may be filled with sediment and no longer will allow water to
    pass. They should be replaced when effectiveness is lost. Generally, they are to be removed by the contractor
    after slopes are established and turf has developed, unless the engineer determines leaving them in place to rot
    would be beneficial.
    6.45.7.3 Sedimentation Basins
    Sedimentation basins are artificial collection ponds excavated to contain and control sediment-laden surface
    runoff. The basin should be of a size sufficient to retain the inflow for the required number of hours or days. The
    resultant clear water then seeps into the ground, evaporates, or is released via a spillway or overflow pipe,
    leaving sediment as a precipitate on the bottom of the basin. Direct flow-through of the basin should not be
    permitted.
    Sedimentation basins must be inspected regularly, cleaned out as needed, and maintained in accordance with
    plan details if they are to be effective. Ultimate disposition of the sedimentation basins must be as shown on the
    plans or special provisions.
    6.45.7.4 Silt Fence
    Silt fences are erected to trap sediment-laden surface water flowing off a slope in a sheet flow or along a
    shallow, low-velocity, low-flow ditch. They are constructed by stretching a geotextile fabric between vertical


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CMM 6.45 Erosion Control



    posts, attaching it to the posts and to support wires strung between the posts, and trenching in the foot of the
    fabric. The fabric allows clear water to eventually pass through while leaving the sediment as a precipitate up
    slope from the fabric. Construction should be in accordance with the plan details, including post diameter, length
    and embedment, fence height, fabric type, fabric overlap, wire gage, and depth of trench. Refer to Standard
    Detail Drawing 8E9 for installation details in FDM chapter 16.
    Do not place silt fence across channels unless it is heavily reinforced. Acceptable reinforcement would be the
    use of steel fence posts with a steel mesh or woven wire fence used behind (downstream of) the silt fence
    fabric.
    Silt fence installations will need to be inspected regularly, cleaned out as needed, and maintained. Additional
    bracing or guying may be needed to provide full support of the fabric under heavy water flows.
    Silt fence should be removed after slopes and turf are established. This may require allowing the silt fence to
    remain until the next year or at least for several weeks. If the contract has not been closed at the time of
    removal, the contractor is required to perform the removal and disposal. If the contract is closed, the
    maintenance forces of the authority controlling the highway must do the removal and disposal.
    6.45.7.5 Silt Screen
    Silt screen is a floating geotextile material used to minimize sediment transport within a body of water. Unlike
    turbidity barriers they do not touch the bottom of the watercourse. Instead they float from the surface of the
    water to approximately two feet above the waterbed.
    Silt screen works by deflecting sediment that then settles out and deposits at the bottom of the screen. It is
    important that silt screen not touch the bottom of the waterbed, as sediment build up could then “sink” the floats
    allowing sediment-laden water to enter the waterway.
    Silt Screens generally work best where the sediment particle size is larger or where water flow prevents the use
    of a turbidity barrier. Selection is normally based on coordination with the DNR/DOT liaison.
    Consideration should also be given to standard spec 107.19, Construction Over or Adjacent to Navigable
    Waters. The designer must have established, and noted in the special provisions, if the waterway is so
    designated.
    6.45.7.6 Turbidity Barrier
    Turbidity barriers are fence-like structures and are placed within a body of water to barricade sediment from
    being transported. A geotextile material is stretched on posts from the bottom of the waterbed to an elevation
    two feet above the anticipated high water mark for the time of the year the barrier is to be placed.
    Turbidity barrier works by totally enclosing a work area and separating it from a body of clean water. It is not
    intended as a device where de-watering may be done behind it, such as with sheet piling, nor is it intended to be
    used where currents exceed 5 feet/second. If currents exceed these limits, other measures should be
    considered to divert water away from the area being worked on or disturbed. This may be accomplished by
    using other devices such as sheet piling, cofferdams, or just reinforcing the turbidity barrier.
    In moving water conditions, provisions must be made to allow the volume of water contained within the barrier to
    change. Since the bottom of the barrier is weighted, the volume of water contained within the curtain will be
    much greater at high water levels. Therefore, measures need to be taken to prevent the barrier from collapsing
    and to allow water to be equalized on each side of the barrier. This may be achieved by constructing part of the
    curtain from a heavy filter fabric. The fabric allows the water to pass through the barrier yet retain the sediment.
    Consideration should be given to the volume of water that must pass through the fabric and sediment particle
    size when specifying fabric permeability.
    Barriers are one of the last lines of defense, and should be used as part of an overall erosion and sediment
    control plan. Other on-land measures should be utilized to minimize sediment in the turbidity barrier enclosed
    area.
    Turbidity barriers generally work best in locations having finer particle sizes. Selection is normally based on
    coordination with the DNR/DOT liaison.
    Consideration should also be given to standard spec 107.19, Construction Over or Adjacent to Navigable
    Waters. The designer must have established, and noted in the special provisions, if the water way is so
    designated.
    The bid item provides for payment of turbidity barrier by the square yard. It is WisDOT’s intent to pay for
    whatever height of barrier is needed to meet the two-foot requirement above the anticipated high water mark for


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CMM 6.45 Erosion Control



    the time of year the barrier is to be placed. This requires the contractor to adjust the height based on anticipated
    seasonal flows. Work being done in the early spring would normally require a higher barrier than work being
    done in midsummer.
    Another consideration would be how long the barrier is to remain in place, or in other words what is the chance
    of a peak event during the time it is to be in place. High water elevations indicated on plans, contacts with local
    officials, contracts with area residents, and discussions with region maintenance representatives are all sources
    of information for obtaining this data. Barriers that are placed unreasonably high for the time of year that the
    work is to be done only create an eyesore, and have been criticized by the public.
    Consideration should be given to the placement of riprap or other permanent erosion control measures as soon
    as possible in order to minimize the duration that the barrier is in place.
    Care should be taken when removing the barrier due to the possible release of sediment. When possible, the
    barrier should be released when the flow rates are low. Consultation with the DNR/DOT liaison is
    recommended.
    6.45.7.7 Riprap
    6.45.7.7.1 Compliance with the Specification
    There are several problems that the DOT typically has with riprap – stone sizes may be too small, stone size
    may be poorly distributed, or too many fines may be included. The riprap specification describes riprap
    dimensionally so that the engineer can, in the field, measure the supplied stone for the project to determine
    whether it meets the specification. The spec requires engineers to determine the average dimensional range for
    the stone and the required fraction of gross in-place volume occupied by the riprap.
    To determine if the supplied stone meets the larger dimension ranges for a project, first mark out a 20 square
    feet area of in-place riprap with paint. Measure the largest stones in the 20 square foot area, marking and
    numbering each stone as it is measured. Measure each stone in three perpendicular dimensions and calculate
    the average of these measurements to get the average dimension. If there are few or no stones that fall within
    the two highest dimension ranges, then the supplied stone does not meet the specification.
    Another way to determine if the stone is within specification is to count the number of stones that fall within the
    size gradations for a type of riprap. Table 1 below describes number of stones required within each average
    dimension size range for each 10 cubic yards of in-place riprap. This method is labor-intensive and requires
    either lifting heavy stones or counting large numbers of stones.
                                                 Average Dimension        Number of stones per
                                                      (inches)             10 cu. yd. of riprap
                                                         >16                         0
                                                        11 – 13                   35 – 48
                               Light Riprap              9-11                    92 – 130
                                                          4-9                   445 – 620
                                                          <4                   1850 – 2700
                                                          >20                        0
                                                         14-16                    10 – 27
                              Medium Riprap              11-14                    45 – 65
                                                          5-11                   240 – 340
                                                           <5                   1080 –1620
                                                         >25                          0
                                                        18-20                      9 – 13
                              Heavy Riprap              14-18                     22 – 32
                                                        6.5-14                   112 –160
                                                         <6.5                    580 – 810
                                                          >30                        0
                                                         22-25                     5–7
                               Extra Heavy
                                                         18-22                    12 – 16
                                 Riprap
                                                          8-18                    56 – 78
                                                           <8                    240 – 345
                                           Table 1: Riprap Gradation Averages

    6.45.7.7.2 Conversion to Weight
    If you need to convert in-place riprap volume to total riprap weight, multiply the in-place volume in ft3 by (1 -


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CMM 6.45 Erosion Control



    0.40), where 0.40 is the assumed void ratio of the riprap, and then multiply the resulting number by the specific
    weight of water (62.4 lbs/ ft3) and by the specific gravity of the stone (SG=2.65). To convert an individual stone
    from stone volume to stone weight, multiply the stone volume (ft3) by the specific weight of water (62.4 lbs/ft3)
    and by the specific gravity of the stone (SG=2.65).
    6.45.7.7.3 Fine Particles in Riprap
    The requirement that no more than 2% of the in-place riprap be less than 1 inch in size was included to prevent
    the contractor from placing large amount of fines with the riprap. From a volumetric point of view, this
    requirement translates into a maximum allowable thickness of fines in the riprap, as described in the table
    below. The acceptable thickness is calculated by multiplying the minimum depth of the riprap volume, as
    described in the specification, by 2%.
    Since the riprap specification is an in-place spec, and since riprap is usually placed on top of geotextile fabric
    Type R or HR, measure the depth of the fine material on the riprap apron in six random locations on a 20 ft2
    area, taking care to include both the bottom and sides of a channel. If the average depth of the sediment
    significantly exceeds the acceptable average thickness listed in Table 2 below, then the riprap supplied by the
    contractor does not meet the DOT’s specification.
    However, in applying this method, good judgment should be used. It should be kept in mind that fines may
    collect on the fabric in the spaces between the riprap stones. This could give the appearance of more fines than
    are actually present. This procedure should be done before it rains, because sediment transport from a rainfall
    will alter the quantity of fines in the riprap. Observing the amount of soil attached to the stones at time of delivery
    would provide a means to judge if excessive fines may be a problem.
                                                                     Acceptable Average Thickness of Fines
                                            Minimum Riprap
                 Riprap Gradation                                    Covering Geotextile Fabric Type R or HR
                                           Thickness (inches)
                                                                                    (inches)
                   Light Riprap                    12                                   1/4
                  Medium Riprap                    18                                   3/8
                   Heavy Riprap                    24                                   1/2
                Extra-Heavy Riprap                 30                                   2/3
                                     Table 2: Acceptable Thickness of Fines for Riprap

    6.45.7.8 Tracking Pads
    6.45.7.8.1 General
    The best approach to preventing off-site tracking is to restrict vehicles to stabilized areas. It is always preferable
    to prevent sediment from being deposited upon the road than cleaning the road later. Sediment on a road can
    create a safety hazard as well as a pollution problem. Any sediment tracked onto a public or private road should
    be removed by street cleaning or sweeping, not flushing, or as directed by the engineer.
    Tracking pads reduce off-site sedimentation by eliminating the tracking of sediment from construction sites. The
    contractor must install a tracking pad wherever traffic will leave a construction site. This practice applies where
    construction traffic is likely to transport sediment off site onto private or public roadways.
    Stone tracking pads remove sediment from the tires of vehicles by allowing the tires to sink into the stone base
    slightly. This action, combined with the rolling motion of the tires, acts to knock loose the majority of sediment
    from a vehicle’s tires before it leaves the site. Manufactured tracking pads should produce similar results.
    6.45.7.8.2 Construction
    The tracking pad must be installed before any traffic leaves the site. The aggregate must meet the gradation
    requirements of select crushed material per standard spec 312.2, with the exception that material passing the
    No. 10 sieve should be negligible by visual inspection. The aggregate layer must be constructed to a minimum
    depth of 18 inches.
    Stone tracking pads must be underlain with a Type R geotextile fabric to prevent migration of underlying soil into
    the stone. The tracking pad must be the full width of the egress point or 12 foot minimum. The tracking pad must
    be at a minimum 50 feet long. Surface water must be prevented from passing through the tracking pad. Flows
    must be diverted away from tracking pads or conveyed under or around them by using culverts, trenches or
    diversion dikes that divert surface water runoff into a dispersion area, or other similar practices. There is no
    additional compensation for practices used to divert water.


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CMM 6.45 Erosion Control



    6.45.7.8.3 Proper Use and Maintenance
    Tracking pads only perform when maintained properly. Vehicles traveling across the tracking pad should
    maintain a slow constant speed. Rocks lodged between the tires of dual wheel vehicles must be removed before
    the vehicle leaves the construction site.
    Maintenance is needed when existing stone becomes buried in sediment or tracking onto roadways creates a
    safety issue. The tracking pad performance must be maintained by scraping or top-dressing with additional
    aggregate. A minimum 18-inch thick pad must be maintained.
    6.45.7.8.4 Removal
    Once the project site has been stabilized and the tracking pad is no longer needed, the materials must be
    removed and the area restored.
    6.45.7.8.5 Alternatives
    Alternative methods, i.e. manufactured products, wash racks, or tire washing stations may be used. If proposing
    an alternative method, the contractor must provide, at a minimum, the following in the ECIP:
           1. Schedule for installation and removal
           2. Standard drawings and installation details
           3. Stabilization after removal




May 2011                                                                                                         Page 13
test
    CMM 8.36 QMP - HMA

                                                                                          Wisconsin Department of Transportation
                     Construction and Materials Manual
                         Chapter 8      Materials Testing, Sampling, Acceptance
                         Section 36     QMP - HMA

                 Materials sampling and testing methods and documentation procedures prescribed in chapter 8 of the
                 CMM are mobilized into the contract per standard spec 106.3.4.1 and standard spec 106.3.4.3.1.
                 Hot Mix Asphalt (HMA) Quality Management Program sampling, testing, materials properties, and
                 documentation as prescribed in CMM 8.36 are called into the contract per standard spec 460.2.8.

    8.36.1 GENERAL
    This section addresses the standard specification for Quality Management Program (QMP), Asphaltic Mixture.
    The QMP for Hot Mix Asphalt (HMA) is detailed in standard spec 460.2.8. The following information is provided
    as additional reference, interpretation, and guidance for procedures outlined in those specifications.
    Overview - WisDOT QMP Requirements:
             -    Personnel and required certifications CMM 8.36.2 and standard spec 460.2.8.2.1.1 ) 

             -    Laboratory facilities. (CMM 8.36.3 and standard spec 460.2.8.2.1.2) 

             -    Random sampling and sampling frequency. (CMM 8.36.4 and standard spec 460.2.8.2.1.3) 

             -    Required testing (and calculated properties). (CMM 8.36.6 and standard spec 460.2.8.2.1.3) 

                       - Mixture bulk specific gravity (Gmb).
                       - Mixture maximum specific gravity (Gmm).
                      - Air voids (Va). 

                      - VMA (voids in mineral aggregate). 

                      - Aggregate gradation.
                      - Percent binder content.
             -    Documentation. (CMM 8.36.8 and standard spec 460.2.8.2.1.4)
                      - Records.
                      - Control charts.
             -    Control limits. (CMM 8.36. and standard spec 460.2.8.2.1.5 )
             -    Warning bands. 

             -    Job mix formula adjustments. (CMM 8.65.8 and standard spec 460.2.8.2.1.6) 

             -    Corrective action. (standard spec 460.2.8.2.1.7) 

             -    Optional contractor assurance. (CMM 8.36.6.2 and standard spec 460.2.8.2.2) 

             -    Verification program. (CMM 8.36.9 and standard spec 460.2.8.3.1) 

    The following sections identify and further attempt to clarify procedures used during field production of HMA
    under the QMP.
    8.36.1.1 Definitions
                          Rule of Retained:	 Split samples for comparison testing are retained. In order to test a retained portion
                                              of any sample, communications must occur between the department and contractor
                                              QMP teams. The department has ownership of QMP required split samples. There
                                              is implied joint ownership between contractor and department on any additional QC
                                              samples recorded.
                         Limiting Liability:	 Additional assurance testing can be performed to validate contractor production
                                              data. Identifies conforming material for consideration during the dispute resolution
                                              process in determining any need for price adjustments (does not exclude price
                                              reductions within contractor QMP).
                  Mixture production days: Days of production of a specific design mixture being tested under QMP. No more
                                              than two working days is intended for getting test results.
                            Working days: Calendar day, except Saturdays, Sundays, and department-specified holidays.
                 Non-Conforming materials: Mixture not meeting acceptable verification parameters, but allowed to be left in
                                              place with appropriate payment reduction.
                   Unacceptable materials: Mixture not meeting acceptable verification parameters and being required to be
                                              removed and replaced.


May 2011 	                                                                                                                         Page 1
CMM 8.36 QMP - HMA



                                 Teams: Personnel listed on QMP organizational charts.
    8.36.2 PERSONNEL REQUIREMENTS (THROUGH HTCP)
    The following list summarizes minimum personnel requirements and associated certifications to satisfy QMP
    Asphalt activities.
             1. QC: Production process.
                 -	 Sampling and testing: HMATech at a level recognized for mixture production testing (formerly
                    known as HMATech 1).
                 -	 Production process changes: HMATech at a level recognized for production process control and
                    troubleshooting (formerly known as HMATech 2).
                 -	 Mix design: at a level recognized for doing mix design work (formerly known as HMATech 3).
             2. CA: Production assurance.
                 -	 Sampling and testing: HMATech at a level recognized for mixture production testing (formerly
                    known as HMATech 1).
                 -	 In the event other properties are being evaluated, have an appropriate certification.
             3. QV: Department quality verification.
                 -	 Sampling and testing: at a level recognized for mixture production testing (formerly known as
                    HMATech 1).
                 -	 Production process change review: at a level recognized for doing mix design work (formerly
                    known as HMATech 3).
    8.36.3 LABORATORY REQUIREMENTS
    The laboratory must be:
             -	 Furnished with equipment to comply with daily testing and communication requirements (calibrated
                testing equipment, phones, faxes, copy machines, etc.).
             -	 Located at the plant site and operational before production.
             -	 A Wisconsin Laboratory Qualification Program participant (for acceptance sampling and testing).
    Any laboratory producing air void test data to comply with QMP requirements must have a Superpave Gyratory
    Compactor (SGC). The intent is for the Gmm and Gmb materials to be tested at the same facility.
    8.36.3.1 CA Laboratory
    A separate set of equipment must be used (inclusive of SGC) to compare QC split samples.
    8.36.4 SAMPLING HOT MIX ASPHALT
    At the beginning of each day the contractor determines the anticipated tonnage to be produced. The frequency
    of sampling (minimum number of required tests for the day’s anticipated production) is defined by the latest
    (QMP) HMA mixture standard spec 460.2.8.2.1.3. A test sample is obtained randomly from each sublot.

         Example 1
         Expected day’s production is 1,900 tons. The number of required samples = 3 (per QMP standard
           spec 460.2.8.2.1.3).

         Sample 1 – from 50 to 600 tons.
         Sample 2 – from 601 to 1500 tons.
         Sample 3 – from 1501 to 2700 tons.
    The approximate location of each sample within the prescribed sublots is determined by selecting random
    numbers using ASTM Method D-3665 or by using a calculator that has a random number generator. The
    random numbers selected are used in determining when a sample is to be taken and will be multiplied by the
    sublot tonnage. This number will then be added to the final tonnage of the previous sublot to yield the
    approximate cumulative tonnage of when each sample is to be taken.
    To allow for plant start-up variability, the procedure calls for the first random sample to be taken at 50 tons or
    greater per production day (not intended to be taken in the first two truck loads). Random samples calculated for
    0-50 ton should be taken in the next truck (51-75 ton).

         Example 2


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CMM 8.36 QMP - HMA



                            Sublot
                           Sample                            Sublot Sample Ton           End of         Cumulative
             Required      Tonnage          Random No.     (Random No. x Sublot         Previous.        Sample
              Sample        Range        ASTM D-3665                ton)                 Range           Tonnage

                1           50 - 600           0.572            RN x 600= 343                0              343

                2          601 - 1500          0.353            RN x 900= 318               600             918

                3         1501 - 2700          0.656            RN x 1200= 787             1500             2287

    This procedure is to be used for any number of samples per day. 

    If production doesn’t allow obtaining the next randomly generated sample, then an arbitrary sample will be taken 

    whenever practical to fulfill the sampling frequency requirement defined in standard spec 460.2.8.2.1.3.1 (5) 

    (Document reasons for any non-compliance). 

    It’s intended that the plant operator not be advised ahead of time when samples are to be taken. If the plant 

    operator is involved in recording a Pb (%AC) to match up with the mix sample tonnage, then notification need 

    not be earlier than 60 minutes before the mix sample being taken. 

    If belt samples are used during troubleshooting, the blended aggregate will be obtained when the mixture 

    production tonnage approximates the sample tonnage. For plants with storage silos, this could be up to 60 

    minutes in advance of the mixture sample that’s taken when the required tonnage is shipped from the plant. 

    QC Sample:
              - Sample size only requires one “test” portion and one “retained” portion.
    CA Sample:
              -	 Must be a companion/split sample with QC (for direct data comparison).
              -	 If an arbitrary CA sample is taken, the QC team must test the companion split in order to be
                 considered for limiting liability.
    QV Sample:
              -	 Must be directly observed by the engineer.
              -	 Engineer takes immediate possession.
              -	 The initial split of QV and QV-retained, can be performed by using a quartermaster. If the contractor
                 performs this split, the engineer, before taking possession, must directly observe it.
    8.36.4.1 Sampling from the Truck Box
    Sampling will be the contractor's responsibility. Truck box sampling presents some safety hazards because it is
    necessary to climb atop the truck box and stand on the hot mixture while sampling. Special care should be
    exercised by the contractor or his designated representative as the sample is procured to prevent falls or burns.
    A shovel or other department approved sampling device should be of such size and configuration that the
    sample can be obtained without spilling or roll off. Note: To satisfy this requirement with a flat bottom shovel, it is
    necessary to attach 2- to 4-inch vertical sides to the shovel.
    8.36.4.2 Sample Location in Truck
                                                                    The total sample for a 1/2" mix will
                                  A                                 weigh at least 70 lbs.
                                                                           X = high reference point
                                        X                                  A = sample point
                                                  B                        B = sample point
                                                                           C = sample point
                                C

                                                Figure 1: Truck Box Sampling



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CMM 8.36 QMP - HMA



    When the last batch has been dumped into the truck box, the sampler must establish a reference point on the
    surface of the load, either at the high point, if a conical shape exists, or near the middle of the truck box if the
    surface shows no such conical shape. Then at least three incremental sample points should be established
    about midway between the previously established point and the sides if the truck and equally spaced around the
    load as seen below in Figure 1. The sampling shovel or other approved device can be inserted into the upper
    two to three inches of mixture to extract the sample increments.
    8.36.4.2.1 QC Sample Sizes:
           -	 Minimum sample sizes are referenced below and are guidance for meeting requirements for test
              completion.
                                    Mixture NMAS                             Sample Size

                                     < 12.5mm (1/2")                              70 lb

                            19.0mm - 25.0mm (3/4" – 1")                          100 lb

                                    > 37.5mm ( 1-1/2")                           160 lb

              -	 The total sample for larger NMAS (nominal maximum aggregate size) mixtures will be enough to
                 provide the required minimum testing sample size as defined in Figure 3.
              -	 The “retained” split must be half of the QC sample.
    8.36.4.2.2 CA Sample Sizes:
    Test sample size may vary based on the tests chosen, but still needs to be large enough to accommodate a split
    for parallel testing and data comparison.
    8.36.4.2.3 QV Sample Sizes:
    Use same guidance as QC sample size (trouble shooting may involve need for a gradation).
    8.36.5 SAMPLE IDENTIFICATION
    The contractor is responsible for obtaining and splitting samples. When the sample is an aggregate sample it
    must be split, placed in bags with plastic liners, and labeled as directed below.
    When a mixture sample is procured, it must be quartered, place in a bag, and labeled as directed below. Figure
    2 provides an example label. The label must include the following items.
              1. Contractor Testing Lab and Certified Technician Name
              2. QC, QC-ret, QV, QV-ret
              3. State project ID
              4. Date
              5. Sample number
              6. Type of asphaltic mixture
              7. State mix design ID (250-XXXX-YR)
              8. Percent binder
              9. Daily tonnage sampled
             10. Current Gsb




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                                               ABC Paving: John Doe
                                                             QC
 

                                                  Prj. ID : 1152   -01-70
 

                                                   7 / 15 / 01 sple 8 
–2

                                                      E – 3 12.5 mm
 

                                                      250-0125-2009
 

                                                         5.5% AC 

                                                    current Gsb: 2.722
 

                                                     1,206 ton (day’s)
 

                                        Figure 2: Example of Sample Labeling

    NOTE: The cumulative/total tons representing mix design production are to be recorded on the QC data sheets.
    8.36.5.1 Reduction of HMA Samples to Testing Size
    For QC sample reduction the HMA sample in the containers is mixed and quartered. The quartering process
    should then proceed as follows:
    8.36.5.1.1 Step 1:
           1. Quarter the sample into “Test” and “Retained” samples. Place entire sample on table, quickly re-mix
              and quarter to minimize temperature loss. Quarter the Test & Retained samples as shown on Figure 3.
              For 1/2" mixes start with at least a total of 70 lbs of HMA.


                                                                           17 lbs
                                  17 lbs
                                            A                     B

                                           QC Retained          QC Test

                                           D                    C

                                                QC Test        QC Retained

                                  17 lbs                                        17 lbs


                                           Figure 3: Superpave Sample, 70 lbs

           2. Diagonal quarters, as indicated on the sketch, must be combined to form the retained sample (A + C)
              and the test sample (B + D). The retained sample must be bagged, labeled, and stored in a safe dry
              place. The retained samples may be tested using the “rule of retained” (see “Definitions” section).
           3. The test sample (B + D) is then further quartered for the specified tests. Continue the quartering
              process in Step 2 for the test materials until individual samples are in the oven.
    8.36.5.1.2 Step 2:
    The 35 lbs of HMA material for testing from Step 1 is to be further reduced for testing according to the following
    sketch (see Figure 4).




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                                                                   Extraction sample
                                                                   (each piece approx 1200g)

                                     Briq A
                                     Approx 2500g
                                                       Briq B
                                                       Approx 2500g


                                   Briq B                                         Gmm sample
                                   Approx 2500g     Briq A
                                                    Approx 2500g                  (each piece approx 1200g)




                                       Figure 4: Superpave Sample, (35 lbs)




                                     Figure 5: Minimum Testing Sample Sizes

    For QV (and some CA) samples a Solvent Extraction Gradation (WisDOT Test Method1560) isn’t routinely
    required.
    8.36.5.2 Use of Alternative Sampling / Quartering Devices (ex: Quartermaster)
    Use of other devices to assist in the sampling and quartering procedures may be used with approval of the
    department. The Quartermaster is one such device. A picture of a Quartermaster device is shown in Figure 6.




                                    Figure 6: Quartermaster Quartering Device




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           Example 3

            1. Dump initial truckbox samples into the machine, noting the chute capacity limit.
            2. Throw lever to allow material to flow into the four quartering buckets. Repeat until all material has been
               quartered.
            3. Combine diagonally opposite buckets to form the test sample (A + C) and the retained sample (B + D)
               making sure to distribute any clinging fines into each bucket.
            4. From this point, remove the QC test material to a heated splitting table for further reduction to testing
               portions. Bag the retained sample, label, and store appropriately.
            5. Clean sides and quartering slats before next use.
    8.36.6 REQUIRED TESTING AND CALCULATED PROPERTIES

    Note: If calculations result in a need to round from an exact half (x.x50), round “even”.
    Example: 14.150 becomes 14.2 and 14.850 becomes 14.8.
    8.36.6.1 QC Tests
    QC testing must be completed, and data posted, on the day the sample was taken or as approved by the
    engineer.
    For administration of projects requiring only one, two, or three single tests per mix design, apply the following
    tolerances table for mixture evaluation:
             Va = 2.0 – 6.0%
             VMA = - 2.0 from required minimums for Table 460-1
             AC = within 0.4 of JMF
    For results not meeting the above ranges, apply pay in accordance with the “Produced Outside JMF Limits”
    guidance listed in standard spec 460.2.8.2.1.7.(6).
    8.36.6.2 CA Tests
    CA tests, by definition in the standard specifications, are at the contractor’s option.
    It should be noted that CA testing not completed before department QV samples are taken might not impact
    recommendations made during dispute resolution unless other communications have occurred between QC/QV
    teams.
    The contract language mentions “two working days after the sample has been obtained by the contractor” as the
    time within which the CA personnel must respond with data to the QC team. The intent is to provide information
    and feedback to the QC team as soon as practical in case there is data disagreement. The interpretation is to
    mean that the time starts when the QC team procures the sample (ex: a QC/QC-ret sample obtained on day 4
    and intended to be tested, would need to be selected by CA on day 4, 5 or 6, with results reported no later than
    day 6).
    If assurance testing is being performed by the department, as part of determining, standard spec 460.2.8.3.1.6,
    Acceptable Verification Parameters; paragraph 3, air voids and VMA will both be determined unless otherwise
    mutually agreed on by the contractor and the engineer. Department assurance personnel will make every effort
    to pick-up the sample on the day the QC personnel procures the test sample.
    If the QC-retained mixture sample temperature is 230F or higher when delivered to the testing facility, quartering
    may start immediately. If the temperature is below 230F, place in a 300F oven, until workable for quartering, not
    to exceed two hours.
    If the difference between the QC and CA test results are outside the allowable differences, the reason must be
    investigated immediately.
    8.36.6.3 CA Data Analysis
    CA test results are evaluated according to the flow chart Evaluation of CA Test Results, located at the end of
    this procedure.




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    8.36.6.4 QV Tests
    The following tests are to be performed in determining product Quality Verification:
             -	 Bulk specific gravity of the mixture (Gmb per AASHTO T 166).
             - Maximum specific gravity of the mixture (Gmm per AASHTO T 209). 

             - Air voids (Va per AASHTO T 269, calculation).

             -	 Voids in the mineral aggregate (per AASHTO R 35, using current field Gsb).
    8.36.6.5 HMA Compaction – AASHTO T 312
             1. Preheat specimen molds (charging funnels, spatulas, etc.) to 300F.
             2. Heat sample, in an open container, to a compaction temperature of 275F + 5F in an oven between
                285F – 320F for no more than 1 hour. If binder modifiers or additives are used, compact to the
                supplier’s temperature recommendations. After quartering to test size, if the mix sample is within the
                proper compaction temperature range, then the specimen can be compacted without further heating.
             3. Place specimen protection disc into the bottom of the mold and charge the mold with the mix sample.
                The sample size should be enough to attain a final specimen height of 115mm + 5mm and is unique to
                the mix design. For Wisconsin aggregates and designs a range of 4700 – 4900g is generally
                appropriate. Charging the mold should be accomplished in one lift action or motion so as to avoid
                segregating the sample inside the mold. Additional funnels or scoop chutes may be used in order to
                accomplish this.
             4. Lightly level off the top of the sample and place a specimen protection disc on top.
             5. Load the mold into the SGC and compact to the appropriate Ndes for the mixture type being produced
                by applying 600kPa ± 18kPa, at an internal angle of 1.16°.
             6. After compaction is completed the specimen is extruded, protection papers removed, the briq is
                labeled, and cooling by fan is required for a period of 1 hr, not to exceed 2 hrs. If the mixture is
                extremely fine or tender, then the initial 5-10 minutes of cooling should take place while the specimen
                is only partially extruded to aid in handling.
             7. Height measurements should be recorded and retained with each specimen.
             8. Reheat the mold for a minimum of 5 minutes if reusing for the second specimen.
    All SGCs being used for QMP specimen preparation will conform to the requirements for calibration as listed in
    the departments Laboratory Qualification Program. Recalibration may be necessary if the testing variation
    between labs exceeds allowable differences or when a continued bias exists in the data attributed to the
    preparation of the specimen.
    8.36.6.6 Bulk Specific Gravity (Gmb) AASHTO T 166
    Determine bulk specific gravity, Gmb, using AASHTO T166.

    Weigh the specimens in air and record (designated this weight as A). 

             -	 Immerse the specimens in 77 ± 2F water bath for 3 to 5 minutes.
             -	 Weigh in water, and record (designating this weight as C).
             -	 Surface dry the specimens by blotting quickly with a damp towel and then weigh in air (include any
                water that may drain from voids in specimens), and record (designating this weight as B).
             - Calculate the Gmb to three decimal places (0.001).
                                                                  A
                                                       Gmb =
                                                               (B − C )
    Determine the average bulk specific gravity for both specimens. If one of the individual specimens deviates by
    more than ±0.015 from the average, results are considered suspect and a new set of specimens is to be
    compacted from the contractor retained sample (following the rule-of-retained).




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    If a 0.020 or greater variability exists between QC and reheated samples (matching QC-retained portion), then a
    Gmb Reheat Correction Factor is to be determined to aid in troubleshooting.

                              Gmb (Un-reheated)                     Then apply the correction factor to the
    Gmb Reheat       =                                              reheated sample by:
                              Gmb (Reheated)
    Correction Factor
                                                                    Corr Gmb = Gmb (Reheated)
    (Calc’d to 0.001)

    When comparing the uncorrected Gmb to the corrected Gmb, if the difference is less than 0.005, then the
    correction factor will not be used.
    8.36.6.7 Maximum Specific Gravity of the Mixture (Gmm) - AASHTO T 209
    Determine maximum specific gravity, Gmm, using AASHTO T 209.
             -	 Use the appropriate sample size Figure 5.
             -	 Subject the Gmm sample to the same heating condition and time period as the Gmb material. 

             -	 Begin to cool the sample. While sample is cooling, break up sample to pieces no greater than ¼”, and 

                continue to cool to an ambient room temperature.
             -	 Place material into a calibrated container and determine the actual dry weight of the sample.
             -	 Add 77F water to cover the sample.
             -	 Apply required vacuum for 15 + 2 minutes, agitating material every 2 minutes minimum.
             -	 After the vacuum time period, completely fill the container with 77F water and determine the volume of
                the sample.
                    -	 Bowl Method: by suspending the container underwater and weighing
                    -	 Flask Method: by weighing the container filled with water and sample (in air).
             -	 Correct the Gmm with a dryback test procedure or by applying a dryback correction factor if aggregates
                have a moisture absorption of > 2.0% (see next subsection).
             -	 Calculate the Gmm to three decimal places, 0.001.

                                                Where: A = dry sample wt
                                   A                        B = pycnometer volume (pot + water)
                      Gmm   =
 

                              (A + B − C )                  C = pot + water + mix
 

    8.36.6.8 Dryback Procedure (Corrected Gmm) for Absorptive Aggregates (AASHTO T 209,
    Supplemental Procedure for Porous Aggregates)
             - Run a dryback procedure on Day 1-Sample 1, and determine a dryback correction factor for that test.
                Average the test dryback correction factor with the design JMF dryback correction factor and apply to
                the test data for a new Gmm. If the new average correction factor changes the Gmm by less than 0.010
                then use the design JMF dryback correction factor until otherwise determined by additional testing.
             -	 Run a dryback procedure every other day of production on the first test sample, or any time there is a
                change in binder content greater than 0.1%, or a change in component blend percentages greater
                than 10% (or 20% combined), using the same averaging method as above to validate the original
                design JMF dryback correction factor.
             -	 If any average dryback correction factor changes the Gmm by more than 0.010, check for math or
                testing error first, otherwise a new dryback correction factor must be established by running drybacks
                on the next three samples. Average the new dryback correction factors and establish that average as
                the new JMF dryback correction factor.
    If a 0.015 or greater variability exists between QC and reheated samples (matching QC-retained portion), then a
    Gmm reheat correction factor is to be determined to aid in troubleshooting. It should be calculated to 0.001.
    Gmm Reheat Correction Factor = Gmm (Un-reheated) / Gmm (Reheated)
    Then apply the correction factor to the reheated sample: Corrected Gmm = Gmm (reheated) * correction factor.
    When comparing the uncorrected Gmm to the corrected Gmm, if the difference is less than 0.005, then the
    correction factor will not be used.


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    8.36.6.9 Air Voids (%Va) – AASHTO T 269
    The air void (%Va ) determination is a relationship between maximum specific gravity (Gmm) and bulk specific
    gravity (Gmb). Calculate to one decimal place.

                                                  Va,   % = (Gmm −Gmb ) x100
                                                               Gmm

    8.36.6.10 Voids in Mineral Aggregate (VMA)
    VMA is calculated using the aggregate bulk specific gravity, Gsb, from the contractor mix design (unless a blend
    change has occurred in which case a new Gsb will be calculated), the asphalt content (Pb determined by
    8.36.6.12), and the average SGC specimen bulk specific gravity, Gmb, as follows (calculate and record to 0.1.):
                                     100 – Pb = Ps (or % stone)
                                                                G mb × (100 − Pb )
                                            VMA,% = 100 −
                                                                      G sb

    8.36.6.11 Aggregate Effective Specific Gravity, (Gse)
    In the Gse calculation, the volume of the aggregate includes all the aggregate internal void spaces except those
    that absorb asphalt. Calculate and record to three decimal places (0.001).
                                                              100 − Pb
                                                G se =
                                                          ⎡⎛ 100    ⎞ ⎛ Pb   ⎞⎤
                                                          ⎢⎜
                                                           ⎜        ⎟−⎜
                                                                    ⎟ ⎜G     ⎟⎥
                                                                             ⎟
                                                          ⎢⎝ G mm
                                                          ⎣         ⎠ ⎝ b    ⎠⎥⎦
    Where:
                                   Gmm    = end of previous days average.
                                     Pb   = end of previous days tank stick.
                                     Gb   = binder specific gravity from the mix design.
    Calculate this Gse at the beginning of each day and use that value for current day’s calculations. If there is a
    change in binder content then recalculate a new Gse with the next available sample (consider it being non­

    random) and average with the previous Gse: 

    Where:

                                   Gmm    = current sample test result.
                                     Pb   = reflecting the intended change (assumed).
                                     Gb   = from the mix design.
    A change in binder source or grade requires a check of the Gb.
    8.36.6.12 Percent Of Asphalt Content (Pb)
    Option is to use a plant gauge reading method and record and chart the Pb reading as close to representing the
    sample as possible.
    When calculating the Pb (an additional option for record and charting) use the following equation:

                                                      ⎛ G       ⎞ (G − G mm )
                                           Pb = 100 × ⎜ b
                                                      ⎜G        ⎟ × se
                                                                ⎟ (G − G )
                                                      ⎝ mm      ⎠    se   b

    Where:
                                   Gmm    = current sample test result.
                                    Gse   = previous day.
                                     Gb   = mix design.



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    Pb method selected should be used consistently to chart and calculate any related mixture properties for
    project. Plant gauge readings may involve a calibration procedure and use of a correction/correlation factor.
    8.36.6.13 Additional Formulas and Example Calculations
           1. Determining the asphalt absorption, Pba, for the following: 

              Given: 

              Gse = 2.761
 

              Gsb = 2.703
 

              Gb = 1.030
 


            Pba = 100 ×
                       (Gse − Gsb ) × G =
                       (Gsb × Gse ) b
            100 ×
                  (2.761 − 2.703 ) × 1.031 = 100 × 0.058 × 1.031 = 0.8
                  (2.703 × 2.761)                  7.463
           2. Determining the effective asphalt content, Pbe, of the asphaltic mixture for the following:
              Given:
              Pb = 5.3
              Pba = 0.8
              Ps = 94.7
                           Pba                ⎛ .8 ⎞
            Pbe = Pb − (       ) × Ps = 5.3 − ⎜     ⎟ × 94.7 = 4.5
                           100                ⎝ 100 ⎠
           3. Determining the percent voids filled with asphalt (VFA) for the following compacted mixture:
              Given:
              VMA = 14.4
              Va = 3.7
                            (VMA − Va )         (14.4 − 3.7)
            VFA = 100 ×                 = 100 ×              = 74.3
                              (VMA )               (14.4 )
           4. Determining the dust to binder ratio (or DP: Dust Proportion):
 

              Given: 

              Pbe = 4.5
 

              % passing 0.075 = 5.0
 

                                        % pas sin g 0.075 5.0
            Dust to Binder Ratio =                       =     = 1.1
 

                                               Pbe         4.5
 

    8.36.6.14 Field Adjusted JMF
    The JMF may be adjusted in the field based on production test results according to the procedures in WisDOT
    method 1559.
    When the JMF asphalt content is changed by 0.2% or more (start new running average for Gmm), the
    compaction target maximum density for the day of the target change can be calculated using the most recent
    Gse and percent asphalt binder (Pb) for the new JMF and Gb (binder specific gravity) at 77/77 F from the mix
    design.
    8.36.6.15 Field TSR Tests
    The tensile strength ratio is determined according to the procedures in ASTM Method D 4867. After
    manufacturing the specimens at the plant, they may be tested in an off site laboratory. Use distilled water for
    saturating and soaking the test specimens.
    8.36.6.16 Rap Sampling And Testing
    The requirement for aggregate gradation testing prior to incorporation to the mix has been eliminated.



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    8.36.6.16.1 Rap Stockpile Samples
    The minimum test sample size must be determined from extracted aggregate gradation size per AASHTO T164.
    That has been divided into aggregate gradation numbers as follows:
                        Nominal Max Size (mm)              Minimum Weight of Test Sample (grams)

                                   25.0                                        3000

                                   19.0                                        2000

                                   12.5                                        1500

                                   9.5                                         1000

    When test results indicate that a change has occurred in the RAP asphalt content, a change in the design RAP
    asphalt percentage may be requested by the contractor or the engineer. The request will include at least two
    recent RAP extractions and also identify all applicable mix designs to be affected. For each affected mix design
    a new Pbr (Percent binder replacement will be calculated and reported). The requested change will be reviewed
    for the department by an HTCP Certified HMA Technician at a level recognized for mix design, and a revised
    JMF can be issued.
    8.36.7 HMA QUALITY MANAGEMENT PROGRAM DOCUMENTATION
    The contractor is responsible for documenting all observations, records of inspection, and test results on a daily
    basis. Results of observations and records of inspection must be noted as they occur in a permanent field
    record. The testing records and control charts must be available in the QC laboratory at the asphalt plant.
    The contractor must maintain standardized control charts. Test results obtained by the contractor must be
    recorded on the control charts the same day the tests are conducted. The aggregate gradation test data must
    be recorded on the standardized control charts for all randomly selected production samples tested.
    Sieve sizes for aggregate gradation tests must include the maximum aggregate sieve size, the NMAS sieve,
    and any following sieves falling below: 1" (25.0mm), 3/4"(19.0mm), 1/2"(12.5mm), 3/8"(9.5mm), # 4 (4.75mm),
    #8(2.36mm), # 16 (1.18mm), # 30 (600μm), # 50 (300μm) # 100 (150μm) and # 200(75μm).
    8.36.8 DOCUMENTATION
    8.36.8.1 QC Records
    In addition to the requirements of the “Records” subsection of the standard specification, the contractor must
    provide:
             -	 A cumulative tonnage value to the engineer on a daily basis.
             -	 Random number generation results and associated tonnage for QMP sampling
             -	 Binder Inventories (inclusive of incremental tonnages used to calculate binder useage for test
                samples and documentation validating calibration checks)
             -	 Blend change history
             -	 Individual sample test property worksheets (Note: More detailed information may be requested or
                observed during actual production for evaluation purposes. In order to verify compliance with
                appropriate test procedure requirements, this information needs to be made available during that on­
                site evaluation).
    Records should be the original (handwritten or electronic) documents.
    8.36.8.2 CA Records
    When CA testing is completed a CA worksheet is filled out and sent to the QV team. Results from CA testing are
    posted on the QC charts for the appropriate property. The CA data point should be represented by a unique
    symbol (ex: blue “X”).
    8.36.8.3 QV Records
    Results of QV testing are posted to the appropriate QC charts for air voids and VMA and represented with a
    unique symbol (ex: red "X").




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    8.36.9 QUALITY VERIFICATION PROGRAM
    8.36.9.1 Monitoring Contractor QMP
    8.36.9.1.1 Pre-Construction
    The QV team is responsible for obtaining the following information:
             -	 Obtain WisDOT test number of the quality test report for the aggregate source being used. If source
                quality testing hasn’t been completed, notify the department’s Bureau of Technical Services
                laboratory.
             -	 Obtain the WisDOT test number of the mix design intended for use or a copy of the contractor's mix
                design, the review report, if available, from department’s Materials Tracking system, and any contract
                special provisions.
             -	 Verify that the QC team personnel have the proper certifications.
             -	 Verify that the QC Laboratory facility is WisDOT qualified and has the equipment required by the QMP
                specification (inclusive of communication devices).
    Review any procedures for determining reheat correction factors and for the Gmm dry back correction factor (if
    applicable). Discuss any necessary calibrations, or pending recalibrations, for the gyratory compactor and what
    procedure will be used.
    8.36.9.1.2 During Production
    During production, the QV team should, as often as they feel necessary:
             1. Random Sampling:
                 -	 Check the QC procedures for proper random number generation for all samples.
                 -	 Verify the QC team is aware they are not to inform the plant before the random sampling will
                    occur.
             2. Samples:
                 -	 Ensure all required samples are being taken for mixture properties and blended aggregate
                    gradations.
                 -	 Ensure that proper sampling and splitting procedures are being used and the field sample size is
                    large enough to accomplish required testing.
                 -	 Ensure that stockpile samples are taken and tested for reclaimed asphaltic pavement (RAP)
                    when applicable.
                 -	 Ensure tensile strength ratio (TSR) tests have been conducted at proper intervals when using
                    anti-stripping agents.
                 -	 Ensure that the retained samples (mix and blended aggregate) are properly labeled and stored in
                    a dry protected area.
             3. Testing:
                 -	 Observe the reduction of the field samples to test size.
                 -	 Observe the testing procedures paying attention to temperature of test samples before
                     compaction, compaction efforts, times allotted between tasks, dry backs, etc.
                 -	 Review data calculations (adjusted with the calibration correction factors when applicable).
             4. Control charts:     

                 -	 Check to see that required control charts are present and up to date. 

                 -	 Check to see that control limits and warning bands are accurately drawn. 

                 -	 Check to see that the proper values are being plotted correctly. 

             5. Documentation:
                 -	 Check to see that records of compliance are being documented and are up to date.
                 -	 Check to see that adjustments to mixtures and JMF changes are noted on field records.
                 -	 Check to see that records have been provided to the QV team on a daily basis.
    8.36.9.2 Verification Sampling
    Product quality verification sampling is the responsibility of the department’s QV team.
    8.36.9.2.1 Design Mixtures
    Samples from the truck box will be taken by a member of the contractor QC team, and directly observed by the
    QV team member. In addition, if the initial split (QV / QV-retained) is performed by the contractor, it is also to be

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    directly observed by the QV team member.
    The QV team will determine and document the random sampling procedure employed for mixture verification
    samples. Any or all of the following methods may be used:
             -   Production tonnage. 

             -   Specific week during production. 

             -   Specific day-of-the-week during production. 

             -   Time-of-day.
    If some other method is used, it should be mutually agreed upon between the QV and QC teams and
    documented before taking place.
    The contract language specifies “two mixture production days” after the sample has been obtained by the
    contractor as the time within which the QV personnel must respond to the QC team relative to the agreement of
    data results. The intent is to provide information and feedback to the QC team as soon as practical in case there
    is data disagreement and the potential need to stop mix production.
    If the QV mixture sample temperature is 230 degrees F or higher when delivered to the testing facility,
    quartering may start immediately. If the temperature is below 230F, place in a 300F oven, until workable for
    quartering, but not to exceed two hours.
    8.36.9.3 Determining Acceptable Verification Parameters
    Whenever a flag has been raised by disagreement of QV test results with the defined acceptable parameters,
    immediate investigation will occur using additional testing, troubleshooting, and dispute resolution actions.
    8.36.9.3.1 Additional Testing
    WisDOT’s Bureau of Technical Services laboratory is to test QV-retained and nearest available backward QC­
    retained sample.

           Example 4
           A QV sample taken after QC test 5-3 falls outside acceptable parameters. The WisDOT – BTS
              lab tests retained portion of non-compliant QV sample, along with QC-ret sample 5-3. If that
              retained sample doesn’t exist, the next nearest backward sample is 5-2, etc. If there are no
              backward retained QC samples, then liability for that mixture may include back to production
              start-up.
    The QV team is to provide assurance (CA) split sample testing on any forward QC sample as soon as practical,
    and continue at a minimum frequency of 1 in 10 until the QC and QV team mutually agree that the problem has
    been solved in a forward direction. In addition, when the QV team is back on the site to obtain the additional
    QC-retained samples, another QV sample will be taken.

           Example 5
           The QV sample taken after QC test 5-3 falls outside acceptable parameters. The QV team
             returns to the plant site on day 7 and obtains QC-ret sample 5-4 for testing, QC-ret 5-3 to send
             to the WisDOT-BTS lab, and directs a new QV sample be taken representing day 7.
    8.36.9.3.2 Troubleshooting
    The following points are to be considered and re-checked:
             -   Calculations. 

             -   QC data trends. 

             -   Any CA testing trends or bias. 

             -   Equipment calibration records. 

             -   Sampling and splitting observations/notes. 

             -   Proper use of re-heat correction factors. 

    8.36.9.3.3 Dispute Resolution
    For the test results of the QV retained portion, the contract language specifies “two working days” after receipt of
    the sample. The receipt day refers to receipt of the sample at the department’s Bureau of Technical Services
    AASHTO accredited laboratory. The intent is to provide test information and feedback to the QC/QV team as
    soon as practical.


May 2011                                                                                                             Page 14
CMM 8.36 QMP - HMA



    At the completion of dispute resolution testing (QV-ret and nearest backward QC-ret) the WisDOT - Bureau of
    Technical Services AASHTO accredited laboratory personnel dealing with asphalt mix designs will determine
    and recommend a range of non-compliant tons based on, but not limited to, the following information:
           -   Project QC data and production trends.
           -   Project CA data.
           -   Any additional forward testing.
           -   JMF changes and cause for change.
           -   Differences between QV, QC and CA comparison testing (single points and running averages).
           -   Affected mixture properties in conjunction with intended application.
           -   Design mixture production and performance history.
    In determining unacceptable or non-compliant materials, the department’s Bureau of Technical Services
    AASHTO accredited laboratory personnel dealing with asphalt mix designs will provide documentation to the QV
    team recommending tonnages to be affected. A standard recommendation will be assessed based on data
    meeting established tolerance levels for split sample testing.
    A standard recommendation will be assessed based on data meeting the following established tolerance levels
    for split sample testing:
           - Gmm WBL: less than or equal to 0.010
           - Gmb WBL: less than or equal to 0.015

           - Gmm JMFL: less than or equal to 0.015
           - Gmb JMFL: less than or equal to 0.020
    Example scenarios are provided in Figure 7.
    In the event that the range of liability is determined to be at the QV tonnage point (isolated problem), a standard
    pay adjustment equivalent to 50 tons will be assessed, unless QMP Quality Control pay adjustments are
    controlling (standard spec 460.2.8.2.1.7). There is no intent to use multiple pay adjustments, but the lowest
    percent pay will supersede others.
    The QV team will further complete documentation responsibilities by determining the dollar amount for any
    affected mixture tonnage and will forward that information to appropriate project personnel and the QC team.




May 2011                                                                                                             Page 15
CMM 8.36 QMP - HMA




                     Figure 7: Example of HMA Verification Dispute Resolution Scenario




May 2011                                                                                 Page 16

CMM 8.36 QMP - HMA




                 Figure 7: Example of HMA Verification Dispute Resolution Scenario (cont'd)




May 2011                                                                                      Page 17

CMM 8.36 QMP - HMA



    8.36.9.4 Evaluation of CA Test Results




May 2011                                     Page 18

CMM 8.36 QMP - HMA



    8.36.9.5 Evaluation of QV Test Results




May 2011                                     Page 19

test
    CMM 8.50 Materials Testing and Acceptance Guide

                                                                                    Wisconsin Department of Transportation
                  Construction and Materials Manual
                     Chapter 8      Materials Testing, Sampling, Acceptance
                     Section 50     Materials Testing and Acceptance Guide

             Materials sampling and testing methods and documentation procedures prescribed in chapter 8 of the
             CMM are mobilized into the contract per standard spec 106.3.4.1 and standard spec 106.3.4.3.1.

    The index is followed by the guide, arranged alphabetically. Generally, the guide presents minimum
    requirements for testing and acceptance of materials.
                         MATERIALS TESTING AND ACCEPTANCE GUIDE - INDEX
    Aggregates                                                      Embankment
    Anchor Bolts and Rods                                           Erosion Mat
    Asphaltic Materials                                             Fencing, Chain Link
    Asphaltic Mixtures (Uncompacted)                                Fencing, Woven Wire
    Asphaltic Pavements (for Density)                               Flexible Tubular Marker Posts and Bases
    Bearing Pads                                                    Fly Ash (for use in concrete masonry for pavement)
    Block & Brick, Concrete                                         Geogrid Reinforcement
    Bridge                                                          Geotextile Fabric
    Bronze Plates, Lubricated                                       High Strength Bolts, Structures
    Castings, Gray Iron                                             Joint Sealers
    Cement, Portland and Masonry                                    Lumber & Timber, Treated
    Concrete Admixtures                                             Paint for Use on Metal
    Concrete Curing Agents                                          Pavement Marking (Permanent)
    Concrete Masonry Reinforcement                                  Piling
    Concrete Mixtures                                               Posts, Treated Wood
    Concrete, Precast Catch Basins, Inlets and                      Prestressed Concrete Members
    Manholes
                                                                    Signing
    Concrete Precast
                                                                    Slag
    Concrete, Prestressed
                                                                    Steel Forgings (Bridges)
    Concrete Protective Surface Treatment
                                                                    Steel Grid Floor
    Concrete, Clear Protective Coating
                                                                    Steel Plate Beam Guard
    Culvert, Sewer Pipe, and Underdrains
                                                                    Steel Reinforcement
    Culvert Pipe End Sections (Apron End Walls)
                                                                    Structural Steel
    Delineators
                                                                    Stud Shear Connectors
    Drains and Downspouts (Bridges)
                                                                    Water for Concrete
    Electrical
                                                                    Waterstops
    Electrical Conduit




May 2011                                                                                                                     Page 1
CMM 8.50 Materials Testing and Acceptance Guide




                                                         MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                            SAMPLE
                                         WHERE                   MINIMUM     SIZE -
                                                                                                                              REMARK
                                        SAMPLED    WHERE        SAMPLING    CENTRAL
              MATERIAL                  ACCEPTED   TESTED      FREQUENCY      LAB


  AGGREGATES

  Source Testing for Quality                                                           The regional person responsible for this area will be responsible for overseeing the
   (Wear, Soundness, etc.)                                                             provisions in items [1] and [2] below.

  Aggregate Base Course                  Source    Central       [1], [2]   100# [3]   Central and Qualified Laboratory Testing
    (Dense and Open-Graded)                         Lab or                             [1] A representative sample of processed material must be submitted from any
                                                   Qualified                               deposit not previously approved by test for compliance with the specifications
                                                     Lab                                   for quality.
  Asphaltic Mixes                                                [1], [2]   100# [3]
                                                                                          Samples for testing and continuing compliance for quality properties (except for
  Breaker Run Stone                                             [1], [23]    100#         soundness and wear) must be submitted as follows:
                                                                                          Yearly - One per deposit, for deposits that exhibit substantial variation in quality
  Granular Subbase & Backfills                                     [1]      100# [7]      test results.
   (if there are plastic fines in the
   material)                                                                              Five-year period - One per deposit, for deposits that exhibit minor variation in
                                                                                          quality test results.
  Pit Run                                                       [1], [23]   100# [7]      Additionally - When visually obvious changes in quality characteristics occur, as
                                                                                          deposit is worked or as the material is delivered to the project.
  Concrete                                                       [1], [2]     [6]      [2] Soundness and wear tests must be run once per pit deposit per five year period
                                                                                           and once per quarry deposit per three year period. For deposits having
  Recycled/Reclaimed Materials or                                  [5]      100# [3]       marginal soundness and wear values (within 5 percent of specification
   Industrial By-Products                                                                  maximum limits), at least one test per deposit per year.
                                                                                       [3] 50# will suffice for wear and soundness tests if only R/No.4 (4.75 mm) material
  Seal Coat                                                      [1], [2]   100# [3]       is submitted. This must be obtained by separating the graded material on a No.
                                                                                           4 (4.75 mm) sieve.
  Selected Borrow                                               [1], [23]   100# [7]   [4] At least one test per contract.
    (when sieve analysis or P.I.
    required).                                                                         [5] At least one test for L.A. Wear per contract. Recycled concrete for use in
  see standard spec 208.                                                                   concrete pavement will require a test for wear if material is supplied from a




May 2011                                                                                                                                                                 Page 2
CMM 8.50 Materials Testing and Acceptance Guide




                                                  MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                    SAMPLE
                                   WHERE                 MINIMUM     SIZE -
                                                                                                                      REMARK
                                  SAMPLED     WHERE     SAMPLING    CENTRAL
             MATERIAL             ACCEPTED    TESTED   FREQUENCY      LAB

  Select Crushed Material                               [1], [23]    100#        source outside the project limits.
                                                                              [6] For concrete-making properties:
                                                                                 Processed:
                                                                                 One bag [±1 cubic foot] each of the fine aggregate and two sizes of coarse
                                                                                 aggregate, except as otherwise requested by the laboratory in specific
                                                                                 instances.
                                                                              [7] 50# will suffice if about 90% or more of the material passes the No. 4 (4.75 mm)
                                                                                  sieve.
                                                                              [23] Alternate engineer acceptance must be documented in the project record. For
                                                                                   Breaker Run refer to standard spec 311.2, Pit Run – standard spec 313.2, and
                                                                                   Select Crushed Material - standard spec 312.2




May 2011                                                                                                                                                      Page 3
CMM 8.50 Materials Testing and Acceptance Guide




                                                      MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                      SAMPLE
                                     WHERE                  MINIMUM    SIZE -
                                                                                                                     REMARK
                                    SAMPLED    WHERE       SAMPLING   CENTRAL
             MATERIAL               ACCEPTED   TESTED     FREQUENCY     LAB

  Project Testing (Gradations,
                                                                                Field Testing
    etc.)

  QMP Contracts                       Field       Field                         QMP Contracts - See the specific contract documents for guidance.
                                                                                All QA and QV tests must be reported in a timely manner on the Materials Tracking
                                                                                System prefix 217 or 162 as applicable.

  Non-QMP Contracts                   Field       Field                         Non-QMP contracts - All acceptance tests must be reported in a timely manner on
                                                                                the Materials Tracking System.
                                                                                The locations of project acceptance tests must be reasonably well distributed
                                                                                throughout the project. Generally, when the aggregates are used as produced and
                                                                                when uniform production and deposit conditions prevail, the minimum field
                                                                                acceptance tests below must be made and, in addition, observation must be
                                                                                maintained at the point of use for indications of deviations from normal gradation.
                                                                                When such deviation is noted, additional tests and necessary adjustment must be
                                                                                made immediately to rectify the condition.
                                                                                The minimum tests are only adequate after plant operations have been stabilized
                                                                                and uniformity of production, well within specification limits, has been obtained.
                                                                                Each sample must be tested for sieve analysis and other tests, as necessary, for
                                                                                determination of conformance with specifications.

  Aggregate Base Course               Field       Field       [8]               [8] One to 500 tons per contract. Acceptance may be in accordance with CMM
    (Non-QMP contracts)                                                             8.45 (Minor Quantity and Incidental Work).
  Includes but is not limited to:                                                   501 tons through 3000 tons /contract. One sample.
  Crushed Agg. Base Course                                                          More than 3000 tons /contract: One sample per 3000 tons accumulative.
  Crushed Agg. Base Course,                                                         For 3000 tons or less/contract the material may be sampled for acceptance in
    Open Graded                                                                     the stockpile at the last location before use.
  Recycled/Reclaimed Aggregates

  Aggregate for chip seals, seal      Field       Field       [9]               [9] One to 500 tons /contract: Acceptance may be in accordance with CMM 8.45
   coats                                                                            (Minor Quantity and Incidental Work).
                                                                                    501 tons through 1500 tons /contract: One sample.
                                                                                    More than 1500 tons /contract: One sample per 1500 tons accumulative per
                                                                                    contract.

  Aggregate for Concrete              Field       Field      [10]               [10] One to 50 CY of concrete/contract: Acceptance may be in accordance with
   Pavement (Non-QMP                                                                 CMM 8.45 (Minor Quantity and Incidental Work).
   Contracts) and Non-QMP


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CMM 8.50 Materials Testing and Acceptance Guide




                                                      MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                      SAMPLE
                                     WHERE                  MINIMUM    SIZE -
                                                                                                                     REMARK
                                    SAMPLED    WHERE       SAMPLING   CENTRAL
                MATERIAL            ACCEPTED   TESTED     FREQUENCY     LAB

    Ancillary                                                                       Incidental paving & ancillary concrete: One sample* per 400 CY concrete
                                                                                    accumulative per source.
                                                                                    Continuous mainline paving: One sample* per 1/2 day or fraction thereof per
                                                                                    source.
                                                                                * One sample must consist of sampling each size of aggregate being incorporated
                                                                                    into the work.

  Aggregate for Concrete Masonry      Field       Field      [11]               [11] One through 100 CY of concrete/contract: One sample*.
   Structures                                                                        101 CY through 400 CY of concrete/contract:
   (Non-QMP Contracts)
                                                                                     A) One sample* for all substructure units.
                                                                                     B) One sample* per deck pour per day.
                                                                                     More than 400 CY of concrete/contract:
                                                                                     A) One sample* per 350 CY or fraction thereof for substructure units. [Contact
                                                                                         the regional materials section for guidance when conditions of construction
                                                                                         are such that more frequent sampling may be warranted (e.g. an extensive
                                                                                         length of construction, mixture/material changes).
                                                                                     B) One sample* per deck pour per day. For pours over 450 CY, additional
                                                                                         samples may be required, contact the regional person responsible for this
                                                                                         area for guidance.
                                                                                * One sample must consist of sampling each size of aggregate being incorporated
                                                                                      into the work.

  Granular Subbase, structural        Field       Field      [12]               [12] One through 500 CY /contract: Acceptance may be in accordance with CMM
   backfill, selected borrow, and                                                    8.45 (Minor Quantity and Incidental Work).
   other backfills                                                                   501 CY through 3000 CY /contract: One sample. Material may be sampled for
                                                                                     acceptance at the source.
                                                                                     More than 3000 CY /contract: One sample per 3000 CY.accumulative.
                                                                                     Contract quantities exceeding 20000 CY contact the region TSS/Materials
                                                                                     unit.

  Breaker Run Stone                                          [13]               [13] Contact region Soils Section for acceptance procedure.

  Mortar Sand                         Field       Field      [14]               [14] Acceptance must be from an approved Regional source.




May 2011                                                                                                                                                       Page 5
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                    SAMPLE
                                   WHERE                  MINIMUM    SIZE -
                                                                                                                    REMARK
                                  SAMPLED     WHERE      SAMPLING   CENTRAL
             MATERIAL             ACCEPTED    TESTED    FREQUENCY     LAB

  ANCHOR BOLTS AND RODS              Shop                                     These items are to be suplied from an approved fabricator. The list of Approved
   for Structures                                                             Fabricators, Bridge Metal Secondary items is located at:
                                                                              http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                              When anchor bolts and rods are not from an approved fabricator, immediately
                                                                              contact the region person responsible for this area, and the Structure Fabrication
                                                                              Unit.
                                                                              See CMM 8.45 for certification guidelines.

  ANCHOR BOLTS for Bases             Field                                    A manufacturer’s certification of compliance is required and must be made
                                                                              available by the contractor. Reference on MTS prefix 900.
                                                                              See CMM 8.45 for certification guidelines.
                                                                              The end of each fabricated anchor bolt unit must be painted to identify the grade
                                                                              as follows:
                                                                                  - Grade 36 - blue
                                                                                  - Grade 55 - yellow
                                                                                  - Grade 105 - red
                                                                              Visually inspect and document dimensions, condition, color marking, etc. Reject
                                                                              rods if not correctly marked.

  ASPHALTIC MATERIALS

  Asphalt Cement                    Source    Central      [15]     1 Quart   [15] For material from certified suppliers, one sample per 900 tons of asphalt or
                                     and       Lab                   (1 L)         fraction thereof for each source and grade per contract. For contracts with less
                                     Field                                         than approximately 25 tons (one truck transport) of asphalt, sampling may be
                                                                                   waived.
                                                                                   The current list of asphalt cement certified suppliers is located at:
                                                                                   http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                   See CMM 8.65 for the "Certification Method of Acceptance for Asphalt
                                                                                   Cements."
                                                                                         CMM 8.65 for "Sampling Asphaltic Materials."
                                                                              See  Indicate on sample tag the type of any additives (silicone or others) in the
                                                                                   asphalt sampled.




May 2011                                                                                                                                                      Page 6
CMM 8.50 Materials Testing and Acceptance Guide




                                                      MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                              SAMPLE
                                   WHERE                      MINIMUM          SIZE -
                                                                                                                                REMARK
                                  SAMPLED     WHERE          SAMPLING         CENTRAL
             MATERIAL             ACCEPTED    TESTED        FREQUENCY           LAB

  Liquid Asphalt                     Field    Central     1 per 5 carloads,   2-1 Quart    Sample in the field per guidelines of standard spec 455.2.2, CMM 8.65 and
    (RC, MC, SC types)                         Lab         5 transports or      (1 L)      AAHSTO T-40.
                                                           fraction thereof   containers   Emulsions have a limited life and should be submitted to the Central Laboratory as
                                                                                           soon as practical. DO NOT allow samples to sit in the sun, be exposed to
  Emulsified Asphalts                Field    Central      1 per contract      1 quart     excessive heat, or freeze. NEVER use metal cans for samples, always use plastic
   (Tack Coats, Slope Paving,                  Lab        when more than        (1 L)      or other non-reactive clean containers.
   etc.)                                                  2500 Gallons is     container
                                                            used 1 per
                                                              contract

  ASPHALTIC MIXTURES                 Field        Field         [16]                       [16] For Quality Management Program (QMP) contracts, see the specific contract
   (Uncompacted)                                                                             documents for guidance.
                                                                                             All QA, QV, and corresponding Qc tests must be reported in a timely manner on
                                                                                             the Materials Tracking System prefix 254.
                                                                                           [17] One to 500 tons (450 Mg)/contract acceptance may be in accordance with
                                                                                             CMM 8.45.
                                                                                           For ASPHALTIC SURFACE (Section 465) a visual inspection must be made and
                                                                                           documented in the inspector’s diary. If visual inspection indicates a problem may
                                                                                           exist, the mixture may be sampled and tested for composition as determined by
                                                                                           the engineer. Reference the approved WisDOT mix design test electronically on a
                                                                                           Materials Tracking System prefix 900.
                                                                                           Sample uncompacted mixtures in accordance with instructions in the CMM,
                                                                                           "Methods of Sampling Asphaltic Paving Mixtures".
                                                                                           See CMM 8.65.

  ASPHALTIC PAVEMENTS                Field        Field                                    For QMP contracts, see the specific contract documents for guidance.
   (for Density)                                                                           For Non-QMP contracts, see standard spec 460.3.3.
                                                                                           Report all HMA pavement Nuclear Density tests on the Materials Tracking System,
                                                                                           prefix 262.

  BEARING PADS                       Shop                                                  These items are to be supplied from an approved fabricator. The list of Approved
                                                                                           Fabricators, Bridge Metal Secondary items is located at:
                                                                                           http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                           If the bearing pads are not furnished by an approved fabricator, the engineer must
                                                                                           immediately contact the region person responsible for this area, and the Structure
                                                                                           Fabrication Unit before installation.
                                                                                           If approved by the above, the below noted documentation must be provided to the



May 2011                                                                                                                                                                 Page 7
CMM 8.50 Materials Testing and Acceptance Guide




                                                    MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                     SAMPLE
                                      WHERE                MINIMUM    SIZE -
                                                                                                                     REMARK
                                     SAMPLED    WHERE     SAMPLING   CENTRAL
             MATERIAL                ACCEPTED   TESTED   FREQUENCY     LAB

                                                                               region contact for this area and the Structure Fabrication Unit.
                                                                                   - For sheet lead and preformed fabric, a manufacturer's certification of
                                                                                     compliance must be made available by the contractor. See CMM 8.45 for
                                                                                     certification guidelines.
                                                                                   - For elastomeric, the engineer must have before use a manufacturer's certified
                                                                                     report of test or analysis indicating conformance to the contract requirements.

  BLOCK & BRICK, CONCRETE              Field                                   A list of approved manufacturers of concrete brick and block is located at:
   Project Testing                                                             http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                               The list will include an identifying mark and/or color, when applicable.
                                                                               Only blocks/bricks from an approved manufacturer must be used.

  BRIDGE                               Field                                   These items are to be supplied from an approved fabricator. The list of Approved
  (Secondary Fabricated Items)                                                 Fabricators, Bridge Metal Secondary items is located at:
    Rail Posts                                                                 http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
    Anchor Assemblies for Posts                                                See CMM 8.75 for the "Certification Method of Acceptance for Bridge Metal
                                                                               Secondary Fabrication Items."
    Sleeves
    Shims                                                                      If not on an approved list, immediately contact the regional person responsible for
                                                                                  this area.
    Rail Panels
                                                                               Note: Each shipment must include a certification statement and a loading
    Anchor Bolts
                                                                                       document from the fabricator. See CMM 8.75 for requirements of certification
    Protection angles                                                                  statement. Reference electronically on a Materials Tracking System prefix
    Structural fasteners                                                               900.
    Expansion devices
    Curb and sidewalk cover plates
    Floor drains
    Guardrail anchors
    Sheet lead
    Elastomeric pads
    Bearing assemblies (steel)
    Structural steel diaphragms

  BRONZE PLATES,                       Shop                                    An approved fabricator usually furnishes these items. The list of Approved
   LUBRICATED                                                                  Fabricators, Bridge Metal Secondary items is located at:
                                                                               http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                               In the event that the plates are not from an approved fabricator, the engineer must
                                                                               have before permitting their installation, a manufacturer's certified report, test or


May 2011                                                                                                                                                       Page 8
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                           SAMPLE
                                    WHERE                   MINIMUM         SIZE -
                                                                                                                           REMARK
                                   SAMPLED    WHERE        SAMPLING        CENTRAL
             MATERIAL              ACCEPTED   TESTED      FREQUENCY          LAB

                                                                                      analysis indicating conformance with the contract requirements.
                                                                                      See CMM 8.45 for certification guidelines.

  CASTINGS, GRAY IRON                Field                                            The list of approved Gray Iron Casting manufacturers is located at:
                                                                                      http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                      For all other manufacturers a certification of compliance must be made available
                                                                                      by the contractor.
                                                                                      See CMM 8.45 for certification guidelines.

  CEMENT, PORTLAND AND              Region    Central     One per year     4 pounds   The list of approved Portland Cement Manufacturers – Certified Suppliers is
   MASONRY                                     Lab       per source and               located at: http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
  Certified Sources and Types on                        type when in use              See CMM 8.70 for the "Sampling of Cement."
   Approved List                                           on WisDOT
                                                              work                    Note: Routine field sampling is not required for certified materials. Random
                                                                                            sampling will be done through region materials staff in accordance with the
                                                                                            Portland cement certification program.
  Non-certified materials            Field    Central     One per 400      4 pounds
                                               Lab           tons

  CONCRETE ADMIXTURES,               Field    Central                                 Approved lists for the following admixture types are located at:
   Liquid                                      Lab                                    http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                      Air Entraining Admixtures
                                                                                      AASHTO M194 Type D Water Reducing Set Retarders
                                                                                      AASHTO M194 Type A Water Reducers
                                                                                      In the case of materials not on an approved list, approval for use must be
                                                                                      requested from the regional person responsible for this area.
                                                                                      Admixtures for which an approved list is not maintained will require a certified
                                                                                      report of tests by a qualified independent laboratory showing that requirements of
                                                                                      ASTM C494 for the type of admixture are satisfactory. Examples of these
                                                                                      admixtures are as follows:
                                                                                      Non-Chloride Accelerators*
                                                                                      Superplasticizers
                                                                                      Reference Certified Reports of Tests and Analysis electronically on a Materials
                                                                                      Tracking System prefix 900.
                                                                                      * When calcium chloride is used as an accelerator, documentation is to include
                                                                                        concentration and addition rate.




May 2011                                                                                                                                                            Page 9
CMM 8.50 Materials Testing and Acceptance Guide




                                                    MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                            SAMPLE
                                   WHERE                     MINIMUM         SIZE -
                                                                                                                            REMARK
                                  SAMPLED      WHERE        SAMPLING        CENTRAL
             MATERIAL             ACCEPTED     TESTED      FREQUENCY          LAB

  CONCRETE CURING AGENTS            Source     Central       When not       1 Quart   [18] See CMM 8.70 for sampling methods for concrete curing compounds.
    (Compounds)                     or Field    Lab            source                 Liquid membrane curing compound, when source inspected, must be marked with
  Liquid Membrane, White                                  inspected. One              evidence of being approved for use in Wisconsin. If there is any doubt whether a
    Pigmented                                            per 2000 gallons             batch is satisfactory, contact the Regional Materials Section.
                                                             or fraction
                                                                                      A list of WisDOT tested and approved batches of White Pigmented Curing
                                                            thereof. [18]
                                                                                      Compounds for the current year is maintained at:
                                                                                      http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                      Lots or batches carried over from the previous year must be tested before use.
                                                                                      When not source inspected, in addition to "Minimum Frequency of Sampling" a
                                                                                      manufacturer's certified report of test or analysis identified with the manufacturer's
                                                                                      name or trademark listing the lot or batch number of the material delivered to the
                                                                                      job.
                                                                                      Field sampling may be waived for small quantities of 220 gallons or less. For these
                                                                                      cases, a manufacturer's certificate of compliance must be made available when
                                                                                      requested by the engineer.
                                                                                      See CMM 8.45 for certification guidelines.
                                                                                      A diary entry is required for lots or batches of curing compound used as per CMM
                                                                                      8.45.

  Clear and Translucent             Source     Central   One per contract   1-Quart   Field sampling may be waived for small quantities of 55 gallons or less. For these
                                    or Field    Lab      in excess of 55              cases, a manufacturer's certificate of compliance must be made available to the
                                                           gallons. [18]              engineer.
                                                                                      See CMM 8.45 for certification guidelines.
                                                                                      A diary entry is required for lots or batches of curing compound used as per CMM
                                                                                      8.45.

  Cure & Seal Compounds              Field                                            A list of WisDOT tested and approved Cure & Seal Compounds for Non-trafficked
                                                                                      Surfaces on Structural Masonry for the current year is maintained at:
                                                                                      http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm

  CONCRETE MASONRY REINFORCEMENT




May 2011                                                                                                                                                             Page 10
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                            SAMPLE
                                   WHERE                    MINIMUM          SIZE -
                                                                                                                            REMARK
                                  SAMPLED     WHERE        SAMPLING         CENTRAL
             MATERIAL             ACCEPTED    TESTED      FREQUENCY           LAB

  Bar Steel                          Field    Central    One for each        5 Feet   It will not be necessary to submit samples from all heats and lots. Submittal of
   (Uncoated – “Black Steel”)                  Lab          50000 lbs                 splice bars or test bars in lieu of cut samples is prohibited. The sampling threshold
                                                          increment or                should be applied individually for each size of bar. Each bar steel size for which
                                                        portion for each              the project quantity equals or exceeds 50,000 lbs should be sampled. When
                                                         individual bar               splicing the replacement piece in the place of the cut sample provide the cut
                                                           size with a                sample length plus lap length as provided in CMM 5.15.5.6.
                                                        quantity equal to             When bars are delivered to the field the engineer must:
                                                          greater than
                                                                                             - Be sure all bundles are identified with heat numbers.
                                                            50,000 lb.
                                                                                             - Obtain one copy of the mill test reports and shipping invoice representing all
  Bar Steel                          Field    Central    One for each        5 Feet   steel types, grades, bar sizes and heat numbers included in the shipment.
   (Epoxy Coated – “Green            [19]      Lab          50000 lbs                        - When epoxy coated, in addition to the above, a copy of the resin
   Steel”)                                                increment or                manufacturer's certification of coating materials and the applicator's certification
                                                        portion for each              attesting to compliance with all of the coating details of the specifications.
                                                         individual bar                      - Attach to the invoice, the mill test reports and when applicable, the coating
                                                           size with a                manufacturer's and applicator's certification. Place in the project records.
                                                        quantity equal to
                                                                                             - Reference electronically on a Materials Tracking System prefix 900 the mill
                                                          greater than
                                                                                      reports and certifications received.
                                                            50,000 lb.
                                                                                      For each sample selected, attach a tag with the following information and submit to
                                                                                      the Central Laboratory for testing.
                                                                                             - Steel type.
                                                                                             - Grade.
                                                                                             - Bar size.
                                                                                             - Heat number and manufacturer.
                                                                                             - If epoxy coated, the epoxy resin manufacturer.
                                                                                             - Quantity of material the sample represents.
                                                                                      When quantities are less than 50000 lbs. of any one bar size visually inspect and
                                                                                      document in accordance with CMM 8.45.
                                                                                      Bar steel delivered without plainly marked heat # tags must not be accepted. If this
                                                                                      occurs immediately contact the regional person responsible for this area.
                                                                                      [19] Only approved powdered epoxy resins are permitted for use. The list of
                                                                                      approved Epoxy Coating for Bar Steel Reinforcement is located at:
                                                                                      http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm

  Tie Bars                           Field                                            Tie Bars, Dowel Bars, & Dowel Bar Assemblies in concrete pavement will not
  Dowel Bars                         [19]                                             require sampling and may be accepted in the field. The contractor must furnish to
  Dowel Bar Assemblies                                                                the engineer a Certified Report of Tests or Analysis for all heat numbers used in



May 2011                                                                                                                                                              Page 11
CMM 8.50 Materials Testing and Acceptance Guide




                                                        MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                               SAMPLE
                                   WHERE                       MINIMUM          SIZE -
                                                                                                                              REMARK
                                  SAMPLED          WHERE      SAMPLING         CENTRAL
               MATERIAL           ACCEPTED         TESTED    FREQUENCY           LAB

                                                                                         the work.
                                                                                         See CMM 8.45 for certification guidelines.

  Dowel Bar Lubricant                Field                                               Dowel Bar Lubricant - A manufacturer’s certification of compliance must be made
                                                                                         available by the contractor when requested by the engineer.
                                                                                         See CMM 8.45 for certification guidelines.

  Hook Bolts                        Source                                               An approved fabricator usually furnishes hook bolts for bridges. The list of
                                    or Field                                             Approved Fabricators, Bridge Metal Secondary items is located at:
                                                                                         http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                         For hook bolts furnished by an unapproved fabricator, the contractor will have a
                                                                                         manufacturer's certification of compliance available.
                                                                                         See CMM 8.45 for certification guidelines.

  CONCRETE MIXTURES

  QMP Contracts                      Field          Field                                For QMP Contracts, see the specific contract documents for guidance.

  Non-QMP Contracts

  Air Entrainment                    Field          Field    Two tests per               See instructions in CMM 8.70 for testing procedures.
                                                             day except for              Observations must be maintained for deviations from selected consistency and
  Slump                              Field          Field   small quantities             entrained air target values and additional tests and adjustments will be necessary
                                                              See remarks                when such occurs. Superstructure elements may also require more frequent
                                                                                         testing to properly administer the contract requirements.
                                                                                         For slip-form paving, slump testing will be as required by the engineer.

  Test Cylinders                     Field                                               Note: One set of cylinders = two cylinders.

  Incidental Construction and                               One set per 200              When daily pours exceed 200 CY using the same source and mix, the rate of
    Ancillary Concrete                       Lab            CY per contract              sampling may be reduced to one set per day. For contracts with quantities less
                                                                                         than 100 CY cylinders do not need to be cast. The QMP ancillary concrete item
                                                                                         covers most incidental concrete construction. Follow the requirements for QMP
                                                                                         ancillary concrete specified in the contract.




May 2011                                                                                                                                                              Page 12
CMM 8.50 Materials Testing and Acceptance Guide




                                                  MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                      SAMPLE
                                   WHERE                 MINIMUM       SIZE -
                                                                                                                     REMARK
                                  SAMPLED     WHERE     SAMPLING      CENTRAL
             MATERIAL             ACCEPTED    TESTED   FREQUENCY        LAB

  Pavement and Base Course                              One set per
                                                       10,000 SY or
                                                           less

  Bridges

  Substructures                                                                 One set per substructure unit (e.g. pier, abutment).

  Superstructures                                                               For bridge decks, one set for each 150 CY or fraction thereof, with at least one set
                                                                                for each pour in a span. For parapets, one set per unit.

  Deck Overlays                                                                 One set per pour. For pours over 450 CY, additional samples may be required,
                                                                                contact regional person responsible for this area for guidance

  Culverts and Retaining Walls                                                  Mold and submit one set per 100 CY or fraction thereof.

  CONCRETE, PRECAST CATCH            Field                                      Acceptance must be by the same procedures as for Concrete Pipe Products under
   BASINS, INLETS AND                                                           CULVERT, SEWER PIPE AND UNDERDRAINS.
   MANHOLES                                                                     The following information must be legibly marked on each precast product:
                                                                                     - Specification and product designation: MH for Manhole base, riser, conical
                                                                                       tops and grade rings.
                                                                                     - Date of manufacture.
                                                                                     - Name or trademark of manufacturer.
                                                                                Document this information in the project records. Contact the region materials
                                                                                engineer immediately if products are not properly marked.
                                                                                The list of Approved Precast Catch Basin, Inlet and Manhole suppliers is located
                                                                                at: http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm

  CONCRETE PRECAST                  Source                                      Acceptance must be by the same procedures as for Concrete Pipe Products under
                                                                                CULVERT, SEWER PIPE AND UNDERDRAINS.
                                                                                If for box sections the following information must be legibly marked on each
                                                                                precast section by indentation, waterproof paint, or other approved means:
                                                                                      - Box section span, rise, table number and specification designation.
                                                                                      - Date of manufacture.
                                                                                      - Name or trademark of manufacture.
                                                                                      - Identification of plant.



May 2011                                                                                                                                                      Page 13
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                    SAMPLE
                                     WHERE                MINIMUM    SIZE -
                                                                                                                   REMARK
                                    SAMPLED    WHERE     SAMPLING   CENTRAL
             MATERIAL               ACCEPTED   TESTED   FREQUENCY     LAB

                                                                              The word “top” lettered with waterproof paint of the inside top surface.
                                                                              Document this information in the project records. Contact the Regional Materials
                                                                              engineer immediately if products are not properly marked.

  CONCRETE, PRESTRESSED                                                       See PRESTRESSED CONCRETE.

  CONCRETE, CLEAR                     Field                                   A manufacturer's certificate of compliance must be made available by the
   PROTECTIVE COATING                                                         contractor.
                                                                              See CMM 8.45 for certification guidelines.
                                                                              A diary entry is required; see CMM 8.45.

  CONCRETE PROTECTIVE                 Field                                   The list of approved Concrete Protective Surface Treatment products is located at:
   SURFACE TREATMENT                                                          http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm

  CULVERT, SEWER PIPE AND                                                     [20] A diary entry is required for these items. See CMM 8.45 for requirements.
   UNDERDRAINS

  Concrete Pipe Products              Field                                   The list of Approved Concrete Pipe Product suppliers is located at:
  Non-reinforced Concrete Pipe        [20]                                    http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
   (Sewer)                                                                    The manufacturer's certification of compliance must be made available by the
   Reinforced Concrete Pipe                                                   contractor when requested by the engineer. See the department's "Procedure for
   Reinforced Concrete,                                                       Acceptance of Concrete Pipe Products" for the certification format.
   Horizontal Elliptical Pipe                                                 For products and plants not on the approved list, immediately contact the regional
                                                                              person responsible for this area.

  Corrugated Metal Pipe Products      Field                                   The list of Approved Corrugated Metal Pipe Product suppliers is located at:
   Aluminum Pipe and Aluminum         [20]                                    http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
   Underdrain                                                                 The manufacturer's certification of compliance must be made available by the
   Metallic Coated Corrugated                                                 contractor when requested by the engineer. See the department's "Procedure for
   Steel                                                                      Inspection and Acceptance of Corrugated Metal Culvert Pipe" for the certification
   (Pipe and Underdrain)                                                      format.
   Structural Plate Pipe and Pipe                                             For pipe products and plants not on the approved list, contact the regional person
   Arch                                                                       responsible for this area.

  Plastic Pipe Products               Field                                   Inspect for AASHTO/ASTM marking as required in standard spec 612 or Special
  ABS Drainage Pipe (Underdrain)      [20]                                    Provisions.
  Polyvinyl Chloride (PVC)                                                    A manufacturer's certificate of compliance must be made available by the



May 2011                                                                                                                                                   Page 14
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                      SAMPLE
                                   WHERE                  MINIMUM      SIZE -
                                                                                                                         REMARK
                                  SAMPLED     WHERE      SAMPLING     CENTRAL
             MATERIAL             ACCEPTED    TESTED    FREQUENCY       LAB

    Drainage Pipe (Underdrain)                                                      contractor when requested by the engineer.
                                                                                    See CMM 8.45 for certification guidelines.

  Corrugated Polyethylene            Field    Central   See remarks    1- 20 foot   Upon receiving a shipment of pipe on a project the engineer must check the
   Drainage Pipe (Underdrain)                  Lab                    length or 2   approved list for the current year for manufacturers and pipe sizes.
                                                                         pieces     The list of Approved Corrugated Polyethylene Drainage Pipe suppliers is located
                                                                        each 10     at: http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                         feet in
                                                                         length     Production of pipe in a NTPEP fully compliant plant is required. If the pipe
                                                                                    manufacturer and size are on the approved list and the pipe is stamped "AASHTO
                                                                                    M 252" and shows no apparent damage, it may be incorporated into the work with
                                                                                    a certification of compliance identifying manufacturer, plant, type, size and
                                                                                    compliance to AASHTO M 252. Pipe not properly marked AASHTO M 252 shall be
                                                                                    rejected
                                                                                    See CMM 8.45 for certification guidelines.

  Corrugated Polyethylene (PE)       Field    Central   See remarks    10 foot      Upon receiving a shipment of pipe on a project the engineer must check the
   Pipe (Culvert)                              Lab                     length       approved list for the current year for manufacturers and pipe sizes.
                                                                                    The list of Approved Corrugated Polyethylene Culvert Pipe suppliers is located at:
                                                                                    http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                    Production of pipe in a NTPEP fully compliant plant is required. If the pipe
                                                                                    manufacturer and size are on the approved list and the pipe is stamped "AASHTO
                                                                                    M294" and shows no apparent damage, it may be incorporated into the work with a
                                                                                    certification of compliance identifying manufacturer, plant, type, size and
                                                                                    compliance to AASHTO M 294. Pipe not properly marked AASHTO M294 shall be
                                                                                    rejected.
                                                                                    See CMM 8.45 for certification guidelines.

  Composite Pipe (Sewer)             Field    Central   See remarks      6 foot     Inspect for AASHTO/ASTM marking as required in standard spec 612 or Special
   ABS (AASHTO M264)                           Lab                      length      Provisions. If not marked, submit a sample to Central Lab for testing.
   Polyvinyl Chloride (PVC)                                                         A manufacturer's certification of compliance must be made available by the
                                                                                    contractor when requested by the engineer.
                                                                                    See CMM 8.45 for certification guidelines.
                                                                                    If the contract quantity exceeds 2000 LF, submit one sample to the Central
                                                                                    Laboratory.

  Joint Materials (Storm Sewer)      Field                                          A manufacturer's certification of compliance must be made available by the
    External Rubber Gaskets                                                         contractor when requested by the engineer.



May 2011                                                                                                                                                         Page 15
CMM 8.50 Materials Testing and Acceptance Guide




                                                    MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                     SAMPLE
                                      WHERE                MINIMUM    SIZE -
                                                                                                                      REMARK
                                     SAMPLED    WHERE     SAMPLING   CENTRAL
               MATERIAL              ACCEPTED   TESTED   FREQUENCY     LAB

    Rubber and Plastic Gaskets                                                 See CMM 8.45 for certification guidelines.

  CULVERT PIPE END                     Field                                   Acceptance must be as outlined for pipe products (concrete or corrugated metal).
   SECTIONS
   (Apron End Walls)

  DELINEATORS                          Field                                   A manufacturer's certification of compliance must be made available by the
                                                                               contractor when requested by the engineer.
  Bracket
    Mounting Hardware                                                          See CMM 8.45 for certification guidelines.

  Reflectors
  Posts
  DRAINS AND DOWNSPOUTS                Field                                   An approved fabricator normally furnishes these items. The list of Approved
                                                                               Fabricators, Bridge Metal Secondary items is located at:
  (Bridges)                                                                    http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                               In the event the item(s) is not furnished by an approved fabricator, a certification of
                                                                               compliance must be made available.
                                                                               See CMM 8.45 for certification guidelines.

  ELECTRICAL                           Shop                                    Acceptance of these items is based on their performing in accordance with the
  Controllers and Related               and                                    sequence in the contract and in many cases, passes an acceptance test by the
   Equipment                           Field                                   WisDOT Electrical Shop in Madison. See the contract plans and specifications for
                                                                               detailed instructions.

  Luminaries                           Field                                   The department specifies approved materials and construction products for
  Fuses, Tape, Fuse Holders,                                                   electrical work on the department’s approved products list. The Qualified Electrical
    Varnish                                                                    Products List (EQPL) is located at:
  Connectors                                                                   http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
  Breakaway Bases                                                              Accept electrical materials not on the EQPL in accordance with standard spec
                                                                               651.2.
  Traffic Signal Standards
  Polyethylene Duct                                                            See CMM 8.45.
  Traffic Signal mounting Hardware
  Traffic Signal Faces
  Junction Boxes
  Pull Boxes
  Cast Rings and Covers



May 2011                                                                                                                                                       Page 16
CMM 8.50 Materials Testing and Acceptance Guide




                                                      MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                            SAMPLE
                                       WHERE                 MINIMUM         SIZE -
                                                                                                                               REMARK
                                      SAMPLED    WHERE      SAMPLING        CENTRAL
              MATERIAL                ACCEPTED   TESTED    FREQUENCY          LAB

  Electrical Service Material
  Splice Kits
  Multi-Conductor Cable
  Cable-In-Duct (Multiple Wires)
  Wiring (Lighting & Signalization)

  Electrical Wire & Cable for           Field                               24” pieces   Accept these electrical materials in accordance with standard spec 651.2.
    Lighting & Signalization                                                     *       * When samples are required, include one complete set of lettering.

  Anchor Rods                           Field    Central   One per signal                When these electrical items are specified in the contract, a manufacturers
  Mast Arms                                       Lab        location                    certification of compliance covering such items must be submitted to the project
   Trombone                                                                              manager with the material list.
   Luminaire                                                                             See CMM 8.45 for certification guidelines.
   Monotubes                                                                             The contractor is to furnish poles, arms and pedestal bases from an approved
  Poles                                                                                  manufacturer. Pre-qualified manufacturers are listed in the EQPL. Per the
                                                                                         requirements of standard spec 657 the contractor is to also furnish a certification of
                                                                                         compliance and shop drawings for all poles and arms.
  Bases, Pedestal & Transformer                                                          Reference Certifications of Compliance, Certified Reports of Test and Analysis,
                                        Field
                                                                                         and shop drawings electronically on a Materials Tracking System prefix 900.
                                                                                         If the engineer requests, the contractor is to provide one randomly selected sample
                                                                                         pedestal base per traffic signal location. The department will base acceptance of
                                                                                         all pedestal bases at that traffic signal location on destructive tests of that sample
                                                                                         base.

  ELECTRICAL CONDUIT                    Field                                            Conduit with Underwriters Laboratories, Inc. (UL) label/emblem affixed to each
   (Rigid Metallic or Rigid                                                              piece signifies acceptable material and may be incorporated into the work. See
   Nonmetallic PVC Schedule 40                                                           standard spec 652.2.1. When the UL label/emblem is not affixed, or the
   and 80)                                                                               label/emblem is suspect, do not use the material. See CMM 6.55.

  EMBANKMENT                            Field                                            For QMP contracts, see the specific contract documents for sampling and testing
                                                                                         guidance.
                                                                                         For non-QMP contracts contact the regional soils engineer for the latest
                                                                                         acceptance procedures and required documentation. For additional guidance, see
                                                                                         the CMM as follows:
                                                                                             - Standard Compaction: CMM 3.30
                                                                                             - Special Compaction: CMM 3.30 & CMM 8.45
                                                                                         Report QV, QA and QC Soils Nuclear Density tests on the Materials Tracking


May 2011                                                                                                                                                                Page 17
CMM 8.50 Materials Testing and Acceptance Guide




                                                    MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                            SAMPLE
                                     WHERE                  MINIMUM          SIZE -
                                                                                                                                REMARK
                                    SAMPLED    WHERE       SAMPLING         CENTRAL
             MATERIAL               ACCEPTED   TESTED     FREQUENCY           LAB

                                                                                          System, prefix 232 or 805 (if applicable).

  EROSION MAT                         Field                                               For a list of approved products see the Erosion Control Product Acceptability Lists
   All classes and types with all                                                         (PAL) available at http://www.atwoodsystems.com/materials/ and
   anchor systems and devices.                                                            http://www.dot.wisconsin.gov/business/engrserv/docs/pal.pdf

  FENCING, CHAIN LINK                 Field    Central   One per 50 rolls   1 SF          When test results indicate noncompliance, additional samples must be taken from
   Fabric                                       Lab        or fraction                    two rolls, units, or coils other than initially sampled, both of which must meet the
                                                            thereof.                      requirements.

    Posts and Top Rails               Field    Central   One per 500 or     2 - 12 inch   Two specimens for determination of weight of coating must be cut approximately
                                                Lab      fraction thereof     lengths     12 inches in length from opposite ends of the lengths of members selected for
                                                             per size.       and 1 - 3    testing. Also, a third specimen, for determination of tensile strength, must be cut
                                                           See remarks           foot     approximately three feet in length, from the center portion of each member
                                                                               length.    selected for testing. Specimens must be cut from one length selected at random
                                                                                 See      from each lot of 500 lengths, or fraction thereof, of each size. If the weight of
                                                                             remarks      coating and/or tensile strength test results of any lot indicate noncompliance,
                                                                                          samples of two additional lengths must be taken for each test from the same lot as
                                                                                          initially sampled both of which must meet the requirements.

  Tension Wire                        Field    Central   One per 10 rolls      3 foot     When test results indicate noncompliance, additional samples must be taken from
                                                Lab        or fraction        length      two rolls, units, or coils other than initially sampled, both of which must meet the
                                                            thereof.                      requirements.

  FENCING, WOVEN WIRE                 Field    Central   One per 50 rolls   3 foot full   When test results indicate noncompliance additional samples must be taken from
   Fabric                                       Lab        or fraction         width      two rolls other than initially sampled, both of which must meet the requirements.
                                                            thereof.         including
                                                                            3 vertical
                                                                            stay wires

    Barbed Wire                       Field    Central     One per 50         6 barb      When test results indicate noncompliance additional samples must be taken from
                                                Lab         spools or        lengths      two spools other than initially sampled, both of which must meet the requirements.
                                                         fraction thereof

    High Strength Wire                Field    Central     One per 50          3 foot     When test results indicate noncompliance additional samples must be taken from
                                                Lab         spools or         length      two spools other than initially sampled, both of which must meet the requirements.
                                                         fraction thereof

  FLEXIBLE TUBULAR MARKER             Field                                               The list of Approved Flexible Tubular Marker products is located at:



May 2011                                                                                                                                                                Page 18
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                       SAMPLE
                                   WHERE                  MINIMUM       SIZE -
                                                                                                                        REMARK
                                  SAMPLED     WHERE      SAMPLING      CENTRAL
             MATERIAL             ACCEPTED    TESTED    FREQUENCY        LAB

    POSTS AND BASES                                                               http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                  A manufacturer's certification of compliance must be made available by the
                                                                                  contractor when requested by the engineer. See CMM 8.45 for certification
                                                                                  guidelines.

  FLY ASH                            Field    Central   One per 2000   4 pounds   At least 14 days prior to use, the engineer must have a copy of a report of tests
                                               Lab          tons                  showing satisfactory chemical and physical properties.
                                                                                  Reference Certified Reports of Test and Analysis electronically on a Materials
                                                                                  Tracking System prefix 900.
                                                                                  A manufacturer's certification of compliance must be made available by the
                                                                                  contractor upon request of the engineer.
                                                                                  See CMM 8.45 for certification guidelines.
                                                                                  For contracts with less than 100 tons, no sampling is required.

  GEOGRID REINFORCEMENT              Field    Central   See remarks      See      The contractor must furnish to the engineer a sample of the Geogrid at least ten
                                               Lab                     remarks    days prior to incorporation in the work.
                                                                                  The contractor must furnish to the engineer at least ten days prior to use in the
                                                                                  work a manufacturer's Certified Report of Test or Analysis that the Geogrid
                                                                                  delivered for use in the work meets the specified requirements.
                                                                                  Reference Certified Reports of Test and Analysis electronically on a Materials
                                                                                  Tracking System prefix 900.
                                                                                  Protect Geogrid samples from ultraviolet light and from damage due to shipping
                                                                                  and handling. Rolls are to be clearly marked.
                                                                                  Samples of fabric for testing will be obtained from the job site for each 10,000 SY.
                                                                                  (8,000 m2.) or lesser portion used on the contract.
                                                                                  Samples must be full width of the fabric and a minimum of 4 feet in length. The
                                                                                  total sample size must be a minimum of 40 S.F. DO NOT flex or bend samples.
                                                                                  Take precautions in shipment to prevent any flexing or bending The samples
                                                                                  should include the machine edge of the fabric, which is perpendicular to the axis of
                                                                                  the roll. Call central lab for guidance on sampling and shipping.

  GEOTEXTILE FABRIC                  Field    Central   See remarks      [21]     [21] This sample size description applies for all types of geotextile fabrics. Samples
                                               Lab                                  must be full width of the fabric and a minimum of 4 feet in length. The total
                                                                                    sample size must be a minimum of 40 SF
                                                                                  See standard spec 645 and contract special provision specifications for additional
                                                                                  information.
                                                                                  Product data sheets will not be accepted as a substitute for the manufacturer's


May 2011                                                                                                                                                         Page 19
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                      SAMPLE
                                   WHERE                  MINIMUM      SIZE -
                                                                                                                       REMARK
                                  SAMPLED     WHERE      SAMPLING     CENTRAL
              MATERIAL            ACCEPTED    TESTED    FREQUENCY       LAB

                                                                                certification of compliance or certified report of test or analysis.
                                                                                Reference Certified Reports of Test and Analysis, and Certifications of Compliance
                                                                                electronically on a Materials Tracking System prefix 900.
                                                                                PROTECT SAMPLES – Geotextile fabric samples must be protected from
                                                                                ultraviolet light.
                                                                                [22] For contracts with quantities or fabrics not requiring a sample, a diary entry is
                                                                                  required.
                                                                                See CMM 8.45 for requirements.

    Type SAS                         Field    Central   See remarks     [21]    For contract quantities up to and including 20,000 SY a manufacturer's certificate
                                     [22]      Lab                              of compliance must be made available.
                                                                                For contract quantities over 20,000 SY. the contractor must furnish to the engineer
                                                                                at least ten days prior to use in the work a manufacturer's Certified Report of Test
                                                                                or Analysis that the geotextile fabric delivered for use in the work meets the
                                                                                specified requirements. The delivered geotextile fabric must bear markings to
                                                                                clearly identify it with the applicable test report furnished to the engineer. If not so
                                                                                marked, the fabric must not be used. Samples of fabric for testing will be obtained
                                                                                from the job site for each 20,000 SY. or lesser portion used on the contract.
                                                                                See CMM 8.45 for certification guidelines.

    Type MS                          Field    Central   See remarks     [21]    The contractor must deliver to the engineer a sample of the geotextile material at
                                     [22]      Lab                              least 15 days prior to its incorporation into the work. At the same time, the
                                                                                contractor must also furnish a sewn seam sample using the same geotextile fabric,
                                                                                thread, seam spacing and number, and overlap distance as are intended or
                                                                                required for use in the work.
                                                                                The contractor must furnish to the engineer at least 15 days prior to use in the
                                                                                work a manufacturer's Certified Report of Test or Analysis that the geotextile fabric
                                                                                delivered for use in the work meets the specified requirements. The delivered
                                                                                geotextile fabric must bear markings to clearly identify it with the applicable test
                                                                                report furnished to the engineer. If not so marked, the fabric must not be used.
                                                                                Samples of fabric for testing will be obtained from the job site for each 10,000 SY.
                                                                                or lesser portion used on the contract.
                                                                                See CMM 8.45 for certification guidelines.

    Type DF                          Field    Central   See remarks     [21]    For quantities up to and including 2,000 SY. a certificate of compliance must be
                                     [22]      Lab                              made available by the contractor.
                                                                                For quantities of 2,001S.Y. to 5,000 SY. the contractor must furnish to the engineer
                                                                                at least ten days prior to use in the work a manufacturer's Certified Report of Test


May 2011                                                                                                                                                          Page 20
CMM 8.50 Materials Testing and Acceptance Guide




                                                     MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                        SAMPLE
                                      WHERE                 MINIMUM      SIZE -
                                                                                                                          REMARK
                                     SAMPLED    WHERE      SAMPLING     CENTRAL
              MATERIAL               ACCEPTED   TESTED    FREQUENCY       LAB

                                                                                  or Analysis that the geotextile fabric delivered for use in the work meets the
                                                                                  specified requirements. The delivered geotextile fabric must bear markings to
                                                                                  clearly identify it with the applicable test report furnished to the engineer. If not so
                                                                                  marked, the fabric must not be used.
                                                                                  For quantities in excess of the initial 5,001 SY, one sample for testing will be
                                                                                  obtained from the job site for the initial 5,001 SY. or lesser portion used on the
                                                                                  contract and one sample for testing will be obtained from the job site for each
                                                                                  additional 10,000 SY or lesser portion used on the contract.
                                                                                  See CMM 8.45 for certification guidelines.

    Type ES                            Field    Central   See remarks     [21]    The contractor must deliver to the engineer a sample of the geotextile material at
                                                 Lab                              least 15 days prior to its incorporation into the work. At the same time, the
                                                                                  contractor must also furnish a sewn seam sample using the same geotextile fabric,
                                                                                  thread, seam spacing and number, and overlap distance as are intended or
                                                                                  required for use in the work.
                                                                                  The contractor must furnish to the engineer at least 15 days prior to use in the
                                                                                  work a manufacturer's Certified Report of Test or Analysis that the geotextile fabric
                                                                                  delivered for use in the work meets the specified requirements. The delivered
                                                                                  geotextile fabric must bear markings to clearly identify it with the applicable test
                                                                                  report furnished to the engineer. If not so marked, the fabric must not be used.
                                                                                  Samples of fabric for testing will be obtained from the job site for each 10,000 SY.
                                                                                  or lesser portion used on the contract.
                                                                                  See CMM 8.45 for certification guidelines.

    Type SR                            Field    Central   See remarks     [21]    For quantities up to and including 10,000 SY. a certificate of compliance must be
                                       [22]      Lab                              made available by the contractor.
                                                                                  For quantities over 10,000 SY. the contractor must furnish to the engineer at least
                                                                                  ten days prior to use in the work a manufacturer's Certified Report of Test or
                                                                                  Analysis that the geotextile fabric delivered for use in the work meets the specified
                                                                                  requirements. The delivered geotextile fabric must bear markings to clearly identify
                                                                                  it with the applicable test report furnished to the engineer. If not so marked, the
                                                                                  fabric must not be used. Samples of fabric for testing will be obtained from the job
                                                                                  site for each 10,000 SY. or lesser portion used on the contract.
                                                                                  See CMM 8.45 for certification guidelines.

    Type FF (Inlet Protection)         Field                                      For a list of approved products see the PAL available at:
    See Subsection 628.2.11 of the     [22]                                       http://www.atwoodsystems.com/materials/ and
    Standard Specifications                                                       http://www.dot.wisconsin.gov/business/engrserv/docs/pal.pdf



May 2011                                                                                                                                                             Page 21
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                           SAMPLE
                                   WHERE                    MINIMUM         SIZE -
                                                                                                                              REMARK
                                  SAMPLED     WHERE        SAMPLING        CENTRAL
             MATERIAL             ACCEPTED    TESTED      FREQUENCY          LAB

                                                                                       A diary entry is required for these items.
                                                                                       See CMM 8.45 for requirements.

    Type R                           Field                                             A manufacturer's certificate of compliance must be made available by the
    Type HR                          [22]                                              contractor when requested by the engineer.
    Type C                                                                             See CMM 8.45 for certification guidelines.
    Silt Fence Fabric

  HIGH STRENGTH BOLTS,              Shop or   Central     Two bolts per    Two bolts   This item is usually pre-sampled. The engineer should check the particular project
    STRUCTURES                       Field     Lab          size per        Three      number for which this item is intended, test prefix 115 of the Materials Tracking
                                                            contract.      nuts and    System.
                                                         Three nuts and    washers     In the event that no Central Laboratory test exists for the lots received, the
                                                        washers per size               engineer must sample as indicated.
                                                          per contract.                Rotational -Capacity testing – two copies of the manufacturers’ or distributor’s
                                                                                       Certified Report of Test of Rotational-Capacity must be provided by the contractor.
                                                                                       Reference Certified Reports of Test and Analysis and field test reports
                                                                                       electronically on a Materials Tracking System prefix 900.
                                                                                       Field rotational-capacity testing is to be completed by the contractor on each bolt,
                                                                                       nut and washer lot combination before installation as specified in Report No.
                                                                                       FHWA SA 91-031 "High Strength Bolts for Bridges". Have the contractor complete
                                                                                       form DT2113. Department staff or consultant must verify the test and submit the
                                                                                       completed form as a part of the permanent project records.

  JOINT SEALERS                      Field                                             [23] A diary entry is required for these items.
   Cold Poured Silicon Type          [23]                                              See CMM 8.45 for requirements.
   Hot Poured Elastic Type                                                             A manufacturer's certification of compliance must be made available by the
   Non-Bituminous                                                                      contractor when requested by the engineer.
                                                                                       See CMM 8.45 for certification guidelines.

    Preformed Elastomeric            Field                                             A manufacturer's certified Report of Test or Analysis must be made available by
    Compression and Lubricant­       [23]                                              the contractor when requested by the engineer for both the sealer and lubricant-
    Adhesive                                                                           adhesive, indicating conformance of the materials with the contract requirements.
                                                                                       See CMM 8.45 for certification guidelines.

  LUMBER & TIMBER, TREATED           Field                                             A certification of treatment and specification compliance must be made available
                                                                                       by the contractor when requested by the engineer.



May 2011                                                                                                                                                             Page 22
CMM 8.50 Materials Testing and Acceptance Guide




                                                     MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                      SAMPLE
                                      WHERE                 MINIMUM    SIZE -
                                                                                                                      REMARK
                                     SAMPLED    WHERE      SAMPLING   CENTRAL
             MATERIAL                ACCEPTED   TESTED    FREQUENCY     LAB

                                                                                See CMM 8.45 for certification guidelines. A diary entry is required for these items.

  PAINT FOR USE ON METAL                                                        See contract special provision specifications for paint system requirements for new
   New Structural Steel                Field                                    structural steel. The list of Paint Systems for New Structural Steel (per STSP 517­
   Structural Maintenance              Field                                    040) is located at:
   Painting                                                                     http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                The list of Approved Paint Systems- Structure Maintenance Painting is located at:
                                                                                http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm

  Other Metal Surfaces                                                          See contract special provision specifications for all other paint system
                                                                                requirements.

  PAVEMENT MARKING,                                                             Solvent born and Waterborne Paint - The list of approved paint products is located
   Permanent                                                                    at: http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                Items not source inspected - the engineer must have, prior to use, a certified
  Cold Preformed Plastic (With         Field                                    report(s) of test(s) for samples of the material(s) furnished for the contract. The
   Glass Spheres)                                                               reports must contain the batch number(s) to which the results apply.
                                                                                See CMM 8.45 for certification guidelines.
  Hot Thermoplastic                    Field
                                                                                Reference electronically on a Materials Tracking System prefix 900 Certified
  Paint (Cold Applied)                                                          Reports of Test and Analysis.
                                       Field

  Paint (Hot Applied)                 Source

  Epoxy                               Source                                    Furnish epoxy from the departments approved list. Pre-qualified products are listed
                                                                                on the Pavement Marking QMP located at:
                                                                                http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                Before use, submit a certificate of compliance certifying the epoxy supplied under
                                                                                the contract conforms to the specification.
                                                                                See standard spec 646.2.4.

  Glass Spheres for Paint             Source                                    Only pre-qualified WisDOT tested batches are permitted for use. A summary list of
                                                                                WisDOT Central Laboratory tested Glass Spheres for pavement marking is
                                                                                maintained at: http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm

  PILING                               Field      See                   See     Before use, the engineer must have certified copies of mill test reports showing
    Piling Steel                                remarks               remarks   satisfactory chemical and physical properties for each heat or lot delivered for the
    Sheet (Permanent Installation)                                              contract. All piling materials are to be marked to identify the materials with the



May 2011                                                                                                                                                       Page 23
CMM 8.50 Materials Testing and Acceptance Guide




                                                      MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                        SAMPLE
                                    WHERE                   MINIMUM      SIZE -
                                                                                                                        REMARK
                                   SAMPLED    WHERE        SAMPLING     CENTRAL
              MATERIAL             ACCEPTED   TESTED      FREQUENCY       LAB

    Bearing                                                                       certified report of test documents. If identification markings are absent, the
    Shell                                                                         contractor must certify that all delivered materials are from the same lot as the test
                                                                                  report represents.
                                                                                  When mill test reports are not available, the engineer must submit a section 2-feet
                                                                                  in length and 9-inches in width to the Central Laboratory for testing.
                                                                                  Reference electronically on a Materials Tracking System prefix 900 Certified
                                                                                  Reports of Test and Analysis.

    Steel Oil Field Pipe             Field        Field   See remarks             See standard spec 511.2.2.
                                                                                  Each piling delivered for the contract must be marked with a unique identification
                                                                                  for each load that must conform to the bill of lading. The marking must be durable
                                                                                  and legible. Markings can be transferred by contractor when cut offs are complete.
                                                                                  A manufacturer's certification of compliance must be made available by the
                                                                                  contractor.
                                                                                  See CMM 8.45 for certification guidelines.
                                                                                  The contractor must also furnish at or prior to delivery a certification of chemical
                                                                                  composition of the pipe from which a carbon equivalency (CE) may be determined.
                                                                                  The CE must be computed by the following equation:
                                                                                  CE = C + 1/6 (Mn + Si + Cr + Mo + V) + 1/15 (Ni + Cu).
                                                                                  (The equation items are the chemical composition values identified on the
                                                                                  certification.)
                                                                                  Reference electronically on a Materials Tracking System prefix 900 Certified
                                                                                  Reports of Test and Analysis.
                                                                                  Pipe delivered in a magnetized condition must be limited to non-welded
                                                                                  applications. Pipe delivered with a CE greater than 0.55 must not be incorporated
                                                                                  into the work unless approved by a representative of the Metals and Fabrication
                                                                                  Inspection Unit.

  POSTS, TREATED WOOD                Field                                        A manufacturer's certification of treatment must be made available by the
   Guardrail                                                                      contractor upon request of the engineer.
   Right of Way (Security Fence)                                                  A diary entry is required for these items.
   Screen Fence                                                                   See CMM 8.45 for diary entry requirements.
   Sign, Etc.

  POZZOLANS                          Field    Central     One per2000             Used as a complete replacement for fly ash. Approved list materials only may be
                                               Lab           tons                 used. The list of Pozzolans - Approved Manufacturers is located at:



May 2011                                                                                                                                                          Page 24
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                       SAMPLE
                                   WHERE                  MINIMUM       SIZE -
                                                                                                                          REMARK
                                  SAMPLED     WHERE      SAMPLING      CENTRAL
              MATERIAL            ACCEPTED    TESTED    FREQUENCY        LAB

                                                                                  http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                  For contracts with less than 100 tons no sampling is required.

  PRESTRESSED CONCRETE                                                            The shipping document must be stamped as indicated in the Plant Certification
   MEMBERS                                                                        Program for Fabrication of Prestressed Concrete Members.
                                                                                  See CMM 8.75.
                                                                                  Reference the shipping documents on a Materials Tracking System, prefix 900.
                                                                                  The list of approved Prestressed Concrete Member suppliers is located:
                                                                                  http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                  If the supplier is not on the list of certified plants, immediately contact the regional
                                                                                  person responsible for this area.

  SIGNING                            Field                                        A manufacturer's certification of compliance must be made available by the
                                                                                  contractor when requested by the engineer.
  Base                                                                            See CMM 8.45 for certification guidelines.
  Face                                                                            A diary entry is required for these items.
  Message
                                                                                  See CMM 8.45 for diary entry requirements.

  Structural Units                  Shop or                                       A manufacturer's certification of compliance or a certified report of test or analysis
    i.e. Sign Bridges, Sign          Field                                        indicating conformance with the contact requirements must be made available to
    Supports                                                                      the engineer by the contractor for all materials not shop inspected.
                                                                                  See CMM 8.45 for certification guidelines.
                                                                                  A diary entry is required for these items.
                                                                                  See CMM 8.45 for diary entry requirements.

  SLAG                               Field    Central   One per 2000   4 pounds   At least 14 days prior to use, the engineer must have a copy of a report of tests
                                               Lab          tons                  showing satisfactory chemical and physical properties.
                                                                                  A manufacturer's certification of compliance must be made available by the
                                                                                  contractor upon request of the engineer. See CMM 8.45 for certification guidelines.
                                                                                  Reference electronically on a Materials Tracking System prefix 900 Certified
                                                                                  Reports of Test and Analysis.
                                                                                  For contracts with less than 100 tons, no sampling is required.

  STEEL FORGINGS (BRIDGES)           Shop                                         An approved fabricator usually furnishes these items. The list of Approved
                                                                                  Fabricators, Bridge Metal Secondary items is located at:



May 2011                                                                                                                                                             Page 25
CMM 8.50 Materials Testing and Acceptance Guide




                                                    MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                       SAMPLE
                                   WHERE                   MINIMUM      SIZE -
                                                                                                                        REMARK
                                  SAMPLED      WHERE      SAMPLING     CENTRAL
             MATERIAL             ACCEPTED     TESTED    FREQUENCY       LAB

                                                                                  http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm

  STEEL GRID FLOOR                  Shop or                                       When not shop inspected a manufacturer's certification of compliance must be
                                     Field                                        made available by the contractor.
                                                                                  See CMM 8.45 for certification guidelines.

  STEEL PLATE BEAM GUARD            Source                                        Lists of Steel Plate Beam Guard pre-qualified inventories and approved shipments
   Sheet Steel Beams                or Field                                      are maintained at:
                                                                                  http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                  If the heat numbers are not listed on the MTS lists of tested and pre-qualified
                                                                                  inventories supplied from the vendor yard the material must not be used.

    End Shoe Sections                Field                                        If the quantity is 20 or more, the engineer must also have before installation a
    Terminal Sections                                                             manufacturer's certified report of test or analysis indicating compliance with the
    Anchor Assembly                                                               contract requirements for all heat numbers delivered to the project.
                                                                                  See CMM 8.45 for certification guidelines.

  STEEL REINFORCEMENT                                                             See “Concrete Masonry Reinforcement.”

  STRUCTURAL STEEL                                                                Items are inspected at the steel fabrication shop and acceptance is on the basis of
                                                                                  a shop inspection report (Structures Fabrication Unit form DT1832).
  Bridges                                                                         Reference shop inspection reports electronically on a Materials Tracking System
                                                                                  prefix 900.

    Carbon Steel Shaftings                                                        These items are usually furnished through an approved fabricator though they are
    Castings, Bronze                                                              manufactured items. Acceptance is on the basis of a shop inspection report
    Castings, Steel                                                               (Structures Fabrication Unit form DT1832).

  STUD SHEAR CONNECTORS              Field                                        A manufacturer's certification of compliance must be made available by the
                                                                                  contractor when requested by the engineer.
                                                                                  See CMM 8.45 for certification guidelines.


  WATER FOR CONCRETE                 Field     Central   No Sampling    1/2 gal   Samples must be submitted in a clean plastic container well packed for shipment
   Municipal Sources                            Lab       Required                to preclude breakage.




May 2011                                                                                                                                                         Page 26
CMM 8.50 Materials Testing and Acceptance Guide




                                                   MATERIALS TESTING AND ACCEPTANCE GUIDE

                                                                           SAMPLE
                                   WHERE                    MINIMUM         SIZE -
                                                                                                                             REMARK
                                  SAMPLED     WHERE        SAMPLING        CENTRAL
             MATERIAL             ACCEPTED    TESTED      FREQUENCY          LAB


    Private Wells                    Field    Central   1/source/5years*    1/2 gal   For water used from sources permitted without test, see standard spec 501.2.4.
                                               Lab                                    * If problems with any water source are suspected, based on current conditions or
                                                                                        historical data, the department may request sampling at any time. In particular,
    Surface Water                    Field    Central    1/source/year*     1/2 gal     surface water sources should be closely monitored at all times during concrete
                                               Lab                                      production. If conditions change significantly during the life of the project (i.e. an
                                                                                        algae bloom or muddy storm runoff, etc.) a fresh sample should be tested prior to
                                                                                        approval of continued use of the source.

  WATERSTOPS                         Field                                            Polyvinyl Chloride - A manufacturer's certification of compliance must be made
  Polyvinyl Chloride                                                                  available by the contractor when requested by the engineer.
                                                                                      See CMM 8.45 for certification guidelines.

  Rubberized Waterproof              Field                                            Must be selected from the department-approved list. The list of approved products
   Membrane                                                                           is located at: http://www.dot.wisconsin.gov/business/engrserv/approvedprod.htm
                                                                                      The material must be backfilled within 30 days of installation or otherwise
                                                                                      protected from ultra violet radiation.




May 2011                                                                                                                                                               Page 27

				
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