Bureau of Bridges and Structures Structural Fabrication Unit

STRUCTURAL FABRICATION UNIT V112917

TABLE OF CONTENTS PAGE 1 of 1

MICHIGAN DEPARTMENT OF TRANSPORTATION

Table of Contents

1. Quality Assurance Structural Fabrication Inspection Flowchart 1 Structural Fabrication Inspection Web Links 2 Structural Fabrication Quality Assurance Guidance Document 3 Materials Quality Assurance Procedures Manual Section 4.04 12 Materials Quality Assurance Procedures Manual Section 4.11 24

2. Request for Information Structural Fabrication Request for Information Process 33

3. Nonconformance Program Structural Fabrication Nonconformance Policy 37 Structural Fabrication Nonconformance Process 42 Structural Precast Concrete Repair Guidance Document 50

4. Buy America Structural Fabrication Buy America Guidance Document 69 Buy America Sample Letters 74

5. Material Sampling Metals Laboratory Sampling Guidance Document 77 Sample Identification (Form 1923) 83 Sample Identification (Form 1923) – Example 84

6. Miscellaneous Structural Fabrication E-construction Process 85 Structural Fabrication Bookmarking Template 87 Industry Letters 88 Commentary for Project Folder Checklist 103

7. Forms Project Folder Checklist (Form 2001) 111 Fabrication Inspection Report (Form 5617) 114 Strand Tensioning Report (Form 0513) 115 Bar Reinforcement Report (Form 1985) 118 Pre and Post Pour Inspection Checklist (Form 5616) 119 Field and Lab Test Report (Form 0590) 121 Repair Observation Report (Form 1981) 122

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v011314

Store Fabrication Inspection Folder

MDOT Structural Precast Concrete Fabrication Inspection Flowchart

MDOT Authorizes Consultant Inspector

MDOT Notifies Fabricator of Assigned Inspector

Fabricator Provides Inspector with Data and Approved Shop Drawings

Inspector Reviews Data and Performs Shop Inspection

Inspector Notifies MDOT of Deficiencies and Non-Conformance

Stock Pile Payment

Notification of Structural Precast Concrete Fabrication

MDOT structural precast concrete fabrication inspection flowchart showing high level functions performed by MDOT (Structural Fabrication Unit). After loading, but prior to shipping, the shop inspector stamps all elements and Bill of Lading approved for use. Construction inspector must collect stamped Bill of Lading, visually inspect unloaded elements, accept/reject the elements, and document in Inspector’s Daily Report. Elements that arrive to the project without a Bill of Lading must be rejected. Fabrication Inspection Memo is electronically distributed to the construction office at the end of the project for information only.

Figure 1.

MDOT Schedules Pre-Fabrication Meeting

Partial Shipment Payment

TSC Requests Information from MDOT

MDOT Requests Information from Inspector

MDOT Sends TSC Approval Email

Fabricator Notifies Inspector of Partial Shipment

Inspector Notifies MDOT of Partial Shipment

Inspector Stamps Elements and Bill of Lading Approved for Use

Contractor Requests Payment from TSC

Fabricator Notifies Inspector of Final Shipment

Inspector Notifies MDOT of Final Shipment

Inspector Stamps Elements and Bill of Lading Approved for Use

Final Shipment Payment

Construction Accepts/Rejects Elements Construction Accepts/Rejects Elements

MDOT Addresses Deficiencies and Non-Conformance

MDOT Issues Fabrication Inspection Memo

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STRUCTURAL FABRICATION UNIT V012418

STRUCTURAL FABRICATION INSPECTION WEB LINKS PAGE 1 OF 1

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication Inspection Web Links Description This document contains several important links to resources related to structural fabrication inspection for the Michigan Department of Transportation. Click on the title of each section for the link.

• 2012 Standard Specifications for Construction This link will take you to a printable/downloadable copy of the MDOT 2012 Standard Specifications for Construction as well as the Supplemental Specifications for Errata to these Specifications. These specifications detail all of MDOT’s policies on construction. There are subsections that are related specifically to structural precast concrete and Structural Steel inspection.

• Materials Quality Assurance Procedures Manual This document provides guidance on MDOT’s requirements for performing QA inspections.

• Materials Source Guide This document describes the acceptance criteria for materials, and should be looked at prior to the materials being incorporated into a project.

• Forms All of the inspection forms are stored on this site which can be searched by the form number.

• Bridge Field Services This site serves as a statewide resource for structures, and contains reference materials for bridge personnel.

1. Field Manual for Concrete Anchoring 2. Field Manual for Structural Welding 3. Field Manual for Structural Bolting

• Structure Technical Section This site contains all of the contact information for the Structural Fabrication Unit for which the inspector is working for. You can also find the current QAI Fabrication Portfolios.

1. MDOT Shop Drawing Review Process 2. 2018 MDOT Structural Steel QAI Manual 3. 2018 MDOT Structural Precast Concrete QAI Manual

• MDOT Buy America Compliance Listing This site contains a listing of Approved Manufacturers, QPL’s and Tested Stock Suppliers that are either fully compliant, partially compliant, or do not have any steel/iron in their product as noted next to each company name. For our use we only need to look at the BA+ or BA- listings.

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STRUCTURAL FABRICATION UNIT V092517

QA GUIDANCE DOCUMENT PAGE 1 of 8

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication Quality Assurance Guidance Document Description The purpose of this document is to provide the Michigan Department of Transportation’s (MDOT) Structural Fabrication Unit guidance to supplement MDOT’s Materials Quality Assurance Procedures (MQAP) Manual. This guidance document will be used to ensure statewide consistency in performing quality assurance (QA) verification inspection at fabrication facilities. The Structural Fabrication Unit is responsible for implementing the Department’s quality assurance program for structural elements

required to be accepted based on “Fabrication Inspection” per MDOT’s MQAP Manual and utilizes vendors to provide the shop inspection. It is imperative for the quality assurance inspector (QAI) to completely understand their role and responsibilities when performing QA verification inspection on MDOT projects to ensure a successful QA program. It is important to note that this document is not contractual and all project related decisions should be based on the project specifications. This document is broken down into the following sections:

1. Definitions2. Contact Information3. Responsibilities4. QAI Roles and Responsibilities5. QAI Frequent Questions and Answers

1. DefinitionsBelow is a list of terms that are significant to this guidance document:

1.1 Contractor The Contractor is responsible for proper completion of all tasks required by the contract. Subcontractors, including fabricators, erectors, and field painters, may be used by the Contractor, but the Contractor retains responsibility for all material, operations, and the final product. The Contractor should permit direct subcontractor interaction with MDOT to expedite the project, but subcontractors must inform the Contractor of any proposed modifications to contract requirements.

1.2 Design Project Manager (PM) The Design PM can be the Engineer of Record or could be managing a consultant contract where the consultant is the Engineer of Record.

1.3 Engineer The Engineer can be the Director of the Department of Transportation or the MDOT Construction Engineer designated by the Director, acting directly or through authorized representatives, who is responsible for engineering supervision of the construction. The Engineer has the authority to allow exceptions to contract document requirements.

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1.4 Engineer of Record (EOR) Those preparing the contract documents, including those responsible for the structure’s adequate design. The Engineer of Record seals and signs the contract plans.

1.5 Fabricator The facility performing such shop activities as cutting, welding, drilling, punching, tying rebar, tensioning strand, pouring concrete, cleaning and painting of structural steel, etc. The Fabricator also includes any agents of the Fabricator, such as those who prepare shop detail drawings, perform non-destructive examinations, paint, etc. In some cases the Fabricator may also be the Contractor, but the Fabricator is typically a subcontractor.

1.6 Fabrication Inspection The examination by MDOT or the Fabricator of processes and products to verify general conformance with contract requirements.

1.7 Fabrication Inspection Acceptance The first step in MDOT’s two part acceptance process for structural elements required to be accepted

based on “Fabrication Inspection” per MDOT’s MQAP Manual.

1.8 Field Inspection Acceptance The second step in MDOT’s two part acceptance process for structural elements required to be

accepted based on “Fabrication Inspection” per MDOT’s MQAP Manual.

1.9 Materials Quality Assurance Procedures Manual (MQAP) The formal written document prepared by MDOT that describes the policies and procedures used to accept materials for incorporation into MDOT projects. The document contains inspection procedures for fabricated structural precast (prestressed and non-prestressed) concrete, structural steel, and other structural elements.

1.10 Michigan Department of Transportation (MDOT) The entity (owner) paying the Contractor to fulfill the terms of the contract. MDOT also encompasses the Engineer who is authorized and responsible for engineering supervision of the construction. The Engineer is an employee of MDOT; however, MDOT may contract with a professional firm to oversee the day to day supervision with all critical decisions coming through the Engineer.

1.11 Nonconformance Report (NCR) An alteration in the work or a fabrication error that results in the element not meeting project specifications. The fabricator generates a NCR submittal after fabrication has begun and their quality control inspector (QCI) has noted a nonconformance to the project specifications. Nonconformances are generally defined to be material or workmanship in nature and are further classified by MDOT to be minor or major. Minor nonconformances can be repaired by the fabricator without approval of a NCR, whereas major nonconformances require approval of a NCR.

1.12 Precast Concrete Precast concrete is a construction product produced by casting concrete in a reusable form, which is then cured in a somewhat controlled environment, transported to the construction site, and lifted into

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place. Precast concrete can be either prestressed or non-prestressed. In contrast, cast-in-place (CIP) concrete is poured into site-specific forms and cured on site.

1.13 Procedure Qualification Record (PQR) A production welding procedure specification (WPS) qualification is based on a procedure qualification test record (PQR) produced by the Contractor in conformance with required heat input qualifications and other code requirements. The test is designed to provide assurance that the weld metal produced by welding in conformance with the provisions of the code must produce weld metal strength, ductility, and toughness conforming to the code.

1.14 Quality Assurance (QA) Quality assurance (QA) encompasses the activities undertaken by the Owner to verify that the final product satisfies contract requirements, including verifying that quality control is performed effectively.

1.15 Quality Assurance Inspector (QAI) MDOT’s representative that is responsible for duties specified in the MDOT MQAP, with the authority to accept work that meets contract requirements.

1.16 Quality Control (QC) The activities undertaken by the Contractor/Fabricator to ensure a product is provided that meets contract requirements.

1.17 Quality Control Inspector (QCI) A qualified employee of the Fabricator who performs inspection as defined by the Fabricator’s

Quality Control Plan.

1.18 Quality Control Plan (QCP) The formal written document prepared by the Fabricator and reviewed by a certification agency (AISC, NPCA, PCI, etc.) that describes the policies and procedures used to verify that fabricated structural precast (prestressed and non-prestressed) concrete, structural steel, and other structural elements will satisfy the contract requirements.

1.19 Request for Information (RFI) Requests by the Fabricator seeking additional information or proposing alternate material, fabrication method, or inspection method for the structural element.

1.20 Spot Inspection The random examination of the Fabricator’s processes or products for verification of conformance with contract requirements.

1.21 Structural Fabrication Unit MDOT’s specialized QA unit that is responsible for implementing the Department’s QA program for all

structural elements required to be accepted based on “Fabrication Inspection” per MDOT’s MQAP.

1.22 Welding Procedure Specification (WPS) Is a formal written document describing welding procedures, which provides direction to the welder or welding operators for making sound and quality production welds as per the code requirements.

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The purpose of the document is to guide welders to the accepted procedures so that repeatable and trusted welding techniques are used.

2. Contact InformationThe Structural Fabrication Unit can be contacted by phone or email. QAI’s are required to bring urgent

matters to the appropriate contact person by phone and then immediately follow up by email for record and attach all applicable supporting documentation to the email. All other matters are required to be submitted via email and then a call, if needed, can be setup. The Structural Fabrication Unit’s email

resource is shown below:

MDOT-StructuralFabrication@michigan.gov

3. Responsibilities3.1 Team Effort

3.1.1 The Contractor, Fabricator, and MDOT will approach quality control and quality assurance as a team effort to facilitate accurate and timely construction.

3.1.2 All parties will cooperate and maintain open lines of communication so that problems can be quickly addressed and resolved.

3.1.3 The QAI’s verification does not relieve the Fabricator from the responsibility to perform the required testing and inspection and produce a product satisfying the contract.

3.2 Fabricator 3.2.1 Provide quality control to ensure that the finished product meets or exceeds contract

requirements.

3.2.2 Develop and implement a QCP that reflects a commitment to quality and describes the quality control activities that will be employed on each project.

3.2.3 Provide MDOT with a copy of the QCP.

3.2.4 Submit shop drawings to MDOT for review with weld procedure specification (WPS) and supporting procedure qualification record (PQR), as applicable.

3.2.5 Provide structural precast concrete Material Source List (MSL) prior to the prefabrication meeting.

3.2.6 Provide qualified QCIs who report to personnel responsible for quality control as defined by the QCP.

3.2.7 Provide MDOT with an accurate notification before beginning work in the shop and all production scheduling as required by the contract requirements.

3.2.8 Present all material for the QAI’s acceptance in a manner that will allow a thorough inspection of components and assemblies.

3.2.9 Provide the QAI full access to shop facilities where the work is being stored, fabricated, or assembled.

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3.2.10 Provide the QAI with all approved shop drawings, NCRs, RFIs, MDOT Welder Qualification test reports, WPSs, QC reports, material certifications/test reports, NDE reports, personnel/plant certifications, equipment calibration reports, and all other applicable documents in a timely manner as required by the contract requirements.

3.2.11 Keep the QAI informed prior to performing in-process repairs, NCRs (if applicable), QC inspection activities, and pending nondestructive examination (if applicable).

3.3 MDOT 3.3.1 Monitor the Fabricator’s control of the operations and verify conformity of the work with the

contract requirements.

3.3.2 Keep the Fabricator’s QCP confidential.

3.3.3 Observe fabrication (either on a schedule or at random) and perform testing of materials and fabricated elements as necessary to confirm the effectiveness of the Fabricator’s QCP.

3.3.4 MDOT has the right to observe all phases of the work, from initial receipt and preparation of raw materials through prestressing, tying steel, fresh concrete testing, placing concrete, testing cylinders, repairs, burning and cutting, welding, nondestructive testing, cleaning, coating, shipping, and any other activities deemed appropriate by MDOT.

3.3.5 The frequency and nature of QA inspection will vary with the type of structure, experience of the Fabricator, strength of the Fabricator’s QC organization, and other similar factors

that affect the quality of work.

3.3.6 Verify that production quality and fabrication processes generally satisfy contract requirements, including the QCP.

3.3.7 Accept materials and fabricated elements that satisfy the contract requirements.

3.3.8 Notify MDOT when fabricator ships elements for projects, and specify if the shipment is the final shipment for the project.

3.3.9 Submit project file to MDOT within one week of final shipment of elements.

3.3.10 MDOT will not waive items that are contractual obligations of the Fabricator and will not accept material that does not conform to the contract requirements. However, based on experience and knowledge of the specific situation, the Engineer may accept materials and elements that are not in conformance with the contract and may allow material substitutions. See the following two documents for more information:

MDOT Structural Fabrication RFI Process

MDOT Structural Fabrication Nonconformance Policy

3.3.11 MDOT will not direct the Fabricator’s work. However, MDOT should advise the Fabricator to

discontinue any operation that would result in noncompliance with the contract.

3.3.12 MDOT will direct all official communications to the Fabricator’s quality control or

management as determined in the prefabrication meeting.

3.3.13 MDOT will not convey directives or personal judgements about overall shop quality or concerns about employee competence to production personnel.

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3.3.14 MDOT will not publish, copy, or distribute any proprietary information, documents, or forms received from the Fabricator for any purpose other than the contractual needs of MDOT.

3.4 Prefabrication Meetings Prefabrication meetings facilitate effective quality control and quality assurance and are conducted by MDOT’s Structural Fabrication Unit prior to the start of fabrication and preferably after shop drawings have been approved. The Structural Fabrication Unit, QAI, Fabricator, and QCI must be present, whereas the Engineer and Contractor should be present to ensure a team effort to facilitate accurate and timely construction. Quality assurance and quality control contact information will be shared during this meeting to ensure effective and timely communication.

4. QAI Roles and Responsibilities4.1 Qualifications of the QAIQualification requirements of the QAI is covered in the MDOT MQAP Manual for the type of inspectionrequired.

4.2 Equipment Requirements of the QAIEquipment requirements of the QAI is covered in the MDOT MQAP Manual for the type of inspectionrequired.

4.3 SchedulingThe scheduling of inspection and other QA functions can have a significant impact on the project.The QAI must follow these guidelines:

4.3.1 Coordinate with the QCI for anticipated production scheduling to anticipate timing and staffing needs. Discuss the progress of the work with appropriate fabrication personnel designated during the prefabrication meeting.

4.3.2 Schedule inspections in a timely manner to facilitate fabrication progress, especially if multiple shifts are used.

4.3.3 Discuss with the Structural Fabrication Unit whether additional presence in the shop is required.

4.3.4 Document problems with scheduling inspection, including inaccurate information from fabrication personnel and production delays.

4.4 Role of the QAI 4.4.1 Perform verification tests, measurements, inspection, or observations to ensure that

fabricated elements conform to the contract requirements. Although the QAI does not perform the QC work, some QA activities may duplicate a portion of the QC activity for verification purposes.

4.4.2 If there are questions about a requirement or level of quality, contact the Structural Fabrication Unit and, if appropriate, alert the Fabricator.

4.4.3 Conduct consistent inspections based on the contract requirements and obtain assistance from the Structural Fabrication Unit as needed.

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4.4.4 Be familiar with the QCP to better understand the QC operations of the shop.

4.5 Responsibilities of the QAI See subsection 3.3 above for a list of QAI responsibilities.

4.6 Interaction with the Fabricator QCI 4.6.1 Verify the effectiveness of the QCI’s evaluation of the work.

4.6.2 Perform verification inspection after the QCI has completed their inspection and testing in accordance with the Fabricator’s QCP. However, serious problems noted at any time or stage of fabrication must be immediately pointed out to the QCI.

4.6.3 Though QA inspection may include all aspects of fabrication, the QAI must not supersede

QC, which is the responsibility of the Fabricator. If QC is not accomplishing its role then the Structural Fabrication Unit, Engineer, Contractor, and Fabricator must determine the necessary corrections.

4.7 Interaction with Fabricator If the Fabricator’s inquiries involve design questions, material substitutions, alternate fabrication

methods, or items that are beyond the authority of the QAI, refer them to MDOT’s Structural

Fabrication Request for Information Process. If the Fabricator’s inquiries involve fabrication or material

nonconformance questions, refer them to MDOT’s Structural Fabrication Nonconformance Reporting

Process. Do not direct the fabricator.

4.8 Interpretation of the Contract Review contract requirements and seek guidance from the Structural Fabrication Unit if the QAI has questions. Do not direct the Fabricator.

4.9 Fabrication Observation 4.9.1 Establish a pattern of regular and frequent observations during the progress of work to

verify satisfactory workmanship without delaying production or missing critical operations.

4.9.2 Coordinate verifications with the QCI and accomplish them with minimal additional material handling by the Fabricator and with as little interference with the work in process as possible.

4.9.3 Though there are not designated points during fabrication when the suitability of materials must be checked, problems should be discovered and addressed as early as possible.

4.9.4 Provide narrative record keeping in accordance with applicable sections of the MQAP manual.

4.10 Nonconforming Materials and Workmanship See MDOT’s Structural Fabrication Nonconformance Policy and MDOT’s Structural Fabrication

Nonconformance Reporting Process for more information.

4.11 Final Acceptance of the Work Acceptance of structural elements must be in accordance with MDOT’s MQAP Manual.

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5. QAI Frequent Questions and Answers The purpose of this section is to provide answers to frequently asked questions to ensure consistency and alignment.

5.1 Fabricating without Approved Shop Drawings The QAI must notify the Structural Fabrication Unit immediately if the Fabricator is working without MDOT approved shop drawings. Approved shop drawings are required prior to stamping elements approved for shipping.

5.2 Inspecting Approved Repair Plans QAI must have the approved repair plan in hand prior to performing QA verification inspection of the repair. Verification inspection also includes confirming that production and QCI have the approved repair plan. If production and QCI do not have the approved plan then the QAI must notify them that they are required to have the approved plan in hand during all aspects of the repair. If the Fabricator begins working on the repair without the approved plan then the QAI must notify the Fabricator of their observation in writing immediately and carbon copy the Structural Fabrication. The Structural Fabrication Unit will notify the Engineer and Fabricator that the repair is recommend to be rejected.

5.3 Stamping Elements Approved for Use QAI must have approved shop drawings prior to stamping any element approved for use. Elements proposed to be shipped by the Fabricator that are not in general conformance with the approved shop drawings must not be stamped. The only exception is if a nonconformance report (NCR) has been approved by MDOT. Approved NCRs are to be used in conjunction with approved shop drawings for acceptance. If elements are not in conformance with the approved shop drawings then they are not to be stamped approved for use by the QAI. If requests for information (RFI) have been approved by MDOT for the project then they must be incorporated into the shop drawings, if applicable, prior to shipping.

5.4 Welder Qualification Testing See MDOT’s Welder Qualification Program for all welding information.

5.5 As-Built Shop Drawings The Fabricator is required to submit as-built shop drawings to MDOT for historical purposes. All approved RFIs that are incorporated into the project must be added to the shop drawings and submitted to MDOT for review and approval. Very minor changes toward the end of fabrication must be documented and submitted as as-built shop drawings to the QAI prior to shipping. The Structural Fabrication Unit can provide more guidance on a project by project basis as to what constitutes a shop drawing revision and what is considered an as-built.

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MATERIALS QUALITY ASSURANCE PROCEDURES MANUAL

Partial Document October 2018 Edition In accordance with the 2012

Standard Specifications for Construction

CONSTRUCTION FIELD SERVICES DIVISION

Materials Quality Assurance Procedures Manual 2012

4.04

4.04 PRESTRESSED STRUCTURAL PRECAST CONCRETE FABRICATION

4.04.01. Scope

A. This prestressed structural precast concrete fabrication inspection procedure should be used to aid the quality assurance inspector (QAI) in interpreting and enforcing the contract for prestressed concrete elements. Fabrication inspection includes the time from verifying materials used for fabrication through loading for shipping to the construction site.

4.04.02. Reference Documents

A. QAI must have a thorough knowledge of the following references:

1. The following sections of the MDOT Standard Specifications for Construction (MDOTSSC) as modified by supplemental specification 12SS-001A – Errata, as applicable:

Section 104 Control of the Work Section 105 Control of the Materials Section 708 Prestressed Concrete

2. The following special provisions, as applicable:

12SP-105A Source of Steel and Iron (Buy America) 12SP-604C QC and Acceptance of PCC for Structural Precast Concrete 12SP-708A Special Provision for Strand Debonding 12SP-708B Prestressed Concrete Bulb-Tee Beam

3. MDOT Structural Precast Concrete QAI Manual

4. Construction Field Services Division (CFS) Materials Source Guide (MSG)

5. MDOT Structural Fabrication Quality Assurance Guidance Document

6. MDOT Structural Fabrication Unit E-Construction Process

7. Prefabrication meeting minutes (if available)

B. QAI must be familiar with the following references:

1. MDOT Structural Fabrication Request for Information Process

2. MDOT Shop Drawing Review Process

3. MDOT Structural Fabrication Nonconformance Process

4. Michigan Test Methods

MTM 102 Michigan Test Method for Abrasion Resistance of Aggregate by the Los Angeles Machine

MTM 108 Michigan Test Method for Materials Finer than No. 75 Sieve in Mineral Aggregates by Washing

MTM 109 Michigan Test Method for Sieve Analysis of Fine, Dense Graded, Open Graded, and Coarse Aggregates in the Field

MTM 114 Michigan Test Method for Making Concrete Specimens for Freeze-Thaw Testing of Concrete Coarse Aggregate

MTM 115 Michigan Test Method for Testing Concrete for Durability by Rapid

Materials Quality Assurance Procedures Manual 2012

4.04

Freezing in Air and Thawing in Water

MTM 206 Michigan Test Method for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders

5. AASHTO Standards

T 22 Compressive Strength of Cylindrical Concrete Specimens

T 23 Making and Curing Concrete Test Specimens in the Field

T 231 Capping Cylindrical Concrete Specimens

6. ASTM Standards

A 185 Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement

A 416 Standard Specification for Low-Relaxation, Seven-Wire Steel Strand for Prestressed Concrete

A 497 Standard Specification for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement

C 31 Standard Practice for Making and Curing Concrete Test Specimens in the Field

C 39 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

C 94 Standard Specification for Ready-Mixed Concrete

C 136 Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

C 138 Test Method for Density (Unit Weight), Yield and Air Content (Gravimetric) of Concrete

C 143 Standard Test Method for Slump of Hydraulic Cement Concrete

C 172 Standard Practice for Sampling Freshly Mixed Concrete

C 173 Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

C 231 Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

C 595 Standard Specification for Blended Hydraulic Cements

C 617 Standard Practice for Capping Cylindrical Concrete Specimens

C 1231 Standard Practice for Use of Unbonded Caps in determination of Compressive Strength of Hardened Concrete Cylinders

C 1260 Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar Bar Method)

C 1567 Standard Test Method for Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar Bar Method)

7. PCI Safety and Loss Prevention Manual SLP-100

8. MDOT Accident Prevention Plan

Materials Quality Assurance Procedures Manual 2012

4.04

4.04.03. Qualifications, Responsibilities, Duties, and Equipment

A. Qualifications of the QAI – QAI performing the fabrication inspection must possess the following qualifications:

1. Michigan Professional Engineer (PE) license or Precast/Prestressed ConcreteInstitute (PCI) Technician Level II;

2. Michigan Concrete Association (MCA) Level I Field Testing Technician certificationor American Concrete Institute (ACI) Concrete Field Testing Technician – Grade I(except period of effectiveness will be reduced from 5 years to 3 years to match MCA);and

3. Michigan Certified Aggregate Technician (MCAT) Level I (only required for aggregatesampling).

B. Responsibilities of the QAI – QAI performing the fabrication inspection is not permitted to make changes to the contract and has the following responsibilities:

The Contractor, Fabricator, and MDOT will approach quality control and quality assurance as a team effort to facilitate accurate and timely construction. QAI’s verification does not relieve the Fabricator from the responsibility to perform the required testing and inspection to produce a product satisfying the contract. Though QA inspection may include all aspects of fabrication, the QAI must not supersede QC, which is the responsibility of the Fabricator. If QC is not accomplishing its role then the Structural Fabrication Unit, Engineer, Contractor, and Fabricator must determine the necessary corrections.

QAI is the responsible party, representing the Engineer, who performs quality assurance verification inspection on the element after quality control (QC) inspects and approves the item of work. The QAI must be at the fabrication facility at all times during fabrication as required by the inspection procedure stated below. If issues arise, it will be at the Engineer’s discretion whether to increase the level of QA inspection.

It is the Engineer’s responsibility to engage the Engineer of Record (EOR) when making structural decisions. The Engineer is also responsible for following internal MDOT procedures for review and approval of shop drawings, fabrication procedures, request for information (RFI), nonconformance reports (NCR), and for professional decision making on fabrication problems that arise. The Engineer relies on the Structural Fabrication Unit to manage and assist when appropriate. The Engineer has the prerogative for holding a prefabrication meeting with the Fabricator to discuss and clarify the contract plans and specifications. The Engineer is the responsible party who ensures MDOT’s fabrication QA program is followed for inspection and acceptance of the element.

Fabrication should proceed only with approved shop drawings. However, if the Fabricator must proceed prior to receipt of approved shop drawings (performing work at their own risk), ensure that the Structural Fabrication Unit is aware of this activity and await instruction on how to proceed. If the Engineer permits the work to proceed without approved shop drawings, proceed with basic QA functions using the non-approved shop drawings. Later, verify notes against approved drawings. Notify the Structural Fabrication Unit immediately if fabrication is not in conformance with the approved shop drawings.

C. Duties of the QAI – QAI performing the fabrication inspection has the following duties:

1. QAI must thoroughly understand the contract.

Materials Quality Assurance Procedures Manual 2012

4.04

2. QAI must verify steel material certifications show compliance with Buy Americacontract requirements.

3. QAI must be proficient in performing fresh concrete tests, sampling aggregate andother materials, verifying material traceability, and inspecting concrete pours.

4. QAI must be proficient in writing reports and using computers.

5. QAI must notify the Engineer if production begins before approved shop drawings areon the shop floor and provided to the QAI.

6. QAI must communicate all concerns through QCI or whomever the Fabricator directsduring the prefabrication meeting.

7. QAI must communicate with QCI to obtain the work schedule.

8. QAI must follow MDOT’s Structural Fabrication E-Construction Process for closingout fabrication inspection file.

D. Deficiencies on Local Agency Projects – MDOT’s QAI must notify the Structural Fabrication Unit if they observe fabrication or inspection deficiencies on local agency program (LAP) projects. The Structural Fabrication Engineer will report the deficiencies via email to the Engineer that is responsible for construction oversight of the local agency project and carbon copy the applicable CFS and Design Division LAP Engineers.

E. Inspection Facilities and Access – Facilities for the QAI must be provided by the Fabricator per contract. QAI must have access to all parts of the work at all times. The authority and general duties of the QAI are specified in Section 104.01.D and E of the MDOT SSC.

F. Inspection Equipment – QAI will be furnished with the following items by the Engineer:

1. Contract (MDOT SSC, special provisions, standard plans, special details, plansheets, etc.)

2. Approved shop drawings (provided by Fabricator)

3. Access to MDOT’s Fabrication Inspection & Construction System (FICS)

4. MDOT shop approval stamp

QAI must provide the following inspection equipment:

1. Computer with high speed internet access

2. Cell phone with camera

3. Flashlight

4. Temperature measuring devices capable of covering the range from 0°F to 200°F

5. Fresh concrete testing equipment (thermometer, slump cone kit, and air-meter)

6. Measuring devices (200 foot and 20 foot steel tape and calipers)

7. Straightedge and levels

8. Safety equipment

9. Other as needed for the project

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4.04.04. Inspection Procedure

A. Prefabrication Meeting – Prefabrication meetings facilitate effective quality control and quality assurance on the project and are conducted by MDOT’s Structural Fabrication Unit prior to the start of fabrication and preferably after shop drawings have been approved. The Structural Fabrication Unit, QAI, Fabricator, and QCI must be present, whereas the Engineer and Contractor should be present to ensure a team effort to facilitate accurate and timely construction. Quality assurance and quality control contact information will be shared during this meeting to ensure effective communication.

B. Fabrication Inspection – Prestressed concrete must be fabricated in accordance with the MDOT SSC and contract. QAI and QCI must pass annual MDOT independent assurance testing (IAT) prior to performing fresh concrete testing. Fabrication inspection must be performed as shown below:

1. Prestressed concrete fabrication inspection consists of verifying compliance with theapproved shop drawings, contract, and approved NCRs. RFIs must be incorporatedinto the approved shop drawings for the QAI to inspect to.

2. An approved Materials Source List (MSL) is provided to the QAI by the Engineer sothat the QAI knows what materials are being incorporated into the project and whatthe basis of acceptance is. The MSL is used to track material sampling by the QAIand to foster communication with QCI to ensure all required sampling and testingoccurs in a timely manner to prevent impacts to the project schedule. It is theFabricator’s responsibility to notify the QAI when materials are available for sampling.

3. QAI begins by inspecting materials that will be used in the fabrication process andensures they are being stored correctly, tagged for traceability purposes, and are inconformance with the contract. Next, the QAI inspects the Fabricator’s operations toensure the condition of the equipment and work area for conformance to the contract.

4. MDOT’s Accident Prevention Plan states, “MDOT employees shall not engage in anyact which would endanger another employee or themselves”. QAI must notify theEngineer immediately if work conditions exist that are not safe. If the level ofinspection diminishes below what is specified in this QA procedure, due to safetyconcerns, then the element will not be approved for use.

C. Strand Tensioning

1. General Information – While the strand is still visible, the QAI must inspect the strandsto assure that they are free of oil or other foreign material. Strands not free of oil orforeign material, or that contain kinks, bends, nicks, or other defects (including scaleor excessive rust) will be brought to QCs attention that incorporation of thesenonconforming strands will render the element unacceptable and the element will notbe approved for use.

a. Strands are positioned to duplicate the strand pattern shown on the approvedshop drawings. Changing the vertical position of the strands must have theapproval of the Engineer. Changing the horizontal position of the strands tosimplify fabrication or to accommodate two strand patterns on a bed ispermitted provided the following is still achieved:

i. Specified concrete cover;ii. Center to center distance of strands is at least 2 inches;iii. Number of strands per row is maintained; and

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iv. Resulting strand pattern is symmetrical about the verticalcenterline of the element.

b. Two strand patterns is permitted to be combined on a casting bed providedthe following conditions are met and approved by the Engineer:

i. Bond breaker must be placed on each of the unrequired strandsfor the full length of each element. Bond breaker (rigid, oversized,and monolithic) material requires the approval of the Engineer.

ii. Maximum of two full length debonded strands per element.

c. All supports used to position the strand rows must be of adequate thicknessto hold the true position of the strands.

d. Inspection of the tensioning operation consists of verifying the jack iscalibrated and observing the accurate introduction of the initial load in each ofthe strands. Final stressing of the strands is performed by application of loadinto each strand or all the strands at once to produce an elongation equalinga net elongation (gross elongation minus live end seating). The QAI mustverify the allowable stress in each strand by measuring the net elongation ofthe individual strands after the final stressing. The maximum load applied toeach strand, as indicated by the pressure gauge of the tensioning device, isalso recorded for back checking.

e. QAI must complete independent strand tensioning calculations for verificationpurposes with QC.

2. The QAI must verify the load (measured in pounds) and elongation (measured ininches) applied to each strand using the following procedures:

a. Initial Load - After all strands are positioned on the casting bed each strand issecured by a strand-vise at the dead end anchoring bulkhead of the castingbed. Each strand is individually fitted at the live end anchoring bulkhead(tensioning end) of the casting bed and an initial load is applied either onestrand at a time or all at once. The initial load must be designated by theFabricator and must not exceed 5000 pounds.

When the initial load is reached, a reference mark is made on the strand onthe outside of the live end anchoring bulkhead such that measurement ofcontinued elongation can be observed. The purpose of applying an initialload to each strand is to establish a constant starting point for measuring thenet elongation measurements by eliminating slack in the system. At this time,the strand pattern is checked at each bulkhead to make certain all strands arein their correct position and none of the strands are crossed.

Final Load – Is the force required beyond initial load.b. Net Elongation – Using the strand mark from the previous step (after initial

load) the final load is applied to the strand. The distance between the strandmark and the reference point must be measured to the nearest 0.0625 inchesto determine when the net elongation is reached. If the measured elongationis equal to or slightly greater than (5 percent or less) the computed elongation,the tensioning operation is complete. Minor adjustments in the jackingoperation are made to bring the reference mark to the desired measurement.When the tensioning operation for each strand is complete and before thetension is released from the jack, a second reference mark must be made on

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the strand at the inside of the anchoring plate and the strand-vise must then be tapped into position against the outside face of the anchoring plate. When the tension has been released from the jack the QAI must check the reference marks on the strand at the inside of the anchoring plate to determine that no slippage of the strand-vise (live end seating loss) has occurred. If slippage has occurred then it must be compared to the assumed live end seating loss used in the strand tensioning calculations. Any differences must be noted and communicated to QC.

c. Strand Elongation - The tensioning operation must be stopped immediatelywhenever the strand is elongating without a corresponding increase in theload, or the load increases without a continuing increase in strand elongation.In these occurrences, the following steps must be taken:

i. Strand elongation computation is checked;ii. Casting bed length is verified;iii. Modulus of elasticity of the strand is verified; andiv. Factors restricting the free movement of the strand are reviewed.

Temperature changes may affect the hydraulic system of the tensioning apparatus resulting in variations in load readings.

d. Tensioning Draped Strands - QAI must be alert to the strand elongation andtensioning operation discussed above. In some cases, the number andefficiency of hold-down/hold-up hardware may restrict the free movement of astrand over the entire bed length resulting in a continuing elongation of strandwithout a corresponding increase in the load. When this situation occurs, thetensioning operation is stopped and the remaining elongation developed inthe strand taken by tensioning the strand from the opposite end of the castingbed.

e. Confirming Uniform Elongation of Draped Strands - This can be accomplishedby marking-off a 10 foot (or more if available) length of draped strand at theopposite end of the bed after the initial load operation has been completed. Atthe completion of the final measured elongation operation, the measureddistance between the marks should have increased to the net elongationcomputation for a 10 foot strand length (or whatever was initially marked off).

f. Wire Failure in Strand - See PCI MNL 116 for acceptance of failure ofindividual wires in a pretensioning strand.

D. Forming and Casting

1. General Information - QAI must confirm the dimensional requirements of thebulkheads, side forms, bearing plates, steel reinforcement, void boxes, inserts, andany other devices per the approved shop drawings as part of their post-pourinspection. The only exception is that anything that cannot be inspected post-pour,must be inspected during pre-pour. It is important to emphasize that QA must notsupersede QC so the QAI’s inspection must come after QC has completed theirinspection and approves the element. QAI then uses the QC inspection reports (ifavailable) during their verification inspection.

2. Concrete Forms - Concrete forms must be maintained and remain true to the shapesand dimensions as shown on the approved drawings.

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a. Metal forms must be used since they are designed and aligned to not restrictthe longitudinal movement of the casting when the prestressing force istransferred. Forms must be well braced and stiffened against undesirabledeformations under pressure of fresh concrete and must have smooth jointsand inside surfaces accessible for adequate cleaning after each use.

b. Joints between panel forms must be made and maintained smooth andtight. Unless otherwise shown on approved shop drawings, all corners orintersections of surfaces exposed in the completed structure must bechamfered with a minimum dimension of 0.50 inches and all re-entrant anglesmust be rounded with a minimum radius of 0.75 inches.

c. Forms that are warped, distorted, damaged, or improperly cleaned must notbe used. Wood forms may be used for bulkheads. The inside faces of allforms must be coated with an approved chemical release agent.

3. Reinforcing Steel – QAI must confirm that the reinforcing steel is of the correct size,free from defects, and properly positioned. The reinforcing steel must be free of oil,lubricants, foreign material, and excessive rust. If epoxy coated bars are to be usedthen nicks in the coating are not permitted.

QAI must spot check that the reinforcing steel has been properly positioned andsecured in accordance with the approved shop drawings and make certain that insertshave been placed where required.

4. Void Boxes - Void boxes must be of the dimensions and positioned in the form inaccordance with the approved shop drawings.

After the bar reinforcement assembly has been positioned in the formwork, the QAImust confirm that the void boxes are securely clamped to the formwork so they cannotmove out of position during consolidation activities. After the unit has been cast, andimmediately after the top has been struck-off, the top slab thickness must beconfirmed by the QAI to assure that there has been no upward movement of the voidbox and that the top slab thickness is within the acceptable specification limits. Thedepth of concrete over the void boxes will be spot checked and any concerns notedand immediately shared with QC.

5. Tests on Fresh Concrete – QAI must perform testing as required in the contract anddocument the results in MDOT Form 0590. The Fabricator must collect additionalfresh concrete for QAI to perform their tests as needed.

6. Placing of Concrete – The concrete must be promptly placed with minimum handlingto avoid segregation of the materials and the displacement of the rein-forcement. Each element must be cast in a continuous operation with minimalinterruption between the placing of adjacent portions of concrete and each layer mustbe placed and consolidated before the preceding layer has taken initial set.

7. Consolidation of Concrete – A minimum amount of vibration necessary to thoroughlyconsolidate the concrete must be used. QAI must verify a rubber coated vibratorhead is used when epoxy-coated or other coated reinforcement is used.

E. Transfer of Prestress – The tension in the strands must not be transferred to the concrete in the element until the concrete has attained the required compressive strength as

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indicated by test results of QC compressive strength test cylinders which have been cast and match cured per the contract. QAI must witness this testing.

1. Forms are removed and the strands are released by simultaneously cutting both endsof the same strand using a torch or other method approved by the Engineer. TheFabricator must release strands in a symmetrical pattern about the vertical centerline.Extreme care must be exercised by the Fabricator to avoid damaging the concrete bysuperheating it with the torch.

2. Elements are moved from the casting bed to the yard upon completion of the transferof prestress. After removal from the bed, the QAI must immediately inspect theelement for any defects created during casting and perform post-pour inspectionsafter QC has completed their inspection and approves the element. QAI must noteany deficiencies on Form 0590 and immediately notify the Fabricator and Engineer.The Engineer may request the QAI to complete a QA NCR and arrange a meetingwith QC to discuss why the deficiency wasn’t caught by QC.

F. Curing Requirements - Curing requirements for prestressed concrete must be as specified in subsection 708.03 of the MDOT SSC as modified by the contract. When steam or radiant heat curing is used, recording thermometers must be provided by the Fabricator that monitors the time/temperature relationship through the curing period while artificial heat is used. The QAI must verify that the recording thermometers are placed in critical locations for monitoring the time/temperature relationship during the curing period. Verify QC has the required number of recording thermometers per the contract and they are placed at locations where the anticipated heat generated by the concrete is the lowest and highest just after initial concrete set. Documentation from the Fabricator's recording thermometer must be given to the QAI for their review. Temperature requirements during the curing operation must be in accordance with the contract specifications.

G. Material Requirements – Materials must meet the requirements of the contract unless a RFI requesting alternate materials has been approved by the Engineer.

H. Shipping Requirements – Elements must attain the required compressive strength as indicated by test results of QC compressive strength test cylinders, which have been cast and match cured for this purpose as described per the contract. These cylinders must be cast with metal MDOT tags and the compression testing must be witnessed by the QAI.

4.04.05. Reports

A. The Engineer may require a periodic status report from the Structural Fabrication Unit; therefore, all reports are required to be completed in a timely and orderly manner using the applicable fillable portable document format (PDF) forms listed below that can be found on MDOT’s website. Make entries as soon as possible after an event or conversation to ensure accuracy. Number the reports consecutively until completion of the work.

B. QAI must complete an accurate and detailed account of fabrication for the project. The report must include a discussion of fabrication progress for all aspects of the work. It is intended to be a detailed record of the status of fabrication and should include number of elements fabricated, documentation of specification and procedure compliance as well as documentation of conflicts, repairs, and other problems or discussion which could affect the project in anyway. If force account work is taking place, document each day that the work occurs in the shop and which elements are being worked.

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C. Documentation is not a substitute for appropriate dialogue with the Fabricator, but should provide a record of important discussions. In some cases, the QAI is more familiar with the events or issues and therefore should review and comment on draft copies of the Structural Fabrication Unit’s correspondence.

D. Reports must be assembled into one fabrication inspection portable document format (PDF) file and stored in MDOT’s ProjectWise document storage program per MDOT’s Structural Fabrication Unit’s E-Construction Process. The Engineer will receive a fabrication inspection memorandum from the Structural Fabrication Engineer after fabrication inspection is complete. The memorandum is for informational purposes and is not used for acceptance.

E. Below is a list of various MDOT reports/forms and a brief description of their purpose and use requirement. Similar forms can be used in place of the standard MDOT form if noted below.

1. Project Folder Checklist (Form 2001) – This form must be completed by QAI for eachproject. The checklist is placed on top of the fabrication inspection folder when theproject is complete.

2. Shop Inspection Report (Form 5617) – This form must be completed by QAI on aweekly basis for each project and should contain a brief narrative of the workperformed over the reporting period. The report must contain the followinginformation: Weather conditions, elements worked on, materials incorporated intoelements (must document visually inspected and accepted), work activity,nonconformances, shipping, force account work (rare), and anything else deemedimportant by the QAI.

3. Sample Identification (Form 1923) – This form must be submitted when materialsampling is required on a project. QAI must completely fill out the form and keep acopy in the fabrication inspection folder.

4. Strand Tensioning Report (Form 0513) – This form must be completed by QAI foreach bed, which may contain several elements.

5. Bar Reinforcement Report (Form 1985) – This form is only used if QAI performs QAverification inspection on bar reinforcement for prefabricated bridge element systems(PBES) or other elements that contain complex reinforcement as directed by theEngineer.

6. Pre and Post Pour Inspection Checklist (Form 5616) – This checklist must becompleted by QAI for a minimum of one element per project. The checklist is placedin the fabrication inspection folder when the project is complete.

7. Field and Lab Test Report (Form 0590) – This form must be completed by QAI foreach pour which may contain several elements.

8. Repair Observation Report (Form 1981) – This form is only used if QAI performs QAverification inspection on repairs that have been approved by the Engineer.

9. Material Source List (Form 0501) – This form is sent in by the fabricator, the QAI willverify that the fabricator filled out the form completely, and document the basis ofacceptance for all materials. If there are any materials that require testing then theStructural Fabrication Unit must be copied on the completed MSL to coordinate theacceptance testing.

4.04.06. Stockpile Payment

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A. This stockpile payment section directs the QAI on the requirements when stockpile payment inspection is requested by the Structural Fabrication Unit. The QAI must perform the following steps:

1. Verify fabricated material meets approved shop drawings (if applicable);

2. Verify stockpile quantity and include quantity in report;

3. Verify material is labeled for MDOT use only;

4. Verify material is correctly stored and protected from the elements; and

5. Provide a report summarizing the inspection and provide adequate photos thatrepresent the general condition of the elements, how they’re being stored, and piecemarks.

4.04.07. Acceptance

A. The Fabricator is required to provide the QAI with a minimum of five (5) copies of the Bill of Lading for each shipment. QAI will stamp each copy of the Bill of Lading with the MDOT “Approved for Use” stamp. It is the Fabricator’s responsibility to distribute the stamped copies of Bill of Lading to the following individuals:

1. QAI

2. Engineer

3. Fabricator

4. Contractor

5. Trucking company

The Bill of Lading is required to contain, at a minimum, the following information:

1. Shipping date

2. Description of cargo (quantity, element size, weight, etc.)

3. Element unique piece mark

4. MDOT project location (route, cross road/river, and city)

5. MDOT project information (structure number, control section, and job number)

6. Manufacturer’s name and address

B. Acceptance consists of the following two-part process:

1. Fabrication Inspection Acceptance: Structural elements must be inspected by the QAIafter they are loaded for shipping. If the structural elements meet the contractrequirements, the QAI will stamp them “Approved for Use”. The elements must bestamped “Approved for Use” prior to shipping. Additionally, the QAI must stamp atleast five copies of the Bill of Lading that is prepared by the Fabricator. The approvalstamp is for use by the Department and does not relieve the Contractor of theirresponsibility to meet contract requirements.

2. Visual Inspection (VI) Acceptance: The Engineer must collect one copy of thestamped Bill of Lading and use it to verify the delivered structural elements.Additionally, the Engineer must verify that the elements are stamped and visuallyinspect them for signs of damage that may have occurred as a result of shipping and

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handling. This visual inspection should be documented in the field inspector’s daily report.

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4.11 NON-PRESTRESSED STRUCTURAL PRECAST CONCRETE FABRICATION

4.11.01. Scope

A. This non-prestressed structural precast concrete fabrication inspection procedure should be used to aid the quality assurance inspector (QAI) in interpreting and enforcing the contract for non-prestressed concrete elements. Fabrication inspection includes the time from verifying materials used for fabrication through loading for shipping to the construction site. The following non-prestressed structural precast concrete elements are included in this inspection procedure:

1. Culverts (if required by the contract or as directed by the Engineer)

2. Prefabricated bridge element systems

3. Mechanically stabilized earth panels (if required by the contract or as directed by the Engineer)

4. Sound wall posts and panels (if required by the contract or as directed by the Engineer)

4.11.02. Reference Documents

A. QAI must have a thorough knowledge of the following references:

1. The following sections of the MDOT Standard Specifications for Construction (MDOT SSC) as modified by supplemental specification 12SS-001A – Errata, as applicable:

Section 104 Control of the Work Section 105 Control of the Materials Section 406 Precast Three-Sided, Arch, and Box Culverts

2. The following special provisions, as applicable:

12SP-105A Source of Steel and Iron (Buy America) 12SP-604C QC and Acceptance of PCC for Structural Precast Concrete

12SP-706D Mechanically Stabilized Earth Retaining Wall System

3. MDOT Structural Precast Concrete QAI Manual

4. Construction Field Services Division (CFS) Materials Source Guide (MSG)

5. MDOT Structural Fabrication Unit E-Construction Process

6. MDOT Structural Fabrication Quality Assurance Guidance Document

7. Prefabrication meeting minutes (if available)

B. QAI must be familiar with the following references:

1. MDOT Structural Fabrication Request for Information Process

2. MDOT Shop Drawing Review Process

3. MDOT Structural Fabrication Nonconformance Process

4. Michigan Test Methods

MTM 102 Michigan Test Method for Abrasion Resistance of Aggregate by the Los Angeles Machine

MTM 108 Michigan Test Method for Materials Finer than No. 75 Sieve in Mineral

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Aggregates by Washing

MTM 109 Michigan Test Method for Sieve Analysis of Fine, Dense Graded, Open Graded, and Coarse Aggregates in the Field

MTM 114 Michigan Test Method for Making Concrete Specimens for Freeze-Thaw Testing of Concrete Coarse Aggregate

MTM 115 Michigan Test Method for Testing Concrete for Durability by Rapid Freezing in Air and Thawing in Water

MTM 206 Michigan Test Method for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders

5. AASHTO Standards

T 22 Compressive Strength of Cylindrical Concrete Specimens

T 23 Making and Curing Concrete Test Specimens in the Field

T 231 Capping Cylindrical Concrete Specimens

6. ASTM Standards

A 185 Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement

A 416 Standard Specification for Low-Relaxation, Seven-Wire Steel Strand for Prestressed Concrete

A 497 Standard Specification for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement

C 31 Standard Practice for Making and Curing Concrete Test Specimens in the Field

C 39 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

C 94 Standard Specification for Ready-Mixed Concrete C 136 Standard Test Method for Sieve Analysis of Fine and Coarse

Aggregates C 138 Test Method for Density (Unit Weight), Yield and Air Content

(Gravimetric) of Concrete C 143 Standard Test Method for Slump of Hydraulic Cement Concrete C 172 Standard Practice for Sampling Freshly Mixed Concrete C 173 Standard Test Method for Air Content of Freshly Mixed Concrete by

the Volumetric Method C 231 Standard Test Method for Air Content of Freshly Mixed Concrete by

the Pressure Method C 595 Standard Specification for Blended Hydraulic Cements

C 617 Standard Practice for Capping Cylindrical Concrete Specimens C 1231 Standard Practice for Use of Unbonded Caps in determination of

Compressive Strength of Hardened Concrete Cylinders C 1260 Standard Test Method for Potential Alkali Reactivity of Aggregates

(Mortar bar Method) C 1567 Standard Test Method for Determining the Potential Alkali-Silica

Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar bar Method)

C. MDOT Accident Prevention Plan

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4.11.03. Qualifications, Responsibilities, Duties, and Equipment

A. Qualifications of the QAI – QAI performing the fabrication inspection must possess the following qualifications:

1. Michigan Concrete Association (MCA) Level I Field Testing Technician certification or American Concrete Institute (ACI) Concrete Field Testing Technician – Grade I (except period of effectiveness will be reduced from 5 years to 3 years to match MCA); and

2. Michigan Certified Aggregate Technician (MCAT) Level I (only required for aggregate sampling).

B. Responsibilities of the QAI – QAI performing the fabrication inspection is not permitted to make changes to the contract and has the following responsibilities:

The Contractor, Fabricator, and MDOT will approach quality control and quality assurance as a team effort to facilitate accurate and timely construction. QAI’s verification does not relieve the Fabricator from the responsibility to perform the required testing and inspection to produce a product satisfying the contract. Though QA inspection may include all aspects of fabrication, the QAI must not supersede QC, which is the responsibility of the Fabricator. If QC is not accomplishing its role then the Structural Fabrication Unit, Engineer, Contractor, and Fabricator must determine the necessary corrections.

QAI is the responsible party, representing the Engineer, who performs quality assurance verification inspection on the element after quality control (QC) inspects and approves the item of work. The QAI must be at the fabrication facility at all times during fabrication as required by the inspection procedure stated below. If issues arise, it will be at the Engineer’s discretion whether to increase the level of QA inspection.

It is the Engineer’s responsibility to engage the Engineer of Record (EOR) when making structural decisions. The Engineer is also responsible for following internal MDOT procedures for review and approval of shop drawings, fabrication procedures, request for information (RFI), nonconformance reports (NCR), and for professional decision making on fabrication problems that arise. The Engineer relies on the Structural Fabrication Unit to manage and assist when appropriate. The Engineer has the prerogative for holding a prefabrication meeting with the Fabricator to discuss and clarify the contract plans and specifications. The Engineer is the responsible party who ensures MDOT’s fabrication QA program is followed for inspection and acceptance of the element.

Fabrication should proceed only with approved shop drawings. However, if the Fabricator must proceed prior to receipt of approved shop drawings (performing work at their own risk), ensure that the Structural Fabrication Unit is aware of this activity and await instruction on how to proceed. If the Engineer permits the work to proceed without approved shop drawings, proceed with basic QA functions using the non-approved shop drawings. Later, verify notes against approved drawings. Notify the Structural Fabrication Unit immediately if fabrication is not in conformance with the approved shop drawings.

C. Duties of the QAI – QAI performing the fabrication inspection has the following duties:

1. QAI must thoroughly understand the contract.

2. QAI must verify steel material certifications show compliance with Buy America contract requirements.

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3. QAI must be proficient in performing fresh concrete tests, sampling aggregate and other materials, verifying material traceability, and inspecting concrete pours.

4. QAI must be proficient in writing reports and using computers.

5. QAI must notify the Engineer if production begins before approved shop drawings are on the shop floor and provided to the QAI.

6. QAI must communicate all concerns through QCI or whomever the Fabricator directs during the prefabrication meeting.

7. QAI must communicate with QCI to obtain the work schedule.

8. QAI must follow MDOT’s Structural Fabrication E-Construction Process for closing out fabrication inspection file.

D. Deficiencies on Local Agency Projects – MDOT’s QAI must notify the Structural Fabrication Unit if they observe fabrication or inspection deficiencies on local agency program (LAP) projects. The Structural Fabrication Engineer will report the deficiencies via email to the Engineer that is responsible for construction oversight of the local agency project and carbon copy the applicable CFS and Design Division LAP Engineers.

E. Inspection Facilities and Access – Facilities for the QAI must be provided by the Fabricator per contract. QAI must have access to all parts of the work at all times. The authority and general duties of the QAI are specified in Section 104.01.D and E of the MDOT Standard Specifications for Construction.

F. Inspection Equipment – QAI will be furnished with the following items by the Engineer:

1. Contract (MDOT SSC, special provisions, standard plans, special details, plan sheets, etc.)

2. Approved shop drawings (provided by Fabricator)

3. Access to MDOT’s Fabrication Inspection & Construction System (FICS)

4. MDOT shop approval stamp

QAI must provide the following inspection equipment:

1. Computer with high speed internet access

2. Cell phone with camera

3. Flashlight

4. Temperature measuring devices capable of covering the range from 0°F to 200°F

5. Fresh concrete testing equipment (thermometer, slump cone kit, and air-meter)

6. Measuring devices (200 foot and 20 foot steel tape and calipers)

7. Straightedge and levels

8. Safety equipment

9. Other as needed for the project

4.11.04. Inspection Procedure

A. Prefabrication Meeting – Prefabrication meetings facilitate effective quality control and quality assurance on the project and are conducted by MDOT’s Structural Fabrication Unit prior to the start of fabrication and preferably after shop drawings have been

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approved. The Structural Fabrication Unit, QAI, Fabricator, and QCI must be present, whereas the Engineer and Contractor should be present to ensure a team effort to facilitate accurate and timely construction. Quality assurance and quality control contact information will be shared during this meeting to ensure effective communication.

B. Fabrication Inspection – Non-prestressed concrete must be fabricated in accordance with the MDOT SSC and contract. QAI and QCI must pass MDOT independent assurance testing (IAT) prior to performing fresh concrete testing on an annual basis. Fabrication inspection must be performed as shown below:

1. Non-prestressed concrete fabrication inspection consists of verifying compliance withthe approved shop drawings, contract, and approved NCRs. RFIs must beincorporated into the approved shop drawings for the QAI to inspect to.

2. An approved Materials Source List (MSL) is provided to the QAI by the Engineer sothat the QAI knows what materials are being incorporated into the project and whatthe basis of acceptance is. The MSL is used to track material sampling by the QAIand to foster communication with QC to ensure all required sampling and testingoccurs in a timely manner to prevent impacts to the project schedule. It is theFabricator’s responsibility to notify the QAI when materials are available for sampling.

3. QAI begins by inspecting materials that will be used in the fabrication process andensures they are being stored correctly, tagged for traceability purposes, and are inconformance with the contract. Next, the QAI inspects the Fabricator’s operations toensure the condition of the equipment and work area for conformance to the contract.

4. MDOT’s Accident Prevention Plan states, “MDOT employees shall not engage in anyact which would endanger another employee or themselves”. QAI must notify theEngineer immediately if work conditions exist that are not safe. If the level ofinspection diminishes below what is specified in this QA procedure, due to safetyconcerns, then the element will not be approved for use.

C. Forming and Casting

1. General Information - QAI must confirm the dimensional requirements of thebulkheads, side forms, bearing plates, steel reinforcement, void boxes, inserts, andany other devices per the approved shop drawings as part of their post-pourinspection. The only exception is that anything that cannot be inspectedpost-pour, must be inspected during pre-pour. It is important to emphasize that QAmust not supersede QC so the QAI’s inspection must come after QC has completedtheir inspection and approves the element. QAI then uses the QC inspection reports(if available) during their verification inspection.

2. Concrete Forms - Concrete forms must be maintained and remain true to the shapesand dimensions as shown on the approved drawings.

a. Metal forms must be used since they are designed to be rigid for repetitivecastings without deforming or weakening due to the heat from the hydrationprocess. Forms must be well braced and stiffened against undesirabledeformations under pressure of fresh concrete and must have smooth jointsand inside surfaces accessible for adequate cleaning after each use.

b. Joints between panel forms must be made and maintained smooth andtight. Unless otherwise shown on approved shop drawings, all corners orintersections of surfaces exposed in the completed structure must bechamfered with a minimum dimension of 0.50 inches and all re-entrant anglesmust be rounded with a minimum radius of 0.75 inches.

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4.11

c. Forms that are warped, distorted, damaged, or improperly cleaned must not be used. Wood forms may be used for bulkheads. The inside faces of all forms must be coated with an approved chemical release agent.

3. Reinforcing Steel – QAI must confirm that the reinforcing steel is of the correct size, free from defects, and properly positioned. The reinforcing steel must be free of oil, lubricants, foreign material, and excessive rust. If epoxy coated bars are to be used then nicks in the coating are not permitted.

QAI must spot check that the reinforcing steel has been properly positioned and secured in accordance with the approved shop drawings and make certain that inserts have been placed where required.

4. Tests on Fresh Concrete – QAI must perform testing as required in the contract and document the results in MDOT Form 0590. The Fabricator must collect additional fresh concrete for QAI to perform their tests as needed.

5. Placing of Concrete – The concrete must be promptly placed with minimum handling to avoid segregation of the materials and the displacement of the reinforcement. Each element must be cast in a continuous operation with minimal interruption between the placing of adjacent portions of concrete and each layer must be placed and consolidated before the preceding layer has taken initial set.

6. Consolidation of Concrete – A minimum amount of vibration necessary to thoroughly consolidate the concrete must be used. QAI must verify a rubber coated vibrator head is used when epoxy-coated or other coated reinforcement is used.

D. Curing Requirements - Curing requirements for non-prestressed concrete must be as specified in the contract. When steam or radiant heat curing is used, recording thermometers must be provided by the Fabricator that monitors the time/temperature relationship through the curing period while artificial heat is used. The QAI must verify that the recording thermometers are placed in critical locations for monitoring the time/temperature relationship during the curing period. At least three recording thermometers must be placed at locations where the anticipated heat generated by the concrete is the lowest and highest just after initial concrete set. Documentation from the Fabricator's recording thermometer must be given to the QAI for their review. Temperature requirements during the curing operation must be in accordance with the contract specifications.

E. Material Requirements – Materials must meet the requirements of the contract unless a RFI requesting alternate materials has been approved by the Engineer.

F. Shipping Requirements – Elements must attain the required compressive strength as indicated by test results of QC compressive strength test cylinders, which have been cast and match cured for this purpose as described per the contract. These cylinders must be cast with metal MDOT tags and the compression testing must be witnessed by the QAI.

4.11.05. Reports

A. The Engineer may require a periodic status report from the Structural Fabrication Unit; therefore, all reports are required to be completed in a timely and orderly manner using the applicable fillable portable document format (PDF) forms listed below that can be

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4.11

found on MDOT’s website. Make entries as soon as possible after an event or conversation to ensure accuracy. Number the reports consecutively until completion of the work.

B. QAI must complete an accurate and detailed account of fabrication for the project. The report must include a discussion of fabrication progress for all aspects of the work. It is intended to be a detailed record of the status of fabrication and should include number of elements fabricated, documentation of specification and procedure compliance as well as documentation of conflicts, repairs, and other problems or discussion which could affect the project in anyway. If force account work is taking place, document each day that the work occurs in the shop and which elements are being worked.

C. Documentation is not a substitute for appropriate dialogue with the Fabricator, but should provide a record of important discussions. In some cases, the QAI is more familiar with the events or issues and therefore should review and comment on draft copies of the Structural Fabrication Unit’s correspondence.

D. Reports must be assembled into one fabrication inspection portable document format (PDF) file and stored in MDOT’s ProjectWise document storage program per MDOT’s Structural Fabrication Unit’s E-Construction Process. The Engineer will receive a fabrication inspection memorandum from the Structural Fabrication Engineer after fabrication inspection is complete. The memorandum is for informational purposes and is not used for acceptance.

E. Below is a list of various MDOT reports/forms and a brief description of their purpose and use requirement. Similar forms can be used in place of the standard MDOT form if noted below.

1. Project Folder Checklist (Form 2001) – This form must be completed by QAI for each project. The checklist is placed on top of the fabrication inspection folder when the project is complete.

2. Shop Inspection Report (Form 5617) – This form must be completed by QAI on a weekly basis for each project and should contain a brief narrative of the work performed over the reporting period. The report must contain the following information: Weather conditions, elements worked on, materials incorporated into elements (must document visually inspected and accepted), work activity, nonconformances, shipping, force account work (rare), and anything else deemed important by the QAI.

3. Sample Identification (Form 1923) – This form must be submitted when material sampling is required on a project. QAI must completely fill out the form and keep a copy in the fabrication inspection folder.

4. Bar Reinforcement Report (Form 1985) – This form is only used if QAI performs QA verification inspection on bar reinforcement for prefabricated bridge element systems (PBES) or other elements that contain complex reinforcement as directed by the Engineer.

5. Pre and Post Pour Inspection Checklist (Form 5616) – This checklist must be completed by QAI for a minimum of one element per project. The checklist is placed in the fabrication inspection folder when the project is complete.

6. Field and Lab Test Report (Form 0590) – This form must be completed by QAI for each pour which may contain several elements.

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7. Repair Observation Report (Form 1981) – This form is only used if QAI performs QA verification inspection on repairs that have been approved by the Engineer.

8. Material Source List (Form 0501) – This form is sent in by the fabricator, the QAI will verify that the fabricator filled out the form completely, and document the basis of acceptance for all materials. If there are any materials that require testing then the Structural Fabrication Unit must be copied on the completed MSL to coordinate the acceptance testing.

4.11.06. Stockpile Payment

A. This stockpile payment section directs the QAI on the requirements when stockpile payment inspection is requested by the Structural Fabrication Unit. The QAI must perform the following steps:

1. Verify fabricated material meets approved shop drawings (if applicable);

2. Verify stockpile quantity and include quantity in report;

3. Verify material is labeled for MDOT use only;

4. Verify material is correctly stored and protected from the elements; and

5. Provide a report summarizing the inspection and provide adequate photos that represent the general condition of the elements, how they’re being stored, and piece marks.

4.11.07. Acceptance

A. The Fabricator is required to provide the QAI with a minimum of five (5) copies of the Bill of Lading for each shipment. QAI will stamp each copy of the Bill of Lading with the MDOT “Approved for Use” stamp and will retain one copy for their records. It is the Fabricator’s responsibility to distribute the remaining copies of Bill of Lading to the following individuals:

1. QAI

2. Contractor

3. Fabricator

4. Contractor

5. Trucking company

The Bill of Lading is required to contain, at a minimum, the following information:

1. Shipping date

2. Description of cargo (quantity, element size, weight, etc.)

3. Element unique piece mark

4. MDOT project location (route, cross road/river, and city)

5. MDOT project information (structure number, control section, and job number)

6. Manufacturer’s name and address

B. Acceptance consists of the following two-part process:

1. Fabrication Inspection Acceptance: Structural elements must be inspected by the QAI after they are loaded for shipping. If the structural elements meet the contract

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requirements, the QAI will stamp them “Approved for Use”. The elements must be stamped “Approved for Use” prior to shipping. Additionally, the QAI must stamp at least five copies of the Bill of Lading that is prepared by the Fabricator. The approval stamp is for use by the Department and does not relieve the Contractor of their responsibility to meet contract requirements.

2. Visual Inspection (VI) Acceptance: The Engineer must collect one copy of thestamped Bill of Lading and use it to verify the delivered structural elements.Additionally, the Engineer must verify that the elements are stamped and visuallyinspect them for signs of damage that may have occurred as a result of shipping andhandling. This visual inspection should be documented in the field inspector’s dailyreport.

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STRUCTURAL FABRICATION UNIT V011717

REQUEST FOR INFORMATION PROCESS PAGE 1 of 3

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication Request for Information Process Description The purpose of this document is to provide the Michigan Department of Transportation (MDOT) with statewide consistency managing and responding to a structural fabrication request for information (RFI). MDOT’s Structural Fabrication Unit is responsible for implementing the Department’s quality assurance program for structural elements that are required to be accepted based on “Fabrication Inspection” per MDOT’s Materials Quality Assurance Procedures (MQAP) manual. MDOT utilizes vendor inspectors to provide shop inspection for these structural elements. When information is requested, it is important for MDOT to quickly respond to a RFI submittal in order to keep the project moving forward. This document is broken down into the following sections:

1. Request for Information 2. RFI Report 3. RFI Submittal Process 4. Innovative Contracting

1. Request for Information Request for information is defined to be a request by the Fabricator seeking additional information or proposing an alternate design, material, fabrication method, or inspection method for the structural element. The Fabricator typically generates RFI submittals before shop drawings are produced, but they are sometimes submitted after fabrication has begun. A RFI submittal is not to be confused with a nonconformance report (NCR) that is defined to be an alteration in the work or a fabrication error that results in the element not meeting project specifications. Each unique request should be submitted on a separate RFI for housekeeping purposes. The Structural Fabrication Unit is responsible for coordinating the RFI review process and should provide a timely response or acknowledgement (explanation, decision, request for additional information, or estimate of time needed to evaluate) within three business days after receiving the RFI submittal. The Structural Fabrication Unit will distribute all RFIs that are design related to the Design PM for their disposition and then the Design PM is responsible for engaging other MDOT areas, as applicable (Roadside Development, Geometrics, etc.). MDOT will consider alternate fabrication methods or configurations, materials, or inspection procedures proposed by the Fabricator provided the alternative will result in improving or equaling the expected performance, maintenance, and longevity of the structure; however, approval of a RFI may be contingent on a reduction in the contract unit price. Contract modification due to approval of a RFI by the Fabricator requesting alternate material, fabrication method, inspection method, or anything else that is not determined by the Engineer to be an extra will be at no additional cost or time extension to MDOT. RFIs are resolved by providing an appropriated response on the RFI form.

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MICHIGAN DEPARTMENT OF TRANSPORTATION

2. RFI Report A RFI is generated by the Fabricator. The Fabricator is required to submit the RFI to MDOT as discussed in Section 3 of this document. MDOT has developed a standard Request for Information (Form 0558) form that should be used by the Fabricator. Use of the form is recommended to facilitate a faster review process. RFIs submitted for review are required to include, at a minimum, the following information:

• Follow MDOT’s file naming convention as shown on the RFI form;

• MDOT project information (structure number, control section, job number, project location, and element mark);

• RFI number in ascending order for each project (resubmittals use a different RFI number);

• Clearly state what information is being requested or what is being proposed;

• Clearly state the required specifications if an alternate is being proposed;

• Include drawings (contract plan, sketches, etc.), numerous high resolution photos, product data sheets, etc.;

• Indicate the urgency of a reply.

Approval of a RFI does not waive the contractual requirement to provide shop drawings prior to the start of fabrication, nor is it sufficient information to allow MDOT’s quality assurance inspector (QAI) to stamp elements approved for use. If the Fabricator elects to use an approved RFI then they need to incorporate the RFI into the shop drawings for MDOT’s review and approval prior to the start of fabrication. MDOT’s QAI is instructed to inspect using approved shop drawings and approved NCRs only. The Fabricator is also required to obtain the Contractor’s acceptance of any contract modifications that alter the finished product.

3. RFI Submittal Process Listed below is MDOT’s structural fabrication RFI submittal process:

1. Fabricator names RFI file per MDOT’s file naming convention shown on Form 0558.

2. Fabricator must send RFI to Structural Fabrication Unit and carbon copy the Engineer and Contractor. All correspondence to the Structural Fabrication Unit must be sent using the following email resource:

MDOT-StructuralFabrication@michigan.gov

3. Structural Fabrication Unit distributes RFI to QAI and Design PM (if applicable) and begins reviewing.

4. Design PM distributes RFI to other areas (e.g. Geometrics, Load Rating, Roadside Development), as applicable, and provides all comments to Structural Fabrication Unit.

5. Structural Fabrication Unit provides response on RFI form via email to Fabricator and carbon copies the Engineer, Contractor, Design PM, and QAI.

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MICHIGAN DEPARTMENT OF TRANSPORTATION

6. QAI places final RFI form and correspondence in the fabrication inspection file that will be stored in ProjectWise.

4. Innovative Contracting The request for information process described above applies to Design-Bid-Build projects. This section will discuss subtle changes required to successfully submit RFIs for innovative contracting such as Design-Build projects. Design-Build is an innovative construction method that pairs the Engineer of Record (EOR) with the Contractor. The main difference between a Design-Build and a Design-Bid-Build project is that the EOR on the Design-Build team is required to completely review and approve the RFI submittal prior to MDOT’s review. Once the Design-Build team is satisfied with the submittal, the MDOT Design-Build Project Manager (Design Build PM) acts as the MDOT RFI coordinator and distributes the submittal to the Structural Fabrication Unit for review. The Structural Fabrication Unit returns any comments to the Design Build PM. Once satisfied, the Structural Fabrication Unit stamps “Approved” on the RFI form. The Design Build PM must be included on all correspondence related to a RFI, therefore Section 3 (RFI Submittal Process) must be revised to reflect this for Design-Build projects.

Michigan Department of Transportation

0558 (01/18) REQUEST FOR INFORMATIONRFI #

To be completed by the fabricator and submitted to the Structural Fabrication Unit. Naming Convention: 0558 SN-CS-JN Fabricator RFI#.pdf

GENERAL INFORMATION FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION JOB NUMBER

RFI SUBJECT STRUCTURE #

DATE

INFORMATION REQUEST

MDOT RESPONSE

Approved RFI, if implemented by the Fabricator, must be incorporated into the shop drawings and approved by the Engineer prior to the start of fabrication.

BBS Approval Block

• Submit to the Structural Fabrication Unit and cc the Contractor and Engineer.

Clear Form

3

STRUCTURAL FABRICATION UNIT V101915

NONCONFORMANCE POLICY PAGE 1 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication Nonconformance Policy Description The purpose of this document is to provide the Michigan Department of Transportation (MDOT) with statewide consistency in addressing material and fabrication nonconformance issues with structural steel and structural precast concrete elements. MDOT’s Structural Fabrication Unit is responsible for

implementing the Department’s quality assurance program for fabrication inspection and utilizes vendor inspectors for inspection of structural steel and structural precast concrete elements at nationwide fabrication facilities. When nonconforming material or fabrication issues are discovered the Structural Fabrication Unit immediately notifies the Project Engineer (hereafter referred to as Engineer) overseeing the construction project of the deficiencies. It is the Engineer’s responsibility to reject or accept

nonconforming elements with consideration of imposing a negative price adjustment in accordance with subsection 104.04 of the MDOT Standard Specifications for Construction. Bridge Field Services is available to provide technical support to the Engineer when additional guidance is needed. Guidelines are provided in this document for the Engineer and Structural Fabrication Unit to use when determining if a price reduction is warranted. When a price reduction is warranted, the Structural Fabrication Unit provides the recommended amount to ensure statewide consistency and alignment. Below is a list of the structural elements inspected for acceptance by the Structural Fabrication Unit for which this document applies (see contract documents for project specific information):

Structural steel for bridges (plate, rolled, hollow structural shape, bridge tube railing, steel deck grating, modular expansion joints, castings, forgings, etc.);

Highway structures (sign structures, tower lighting units, mast arm traffic signals, DMS, etc.);

Structural precast concrete (prestressed concrete beams, spun concrete poles, sound wall panels/posts, MSE wall panels/posts, etc.);

Precast concrete three-sided, arch, and box culverts (span lengths 20 feet and greater measured parallel to the roadway centerline).

This document does not address fabricated elements cast by the contractor on the project site or non-structural precast concrete (concrete pipe, manhole, etc.).

1. Control of Materials The service life of a highway is dependent upon the quality of the materials used in its construction as well as the method of construction. Therefore, it is critical to ensure the materials incorporated into the work meet the project specifications. Control of materials is discussed in subsection 105 of the MDOT 2012 Standard Specifications for Construction (hereafter referred to as Standard Specifications) with information on approval of materials in subsection 105.05 and nonconforming materials in subsection 105.08. The Engineer may inspect materials that the contractor will incorporate into the work at any time

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MICHIGAN DEPARTMENT OF TRANSPORTATION

and at any place during the preparation, storage, and use of the materials. The Engineer will perform inspections of the materials, including sampling and testing, in accordance with the methods required by the contract to determine if the material is approved for use. Approval of materials is discussed in the Department’s Materials Quality Assurance Procedures Manual (MQAP).

2. Nonconforming Materials – Acceptable and Unacceptable UseIt is the Department’s intent to discourage the use of nonconforming materials from being incorporated into the work even if they are found acceptable for use. Subsection 105.08 of the Standard Specifications gives the Engineer the authority to either reject nonconforming materials or to allow the nonconforming materials to remain in place. If materials are found to be unacceptable before or after placement into the work, the Engineer may reject the materials, and the contractor must remove the materials from the site at no cost to the Department. Materials that have been tested and approved at their source or otherwise previously approved, but have become damaged or contaminated before use in the project, are also subject to rejection by the Engineer.

Materials that are nonconforming, but determined by the Engineer to be acceptable for use may be subject to a negative price adjustment. To ensure consistency in the decisions made for acceptance of nonconforming material or workmanship, it is recommended the Engineer involve Bridge Field Services before finalizing any decision. This communication will help keep the applicable technical sections of the Bureau of Field Services informed about contractor or material problems that may require specification changes, a Bridge Field Services Advisory, or discipline of a contractor. Additionally, this communication will aid in the consistent treatment of nonconforming materials statewide. The Bureau of Field Services is available to provide technical support if the Engineer has any questions regarding the acceptance or rejection of nonconforming materials. It is the Engineer’s responsibility to determine whether a

nonconforming material is acceptable for use; however, Bridge Field Services can assist with recommendations.

2.1 Determining if Nonconforming Material can be Incorporated into the Work Good engineering judgment is required when making decisions on nonconforming materials. The Engineer may choose to approve nonconforming materials, allow them to be incorporated into the work, and impose a negative price adjustment. When making the decision to direct the contractor to remove and replace the materials versus leave the materials in place, it is important to consider the following:

Safety;

Long-term consequences on quality and durability;

Implications on the structural element’s life cycle costs, service life, serviceability, andmaintenance;

Environmental and aesthetic considerations;

Impacts on the project’s traffic, staging, and construction timeframes;

Future costs associated with maintenance.

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NONCONFORMANCE POLICY PAGE 3 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

2.2 Determination of Price Reductions After the Engineer has decided to allow nonconforming materials to remain in place, the Structural Fabrication Unit will carefully evaluate each situation in deciding whether to recommend a price reduction. The goal is to achieve statewide consistency in administering price reductions for nonconforming materials that are allowed to remain place. The purpose of the price reduction is to facilitate an environment that encourages the contractor to incorporate materials meeting contract specifications and to make it fair for all contractors.

Results of retests and related quality tests should be considered. The following list includes some examples of the types of factors the Structural Fabrication Unit will consider when deciding if a price reduction is warranted:

Has the contractor been conscientious to provide quality by carefully controlling materials and construction operations?

Has the contractor been proactive and made good use of quality control (QC) data to maintain and improve quality?

Did the contractor notify the Engineer of materials that needed to be tested in a timely manner to ensure the test results would be reported prior to the materials being incorporated?

Did the Engineer process the test results within the industry accepted timeframe so the contractor could make process or materials corrections?

Upon becoming aware of a materials quality problem, has the contractor responded quickly to correct it?

Is the nonconforming test an isolated incident or a recurring situation?

How does the nonconforming test compare to the rest of the project data:

o Have material test results been well within specification requirements or consistently at the very limit of what is acceptable?

o How many tests are nonconforming versus how many tests have passed?

o How far out of specifications is the nonconforming test?

2.3 Nonconforming Structural Precast Concrete If the Engineer has decided to accept nonconforming material and it is determined that a negative price adjustment is warranted then the final step is for the Structural Fabrication Unit to determine a recommended price reduction. The following guidelines provide a list of common nonconformance issues related to the structural precast concrete industry and are intended to aid the Structural Fabrication Unit in determining the recommended price reduction. The goal of these guidelines is to provide consistent price reductions independent of the type of project or project office location.

The Engineer must justify and document the incorporation of any nonconforming materials into the work. The Structural Fabrication Unit will provide the Engineer with the quantity and type of nonconforming material for the project office’s records. Only one price adjustment should be

applied to a given quantity of material; however, if multiple nonconformance issues occur then

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NONCONFORMANCE POLICY PAGE 4 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

the price reduction may be increased on a case by case basis. In general, if the quantity in question is subject to more than one of the following price reductions then the greater price reduction would apply.

Any structural precast concrete element judged to be structurally or otherwise unacceptable by

MDOT due to low strength, cracking, breakage, honeycombing, or other deficiency will be

rejected and replaced. Note that honeycombing with exposed prestressing strand automatically

falls into this category.

Any structural precast concrete element judged to be acceptable, but deficient by MDOT due to any of the following issues will be subject to the pay deductions listed below. These guidelines for standard deductions are intended to be applied to typical problem severity in the majority of cases. In occasional cases where problem severity is lower or higher than typical, the pay deduction may be decreased or increased, respectively. Standard deductions shown represent a percentage of bid item price for the structural precast concrete element.

2.3.1 Nonconforming Compressive Strength Compressive strength below specified level at required test age for strand release, stripping forms, shipping, etc. is subject to the greater of $500 or 20% deduction on the bid item price if the elements are approved for use. This price reduction would apply for all elements represented by the tested cylinders.

2.3.2 Nonconforming Fabrication Defects Price reduction for the following fabrication defects and nonconformance issues will be recommended by the Structural Fabrication Unit and should be implemented by the Engineer. The following table of deductions will be applied to infrequent occurrences of the stated defects. In the event of repeated occurrences of the same defect, these deductions will be doubled. Note that negative pay adjustments may be waived for minor fabrication and nonconformance defects judged to be inconsequential. The

following price reduction percentages are deducted from the bid item price and are only

applicable to nonconforming structural precast elements determined by the Engineer to

be acceptable:

Misalignment of form and soffit joints (1/8 inch or greater on flat surface) – 10%deduction;

Inadequately sealed joints with significant mortar washout – 10% deduction; Cracking/spalling caused by fabrication and curing – 10% deduction; Dimensional tolerance deviations outside contract documents – 10% deduction; Honeycombing – 10% deduction; * Curing temperature – 10% deduction; Broken/cracked components – 10% deduction.

* Structural precast concrete elements cured at elevated temperatures are suspect in

terms of durability. The Structural Fabrication Unit will make a recommendation to the

Engineer to either reject the element or accept it with a price reduction.

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NONCONFORMANCE POLICY PAGE 5 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

2.3.3 Nonconforming Miscellaneous Items The Engineer must determine the quantity of nonconforming material. Only one price adjustment will be applied to a given quantity of material. If the quantity in question is subject to more than one of the following conditions, apply the adjustment with the greater price reduction.

2.3.4 Minor Nonconformance If the structural element does not conform to the requirements of the contract, but is accepted, apply one of the following two price reductions (if not already covered in part 2.3.1 or 2.3.2):

1. 20% price reduction on the bid item price;

2. 50% price reduction on all material (invoice) costs utilized to fabricate the structural precast concrete element.

2.3.5 Major Nonconformance The Engineer should not pay for elements determined by the Department to be in major nonconformance with the contract requirements.

2.4 Nonconforming Structural Steel Due to the specialized nature and track record of structural steel fabrication, acceptable nonconformance rarely lends itself to recommended price reductions. In general, deficient structural welds can be easily replaced and the homogenous nature of steel typically means if the material does not meet specification then it is rarely accepted even with a price reduction. However, the Structural Fabrication Unit would review and provide a recommended price reduction to the Engineer on a case by case basis depending on the nature of the deficiency, recurrence, etc. Dimensional tolerance deviations outside the contract documents is an example of a workmanship nonconformance subject to a 10% price deduction from the bid item price if the structural steel element is determined by the Engineer to be acceptable.

2.5 Special Cases For other nonconforming issues not covered above, consult personnel in the appropriate area of the Bureau of Field Services for guidance. Some examples of items in which it may be unacceptable to leave the nonconforming item in place, even at reduced cost, include the following:

Bar reinforcement;

Anchor bolts;

High strength bolts.

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STRUCTURAL FABRICATION UNIT V092517

NONCONFORMANCE PROCESS PAGE 1 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication Nonconformance Reporting Process Description The purpose of this document is to provide the Michigan Department of Transportation (MDOT) with statewide consistency managing and responding to a structural fabrication nonconformance report (NCR). MDOT’s Structural Fabrication Unit is responsible for implementing the Department’s quality

assurance program for structural elements that are required to be accepted based on “Fabrication

Inspection” per MDOT’s Materials Quality Assurance Procedures (MQAP) manual. MDOT utilizes vendor inspectors to provide shop inspection for these structural elements. When nonconformance occurs, it is important for MDOT to quickly respond to a NCR submittal to keep the project moving forward. This document is broken down into the following sections:

1. Nonconformance 2. QC Nonconformance Report 3. QA Nonconformance Report 4. NCR Submittal Process 5. MDOT Standard Repair Procedures 6. Innovative Contracting

1. Nonconformance Nonconformance is defined to be an alteration in the work or a fabrication error that results in the element not meeting project specifications. A NCR is not to be confused with a request for information (RFI) that is defined to be a request by the Fabricator seeking additional information or proposing an alternate material, fabrication method, or inspection method. A RFI is typically submitted before fabrication work begins, whereas a NCR is submitted after a nonconformance is observed by quality control (QC). Nonconformance renders the affected element unacceptable until such time as the issue is referred to MDOT for disposition. Nonconformance that results in the Fabricator rejecting an element does not require a NCR to be submitted for review; however, MDOT does request the Fabricator to send our quality assurance inspector (QAI) written correspondence that clearly documents who rejected the element, why it was rejected, when it was rejected, and proposed changes to the piece mark naming convention for the fabrication inspection records. Nonconformance is generally defined to be material or workmanship in nature and is further classified by MDOT to be minor or major. Minor nonconformance can be repaired by the Fabricator using a preapproved MDOT standard repair procedure that can be found in the MDOT Structural Precast

Concrete Standard Repair Program and does not need to be approved by MDOT on a case by case basis throughout the project. Major nonconformance can typically be repaired by the Fabricator using a MDOT standard repair procedure that can be found in the MDOT Structural Precast Concrete Standard

Repair Program and does need to be approved by MDOT on a case by case basis throughout the

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NONCONFORMANCE PROCESS PAGE 2 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

project. Below are common minor nonconformances that can be repaired using a preapproved MDOT standard repair procedure:

Cosmetic and in-process weld defects; Concrete air hole; Epoxy coated reinforcing steel damage; Coating damage; Hot-dip galvanizing damage.

Examples of major nonconformances include, but are not limited to the following:

Buy America; Material specifications; Element dimensions; Unauthorized repairs; NCR corrective action without adequate notification; Coating system requirements; Unauthorized welds; Defective structural welds; Unqualified welder or welding operator; Welding without approved weld procedure specifications (WPS); Overheating steel and not maintaining preheat; Fresh concrete properties; Strength requirements; Concrete curing requirements; Honeycombing, voids, and concrete damage (except air holes).

The QAI should obtain clarification from the Structural Fabrication Unit if the QAI has questions regarding the proper disposition method for nonconformances. All nonconformance issues observed by the QAI must be brought to the attention of the Fabricator immediately upon discovery; however, the QAI must not direct corrective action. The QAI must notify the Structural Fabrication Unit immediately if the Fabricator fails to take corrective action or continues to fabricate nonconforming elements. Verbally notifying the Fabricator of nonconformance is sometimes sufficient; however major nonconformance issues should always be followed up in writing to the Fabricator via email with a carbon copy to the Structural Fabrication Unit. The Structural Fabrication Unit will decide if the Fabricator’s operations

warrant notifying the MDOT Construction Engineer (Engineer) and MDOT Design Project Manager (Design PM) to prevent schedule delays or potential claims. An internal conference call amongst the Structural Fabrication Unit, Engineer, Design PM, and QAI may be needed to better understand the issue and to discuss MDOT’s Structural Fabrication Nonconformance Policy to ensure statewide consistency with acceptance of nonconforming materials and potential price reductions if nonconforming elements are permitted to be incorporated into the project.

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The Structural Fabrication Unit is responsible for coordinating MDOTs NCR review process and should provide a timely response or acknowledgement (explanation, decision, request for additional information, or estimate of time needed to evaluate) within three business days after receiving the NCR submittal. The Structural Fabrication Unit will distribute all NCRs that are design related to the Design PM for their disposition and then the Design PM is responsible for engaging other MDOT areas (Roadside Development, Geometrics, etc.), as applicable. All NCRs are required to be stamped “Approved” by the Structural Fabrication Unit on the coversheet if they are found to be acceptable to MDOT. Unacceptable NCRs are returned to the Contractor with an appropriate response and stamped “Not

Approved”. Corrective action that requires use of a weld procedure specification (WPS) will require the Structural Fabrication Unit to stamp the WPS in addition to the NCR.

2. QC Nonconformance Report QC NCRs are generated by the Fabricator after their QCI observes a nonconformance during their inspection. The Fabricator is required to submit the NCR to MDOT as discussed in Section 4 of this document if they intend to have the element considered by MDOT to be incorporated into the project. Although not required, it is highly recommended that the QCI discuss the NCR submittal with the QAI to ensure it is in general conformance with MDOT requirements. The QAI should not review the actual NCR at this point in time since they will be asked to verify that the NCR is accurate by the Structural Fabrication Unit after the Contractor submits it to MDOT. MDOT has developed a standard Nonconformance Report (Form 0559) that should be used by the Fabricator. Use of the form is recommended to facilitate a faster review process. NCRs submitted for review are required to include, at a minimum, the following information:

Follow MDOT’s file naming convention as shown on the NCR form;

MDOT project information (structure number, control section, job number, project location, and element mark);

NCR number in ascending order for each project (resubmittals use the same NCR number, but would have a different revision number);

Clearly state the nonconformance;

State the reason for nonconformance;

State measures to prevent nonconformance from occurring again;

Include supporting documentation (marked up shop drawings, QC reports, WPS, PQR, numerous high resolution photos showing all locations proposed to be repaired, etc.);

State proposed corrective action (repair procedure, NDE, MDOT standard repair procedure, etc.);

Indicate the urgency of a reply.

The Fabricator must notify the QAI, prior to performing repairs to the nonconforming element, so MDOT has the opportunity to witness the repair. Elements containing repairs performed without adequate notification for QA inspection may not be approved for use. All nonconformances must be properly resolved before the element can be considered for acceptance.

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3. QA Nonconformance Report It is not common for MDOT to write a NCR; however, a QA NCR could be issued due to the following reasons:

1. Fabricator does not acknowledge a material or workmanship nonconformance. 2. QAI verification inspection results in major nonconformance missed by QCI during their inspection.

The Structural Fabrication Unit uses the standard Quality Assurance Nonconformance Report (Form 0560) for a QA NCR and submits the completed form to the Engineer and Design PM for their review and subsequent discussion. It is important for QA to document when QC is ineffective so the appropriate quality management system organization (AISC, NPCA, and PCI) specified by MDOT in the contract documents can follow up with the complaint. The Fabricator is required to respond to the QA NCR by either submitting their own NCR acknowledging they are in agreement with the QA NCR or in writing that they are in disagreement. The Fabricator’s NCR is required to include all of the information stated in Section 2 of this document. A conference call may be requested by the Structural Fabrication Unit between the Engineer, QAI, Contractor, Fabricator, and QCI to discuss the NCR. Once all elements have been re-inspected by the QCI, they must notify the QAI via email or by submittal of the QC report that the QC inspection is complete for the elements under consideration. The QAI will start the QA verification inspection again and if major nonconformances are found then the process will repeat itself. It is important to note that the QAI must not perform their QA verification inspection until after QCI notifies them via email or by submittal of the QC report that their QC inspection is complete for the elements under consideration. This prevents QA from inspecting prior to QC.

4. NCR Submittal Process Listed below is MDOT’s structural fabrication NCR submittal process:

1. Fabricator names NCR file per MDOT’s file naming convention shown on Form 0559.

2. Fabricator must send NCR to the Structural Fabrication Unit and carbon copy the Engineer and Contractor. All correspondence to the Structural Fabrication Unit must be sent using the following email resource:

MDOT-StructuralFabrication@michigan.gov

3. Structural Fabrication Unit distributes NCR to QAI and Design PM (if applicable) and begins reviewing.

4. Design PM distributes NCR to other areas (e.g. Geometrics, Load Rating, Geotechnical, Roadside Development), as applicable, and provides all comments to the Structural Fabrication Unit.

5. Structural Fabrication Unit provides response on NCR via email to Fabricator and carbon copies the Engineer, Contractor, Design PM, and QAI.

6. QAI places final NCR and correspondence in the fabrication inspection file that will be stored in ProjectWise.

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5. MDOT Standard Repair Procedures The Structural Fabrication Unit has developed standard repair procedures to expedite the review process for common repairs to structural elements. These repair procedures have been reviewed by industry and should be used by Fabricators when applicable to speed up the review process. Standard repair procedures for structural steel have not been developed at the time of this document, but will be added in subsequent revisions.

Listed below are the MDOT standard structural precast concrete repair procedures, which can be found in MDOT’s Structural Precast Concrete Repair Guidance Document on MDOT’s Structural Fabrication

Unit’s website:

1. * Procedure #1: Air Hole

2. Procedure #2: Minor Surface Defect

3. Procedure #3: Major Surface Defect

4. * Procedure #4: Hot-Dip Galvanize

5. Procedure #5: Fiber Reinforced Polymer

6. * Procedure #6: Epoxy Bar

7. Procedure #7: Epoxy Injection

* Indicates MDOT standard repair procedure for minor nonconformance. These procedures can be preapproved by the Structural Fabrication Unit before the project begins and do not need to be approved on a case by case basis throughout the project. Fabricator is required to notify the QAI when the repairs will be performed so they can have the opportunity to witness. Fabricator must have copies of the standard repair plan with them at all times while performing the repair.

Listed below is the MDOT standard structural steel repair procedure:

1. Procedure #1: Shop Coating Repairs

6. Innovative Contracting The nonconformance reporting process described above applies to Design-Bid-Build projects. This section will discuss subtle changes required to successfully submit NCRs for innovative contracting such as Design-Build projects. Fabrication nonconformance should already be addressed in the Design-Build Design Quality Manual (DQM); however, MDOT’s Structural Fabrication Nonconformance Policy provides MDOT with statewide consistency in addressing material and fabrication nonconformance issues.

Design-Build is an innovative construction method that pairs the Engineer of Record (EOR) with the Contractor. The main difference between a Design-Build and a Design-Bid-Build project is that the EOR on the Design-Build team is required to completely review and approve the NCR submittal prior to MDOT’s review. Once the Design-Build team is satisfied with the submittal, the MDOT Design-Build Project Manager (Design Build PM) acts as the MDOT NCR coordinator and distributes the submittal to the Structural Fabrication Unit for review. The Structural Fabrication Unit returns any comments to the Design

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Build PM. If satisfied, the Structural Fabrication Unit stamps “Approved” stamp on the NCR. The Design Build PM must be included on all correspondence related to a NCR, therefore Section 4 (NCR Submittal Process) must be revised to reflect this.

Michigan Department of Transportation

0559 (01/18) NONCONFORMANCE REPORT NCR #

To be completed by the fabricator and submitted to the Structural Fabrication Unit. Naming Convention: 0559 SN-CS-JN Fabricator NCR# REV#.pdf

GENERAL INFORMATION FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION JOB NUMBER

NCR SUBJECT STRUCTURE #

DATE

NONCONFORMANCE DESCRIPTION

REASON FOR NONCONFORMANCE

RECURRENCE PREVENTION ACTION

CORRECTIVE ACTION

Nonconformances render the element unacceptable for use unless the Engineer approves the nonconformance. BBS Approval Block

• Combine this document with all relevant QC reports, photos, repair plans, WPS, etc. into one PDF document prior tosubmitting to the Structural Fabrication Unit for approval. cc the Contractor and Engineer.

Clear Form

Michigan Department of Transportation

0560 (01/18) QUALITY ASSURANCE NONCONFORMANCE REPORT

QA NCR #

To be completed by the MDOT QA inspector and submitted to the Structural Fabrication Unit. Naming Convention: 0560 SN-CS-JN Fabricator QA NCR# REV#.pdf

GENERAL INFORMATION PREPARED BY - COMPANY CONTROL SECTION

FABRICATOR / LOCATION JOB NUMBER

JOB DESCRIPTION STRUCTURE #

NCR SUBJECT DATE

NONCONFORMANCE DESCRIPTION

• Combine this document with all relevant QC reports, photos, repair plans, WPS, etc. into one PDF document prior tosubmitting to the Structural Fabrication Unit.

Clear Form

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Structural Precast Concrete Repair Guidance Document Description The purpose of this guidance document is to provide the Michigan Department of Transportation (MDOT) with statewide consistency reviewing and approving structural precast (prestressed and non-prestressed) concrete repair submittals. It provides internal guidance for the minimum acceptable procedures to ensure a durable repair that will preserve the integrity of the fabricated structural element. MDOT uses a minimum 75-year bridge design life and any proposed repairs to the element should be consistent with the original design. MDOT’s Structural Fabrication Unit is responsible for implementing the Department’s quality assurance program for structural elements required to be accepted based on “Fabrication Inspection” per MDOT’s Materials Quality Assurance Procedures (MQAP) manual and utilizes vendor inspectors to provide the shop inspection. The fabricator is required to notify MDOT’s quality assurance inspector (QAI) prior to performing any approved repairs for the opportunity to perform verification inspection.

Structural precast concrete elements may contain defects from the fabrication process or are often damaged during formwork removal or shipping and handling. The fabricator’s quality control inspector (QCI) is required to notify the MDOT QAI of all defects/damages that occur to the elements. The fabricator is responsible for submitting a NCR with proposed corrective action (repair plan) to bring the element into conformance if it is to be considered for incorporation into the project. MDOT will consider the corrective action and provide a response to the contractor in accordance with MDOT’s Structural Fabrication Nonconformance Reporting Process. Submittal of a NCR does not guarantee approval since the defect/damage may have resulted in structural, durability, or aesthetic concerns that is not addressed by the repair plan. Repairs are not permitted to be performed until after the NCR has been approved and the QAI has been notified in a timely manner when the repair will take place. See MDOT’s Structural Fabrication Nonconformance Policy for more information on when nonconformances can be incorporated into the project and associated price reductions. See MDOT’s Structural Fabrication Nonconformance Reporting Process for more information on what NCR’s are and how to submit them. Both of these documents can be found on the MDOT Structural Fabrication Unit website located inside the Structural Precast Concrete Fabrication Inspection Portfolio document.

MDOT Standard Repair Procedures 1. *Standard Structural Precast Concrete Repair Procedure #1: Air Hole

2. Standard Structural Precast Concrete Repair Procedure #2: Minor Surface Defect

3. Standard Structural Precast Concrete Repair Procedure #3: Major Surface Defect

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4. *Standard Structural Precast Concrete Repair Procedure #4: Hot-Dip Galvanize

5. Standard Structural Precast Concrete Repair Procedure #5: Fiber Reinforced Polymer System

6. *Standard Structural Precast Concrete Repair Procedure #6: Epoxy Repair

7. Standard Structural Precast Concrete Repair Procedure #7: Epoxy Injection

*Indicates standard structural precast concrete repair procedure that does not require submittal of a NCR for MDOT approval; however, the fabricator is required to follow these procedures and notify the QAI when the repairs will be performed so they have the opportunity to witness. Fabricator must have copies of the standard repairs plans with them at all times.

MDOT’s Structural Precast Concrete Specialist will consult with the Structural Fabrication Engineer and other technical resource areas when repair plans fall outside the scope of the above stated standard repair procedures. The following non-standard materials/procedures have been used in limited applications on past projects with success:

1. BASF HB2 (formerly Thoroc) for overhead structural repairs and when latex repair mixtures can’t be bird-mouthed into the formwork.

2. BASF Emaco (#1) and Sika 123 Plust (#2) for non-structural applications when latex repair mixtures can’t be bird-mouthed into the formwork. Note it is rare to have a non-structural repair application.

3. Non-structural crack repair: Healer sealer is a good non-structural crack repair to effectively impede moisture intrusion and chloride penetration.

4. Sealing exposed aggregate saw cuts: Healer sealer is a good product for sealing a saw cut edge. Water repellent treatment would be the second best option. Both products will be difficult to apply on a vertical surface.

5. Coating exposed steel reinforcement: Aluminum mastic epoxy is a good coating system to coat exposed steel reinforcement. The epoxy must be from a manufacturer that is listed in MDOT’s MSG QPL (Section 915: Coating Systems for Steel Structures). The steel must be cleaned to SSPC SP 6 or better. The manufacturer’s recommendations must be followed. A minimum of two coats of the aluminum mastic epoxy (see manufacturer for recommended min/max DFT) should be applied with the proper cure time between coats. An acceptable concrete repair material can then be placed over the coated steel reinforcement.

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Appendix A – Air Hole

Figure 1. Air holes greater than 3/4” in any direction and greater than 3/8” deep.

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Appendix B – Minor Surface Defect

Figure 2. Rubber gasket crease

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Figure 3. Moderate honeycombing along MI 1800 girder.

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Figure 4. Moderate honeycombing at end of PCI beam.

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Appendix C – Major Surface Defect

Figure 5. Broken corner at end of PCI beam.

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Figure 6. Spalled bottom corner at end of box beam.

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Figure 7. Spalled bottom corner at end of box beam.

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Standard Structural Precast Concrete Repair Procedure #1: Air Hole Description This structural precast concrete repair procedure is for patching air holes that exceed acceptable dimensional tolerances. The repair plan is in accordance with subsections 406 and 708 of the 2012 Michigan Department of Transportation Standard Specifications for Construction (MDOT SSC) as applicable.

The Type R-2 mortar used for patching air holes must be selected from the following locations:

• Cement: Approved Manufacturer or Test• White Cement: Visual inspection• Fine aggregate (2NS or 2MS): Prequalified Aggregate Source or Test• Air entrainment: Qualified Products List

Procedure Below is the standard repair procedure for air holes:

1. Immediately patch all air holes larger than 3/4 inch in any direction and greater than 3/8 inch deepwith Type R-2 mortar after removing forms.

2. Perform the following steps prior to patching air holes if they are not filled immediately after forms areremoved:

o Flush the area with minimum 2500 psi pressurized clean water.

o Remove excess water from patch area by blasting with minimum 90 psi oil-free compressed air toproduce a saturated surface dry condition immediately prior to application of mortar.

3. Place mortar when substrate is at least 40 degrees, and maintain a temperature of at least 40 degreesFahrenheit during the placement and curing period.

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Standard Structural Precast Concrete Repair Procedure #2: Minor Surface Defect Description This structural precast concrete repair plan is for minor surface defects defined to have a patch depth of less than 1.5 inches. This repair plan is in accordance with the following subsections of the 2012 Michigan Department of Transportation Standard Specifications for Construction (MDOT SCC):

• 712.03.F.2 - Hand Chipping Concrete Other Than Deck Concrete;• 712.03.O - Mixing, Placing, Finishing, and Curing Concrete Patches;• 712.03.R - Cold Weather Limitations for Placing SFMC or LMC Overlay Mixtures; and• 712.03.S - Hot Weather Limitations for Placing Overlay Mixtures.

The latex bonding agent and cement used for patching mixtures must be selected from an Approved Manufacturer in the MDOT Materials Source Guide (MSG). The aggregate must be from a MDOT prequalified source or tested for acceptance.

Procedure Below is the standard repair procedure for minor surface defect:

1. Remove unsound or loose concrete with air hammers (15 pound class or smaller) or grinding. Saw-cut areas requiring patching to an edge depth of at least ½ inch. Patch area must have verticaledges (normal to the surface) and re-entrant corners rounded with a minimum 1 inch radius. Ensurethere are no voids or delaminated concrete by sounding. Clean exposed areas by sandblastingto provide an anchor profile.

2. Remove loose material from patch area by blasting with minimum 90 psi oil-free compressed air.Flush the area with minimum 3000 psi pressurized clean water. Remove excess water from patcharea by blasting with oil-free compressed air immediately prior to application of patching material.

3. Drill galvanized or epoxy coated anchors into the repair area spaced 2-3 inches apart and usecoated tie wire to create a floating mesh with spaces large enough for latex repair mixture to flowthrough. Provide at least 1 inch concrete clear cover over the anchors and tie wire. Use extremecare not to damage mild reinforcing steel or prestressing strand.

4. Patch the area with a F-L patching mixture in accordance to Table 703-1 (Structures PatchingMixtures) of the 2012 MDOT Standard Specifications for Construction. Maintain a SSD (saturatedsurface dry) condition prior to placing patching mixture. Vibrate forms or use a tamping rod toconsolidate the concrete patch.

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5. Place a layer of wet burlap immediately over the finished concrete patch. Burlap must be soakedin water for at least 12 hours prior to placing patching mixture. Place a 4-mil thick layer ofpolyethylene film immediately over the burlap to protect the top surfaces from evaporation.

6. Wet cure patches using burlap and polyethylene for 48 hours and allow concrete to air cure for anadditional 48 hours.

7. Air and concrete substrate temperatures must be at least 40o F and rising, but below 85oF. Theforecast air temperature during the curing period must be 35o F or higher. Use insulating blankets ifthe curing period forecasted (or actual) air temperature is below 45o F.

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Standard Structural Precast Concrete Repair Procedure #3: Major Surface Defect Description This structural precast concrete repair plan is for major surface defects defined to have a minimum patch depth of 1.5 inches. This repair plan is in accordance with the following subsections of the 2012 Michigan Department of Transportation Standard Specifications for Construction (MDOT SSC):

712.03.F.2 - Hand Chipping Concrete Other Than Deck Concrete; 712.03.O - Mixing, Placing, Finishing, and Curing Concrete Patches; 712.03.R - Cold Weather Limitations for Placing SFMC or LMC Overlay Mixtures; and 712.03.S - Hot Weather Limitations for Placing Overlay Mixtures.

The latex bonding agent and cement used for patching mixtures must be selected from an Approved Manufacturer in the MDOT Materials Source Guide (MSG). The aggregate must be from a MDOT prequalified source or tested for acceptance.

Procedure Below is the standard repair procedure for major surface defect:

1. Remove unsound or loose concrete with air hammers (15 pound class or smaller) or grinding. Saw-cut areas requiring patching to an edge depth of at least ½ inch. Patch area must have verticaledges (normal to the surface) and re-entrant corners rounded with a minimum 1 inch radius. Ensurethere are no voids or delaminated concrete by sounding. Clean exposed areas by sandblastingto provide an anchor profile.

2. Do not damage any prestressing strand or mild steel reinforcement. If mild steel reinforcement isexposed, remove concrete to provide ¾ to 1 inch of clearance around the steel for anchoring.

3. Remove loose material from patch area by blasting with minimum 90 psi oil-free compressed air.Flush the area with minimum 3000 psi pressurized clean water. Remove excess water from patcharea by blasting with oil-free compressed air immediately prior to application of patching material.

4. Drill galvanized or epoxy coated anchors into the repair area spaced 2-3 inches apart and usecoated tie wire to create a floating mesh with spaces large enough for latex repair mixture to flowthrough. Provide at least 3/4 inch concrete clear cover over the anchors and tie wire. Use extremecare not to damage mild reinforcing steel or prestressing strand.

5. Repair damaged epoxy coating in accordance with subsection 706.03.E.8 of the MDOT SSC.

6. Patch the area with a C-L patching mixture in accordance to Table 703-1 (Structures PatchingMixtures) of the 2012 MDOT Standard Specifications for Construction. Maintain a SSD (saturated

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surface dry) condition prior to placing patching mixture. Vibrate forms or use a tamping rod to consolidate the concrete patch.

7. Place a layer of wet burlap immediately over the finished concrete patch. Burlap must be soakedin water for at least 12 hours prior to placing patching mixture. Place a 4-mil thick layer ofpolyethylene film immediately over the burlap to protect the top surfaces from evaporation.

8. Wet cure patches using burlap and polyethylene for 48 hours and allow concrete to air cure for anadditional 48 hours.

9. Air and concrete substrate temperatures must be at least 40o F and rising, but below 85oF. Theforecast air temperature during the curing period must be 35oF or higher. Use insulating blankets ifthe curing period forecasted (or actual) air temperature is below 45oF.

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Standard Structural Precast Concrete Repair Procedure #4: Hot-Dip Galvanize Description The following plan is for the repair of hot-dip galvanized components and is in accordance with subsection 716.03.E of the 2012 Michigan Department of Transportation Standard Specifications for Construction (MDOT SSC) and ASTM A780-09.

Procedure Below is the standard repair procedure for hot-dip galvanizing. The fabricator must select a zinc-rich paint that meets ASTM A780 requirements and the following procedures:

1. Prepare the damaged galvanized area in accordance with paint manufacturer’s instructions or asstated herein, whichever is stricter. Surface preparation must extend into the undamagedgalvanized coating to ensure a smooth reconditioned coating can be effected.

2. Surfaces to be reconditioned with paints containing zinc dust shall be clean, dry, and free of oil,grease, preexisting paint, and corrosion by-products in accordance to SSPC-SP1 (Solvent Cleaning).

3. Clean the surface to bare metal, in accordance with SSPC-SP10 (Near-White Blast Cleaning) orSSPC-SP11 (Power Tool Cleaning to Bare Metal). Use a grinder and wire wheel to grind burrs, fins,tears, slivers, irregularities, or sharp edges. Sharp corners must be “broken” to ensure adequateedge dry film thickness.

4. Use a clean cloth to remove any contaminant from the area being repaired. Oil free pressurized air(90 psi minimum) must be used to remove any dust or any other particles.

5. If the area to be repaired includes welds, first remove all weld flux residue and weld spatter (of asize that cannot be removed by wire brushing or blast cleaning) by mechanical means such aschipping, grinding, or power scaling.

6. Hand coat the area according to the paint manufacturer’s instructions or as stated herein,whichever is stricter.

7. Allow adequate cure time before recoating or placing the repaired component into service inaccordance with paint manufacturer’s product data sheet.

8. Use a magnetic, electromagnetic, or eddy-current gage to measure dry film thickness inaccordance with SSPC-PA2 (Measurement of Dry Paint Thickness with Magnetic Gages). QC mustcalibrate the gage prior to each use. The repaired area must have a coating thickness of 1.5 timesthe thickness or thickness equivalent specified or 5 mils, whichever is greater. Spot or areameasurements, as applicable, must be taken in accordance with the SSPC– PA 2 (Required Numberof Measurements for Conformance to a Thickness Specification). Record thickness measurementsfor the job file on QC reports and provide to MDOT’s QAI.

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Standard Structural Precast Concrete Repair Procedure #5: Fiber Reinforced Polymer System Description The following repair plan is for elements required to be reinforced with a fiber reinforced polymer (FRP) sheet and adhesive composite system due to surface defect, honeycombing, damage, etc. and would be used in conjunction with another MDOT standard structural precast concrete repair procedure or approved unique repair procedure. This FRP repair plan is in accordance with the latest Michigan Department of Transportation Special Provision for Fiber Reinforced Polymer System for Prestressed Concrete Beam Repair (hereafter referred as FRP SP). A MDOT approved FRP system from Table 1 of the FRP SP must be selected.

Submit the following items for MDOT’s review and approval:

1. FRP manufacturer’s product data sheet for the following: sheet, resin, and protective top coat; 2. Concrete surface coating manufacturer’s product data sheet, federal color number, and swatch

of the color proposed for coating. The coating color must match the color of the beam unless the beam will be concrete surface coated, which would require the coating color to match the concrete surface coating.

3. Manufacturer’s recommended installation procedures; 4. Details of any construction device that may be attached to the structure during construction; 5. Quality control inspector (QCI) information (at a minimum the full name, FRP training, and FRP work

history) for individual responsible for inspection and fabricator acceptance of FRP sheet and adhesive composite system; and

6. FRP manufacturer’s on-site technical representative trained in the application of FRP sheet and adhesive composite system installation on concrete substrate. Representative must be physically on-site during startup of the FRP installation process to assist the fabricator and answer questions from the Department’s representative.

Procedure Below is the standard repair procedure for the FRP sheet and adhesive composite system. In general, the manufacturer’s recommended installation procedures must be followed. In the event of a conflict, the more strict procedures must be adhered to:

1. Verify latex repair patches have been wet cured for 48 hours and air cured for 48 hours prior to installation of FRP sheet and adhesive composite system.

2. Grind all rough edges on latex repair patches smooth after they have completely cured.

3. Remove concrete dust from surface by blasting with minimum 90 psi oil-free compressed air.

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4. Verify environmental conditions (dew point, humidity, concrete moisture content, and concrete substrate temperature) are within the FRP SP prior to placing primer and FRP sheet. Fabricator’s QCI must possess one of the following endorsements:

a. National Association of Corrosion Engineers (NACE) – National Coating Inspector Training and certification Program Session I: Coating Inspection Training;

b. SSPC-C1 Fundamentals of Protective Coatings for Industry for Industrial Structures; or

c. National Highway Institute (NHI) – Bridge Coating Inspection Course.

5. Apply the FRP primer and FRP sheet in accordance with the FRP SP.

6. FRP sheet must extend past the patch area by at least 3 inches in all directions, but extend across the entire bottom flange and up both sides of the web to the bottom of the top flange.

7. FRP sheet must be placed with fiber orientation perpendicular (90 degrees) to the beam’s longitudinal axis.

8. Allow at least 24 hours for initial resin to cure prior to performing direct adhesion testing in accordance with ASTM D7522.

9. Completely cure the FRP sheet and adhesive composite system per the manufacturer’s recommendations before applying the protective top coat per the manufacturer’s recommendations.

10. After curing, check entire FRP wrap for any delamination by acoustic tap inspection per the FRP SP.

11. Use the project’s Special Provision for Concrete Surface Coating, if available, to coat the FRP system in accordance with the manufacturer’s product data sheet except as modified by subsection 716 of the MDOT SSC. If the project does not have concrete surface coating then a special provision will be provided.

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Standard Structural Precast Concrete Repair Procedure #6: Epoxy Repair Description The following plan is for the repair of epoxy coated reinforcing steel and is in accordance with subsection 706.03.E.8 of the 2012 Michigan Department of Transportation Standard Specifications for Construction (MDOT SSC) and ASTM A775.

Procedure Below is the standard repair procedure for epoxy coating. The fabricator must select a patching or repair material selected from the MDOT Qualified Products List (QPL) and follow the following procedures:

1. Prepare the damaged areas by cleaning to remove surface contaminants in accordance withmanufacturer’s instructions or as stated herein, whichever is stricter.

2. Roughen the area requiring patching before applying patching material.

3. Remove rust by dry blast cleaning or power tool cleaning immediately before applying patchingmaterial.

4. Immediately treat bars in accordance with the manufacturer’s recommendations and beforeoxidation occurs.

5. Overlap patching material onto the original coating by 2 inches, or as recommended by themanufacturer.

6. Provide at least 8 mils of dry film thickness on the patched areas.

7. Bars with 5 percent or more damaged in a 12 inch bar length is considered to be severely damagedand will be rejected.

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MICHIGAN DEPARTMENT OF TRANSPORTATION

Standard Structural Precast Concrete Repair Procedure #7: Epoxy Injection Description The following plan is for the repair of concrete cracks using epoxy injection in accordance with subsection 712.03.U of the 2012 Michigan Department of Transportation Standard Specifications for Construction (MDOT SSC).

The epoxy resin used for injecting into the cracks must be selected from the Qualified Products List (QPL) in the MDOT Materials Source Guide (MSG).

Procedure Below is the standard repair procedure for epoxy crack injection. The fabricator must follow the following procedures or the manufacturer’s recommendations, whichever are more strict:

1. Remove leaching deposits from cracks by abrasive blasting or wire brushing.

2. Apply a temporary seal, with entry ports for adhesive, along the clean, dry crack without defacingthe concrete surface. Ensure the seal will contain the pumped adhesive.

3. Space ports farther apart than the estimated crack depth and close enough to allow adhesivematerial to travel between ports.

4. Flush the cracks with water by pressure washing through injection ports. Wash out concrete laitanceor contaminants in the crack. Remove free water by blowing oil-free air (90 psi minimum) throughthe crack after flushing.

5. Perform injection when the concrete and ambient air temperatures are above 50 degreesFahrenheit.

6. Begin injection at the lower entry port and continue until adhesive is visible at the port directlyabove, or next to the pumping port. Stop injection and seal the port. Transfer the injector fromboth sides of a cracked member to complete crack repair. Prevent leakage of the adhesive fromthe crack after injection is complete.

7. Cure adhesive at temperatures of at least 50 degrees Fahrenheit for the minimum cure timerecommended by the manufacturer. Remove the seal or grind flush with the concrete surface.

8. Clean areas repaired by injection of surface contamination caused by injections.

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4

STRUCTURAL FABRICATION UNIT V092717

BUY AMERICA PAGE 1 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication Buy America Guidance Document Description The purpose of this document is to provide the Michigan Department of Transportation’s (MDOT) Structural Fabrication Unit with guidance to supplement MDOT’s 12SP-105A Special Provision for Source of Steel and Iron (Buy America). The Structural Fabrication Unit is responsible for implementing the Department’s quality assurance program for material required to be accepted based on “Fabrication Inspection” per MDOT’s Materials Quality Assurance Procedures (MQAP) manual. It is important to note that this document is not contractual and all project related decisions should be based on the project specifications. This guidance document will be used to ensure statewide consistency in performing quality assurance (QA) verification inspection at fabrication facilities for Buy America compliance. It provides a brief background on FHWA’s Buy America policy, what step certification is, where more Buy America information can be found, how foreign steel or iron could be incorporated into the project, and tables that provide common steel and iron components used in the fabrication process of structural precast concrete and structural steel elements. This document is broken down into the following sections:

1. Background2. Step Certification3. Foreign Steel or Iron4. Buy America Tables

1. BackgroundThe FHWA’s Buy America policy is based upon the statutory provisions in the Surface Transportation Assistance Act of 1982, as implemented with a November 25, 1983 final rule. FHWA has since issued clarifications and interpretations on the Buy America policy and standing waiver of 1983 with memo’s issued on December 22, 1997, June 13, 2011 and December 21, 2012; however, the December 21, 2012 memo was rescinded on December 22, 2015. In general, FHWA’s Buy America policy requires a domestic manufacturing process for all steel (including stainless steel; however, brass, bronze and copper are not subject to Buy America) or iron manufactured products (including the application of protective coatings, but not the coating itself) that are permanently incorporated into a Federal-aid highway construction project.

Title 23 Section 313 and FHWA's regulations in 23 CFR 635.410 provide that the Administrator may issue a waiver. Procedures for any waivers are in the FHWA guidance for Buy America on the FHWA website. Waivers are very rare and typically take about 9 months to be issued, which would require them to be submitted during the design stage. Additionally, the FHWA's regulations permit a minimal use of foreign steel and iron in the amount of $2,500 or one-tenth of one percent (0.1%), whichever is greater, to be used in a Federal-aid project. Note that application of Buy America is triggered by the obligation of Federal funds. If any amount of Federal funding is used in the project then Buy America requirements apply. Map 21 requires all parts of a project to comply with Buy America if any previous parts of the

STRUCTURAL FABRICATION UNIT V092717

BUY AMERICA PAGE 2 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

larger project used Federal funds. This includes environmental EIS, planning, design, small subparts, etc. FHWA may issue a standing national or regional waiver if it is warranted, although it is extremely rare (only 4 ever issued). The waiver would be granted by the Secretary of Transportation if the product is not manufactured in the United States and the public rulemaking process demonstrates that non-domestic availability of the product would adversely impact the Federal-aid program in multiple states, specific region, and/or nationwide.

2. Step CertificationStep certification is the process under which each handler (supplier, fabricator, manufacturer, processor, etc.) of the steel and iron products certifies that their step in the manufacturing process was domestically performed. Contractors must provide manufacturers’ step certifications to the Engineer showing the steel and iron products are of domestic origin prior to permanent incorporation into the Federal-aid highway project. MDOT requires step certification for all steel and iron related pay items, materials, products, and components as specified on the Department website. The Department will maintain a list of these pay items, materials, products, and/or components on the following website:

http://www.michigan.gov/documents/mdot/MDOT_BuyAmericaRequirements_387704_7.pdf

Raw materials are not required to meet Buy America; however, every step from melting through coating application and anything else is subject to meet Buy America. If a steel or iron component has any step performed by a non-domestic source then the total cost for the entire component would need to be less than the allowable foreign limit in order to be incorporated into the project.

3. Foreign Steel or IronIt is the Contractor’s responsibility to seek approval from the Engineer to use foreign steel or iron prior to incorporation into the project. Additionally, it is the Contractor’s responsibility to keep track of the amount of foreign steel or iron used on the project.

For additional information on Buy America requirements, please refer to any project specific Special Provision for Source of Steel and Iron (Buy America), MDOT Construction Manual, MDOT MQAP Manua (section 4.12), and the FHWA website.

4. Buy America TablesBelow are several tables displaying common steel and iron components used in the fabrication of structural precast concrete and structural steel elements. This information has been prepared exclusively for MDOT’s Structural Fabrication Unit to assist with the Buy America requirements. These tables are not complete and in no way relieve the contractor of their contractual obligations to meet Buy America requirements for MDOT projects.

STRUCTURAL FABRICATION UNIT V092717

BUY AMERICA PAGE 3 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

Table 1. Steel and iron components used in fabricating structural precast concrete elements.

STRUCTURAL PRECAST CONCRETE FABRICATION

Component Description Buy America

Step Cert

Why Buy America is/is not Required

Prestressing Strand

High strength strand for prestressing concrete Yes Yes

Prestressing strand is specified in contract documents and

permanently incorporated

Bar Reinforcement

Mild bar reinforcement for strengthening

concrete Yes Yes

Bar reinforcement is specified in contract documents and

permanently incorporated

Welded Wire Fabric

Mild fabric reinforcement for

strengthening concrete Yes Yes

Welded wire fabric is specified in contract documents and

permanently incorporated

Sole Plates Steel plate cast over support and bears on the elastomeric pad

Yes Yes Sole plates are specified in the

contract documents and permanently incorporated

Position Dowels Dowels used to provide translation restraint for

beams Yes Yes

Dowels are specified in the contract documents and

permanently incorporated

MSE Connection Lug

Connects wall panel to reinforcement Yes Yes Connection lug is specified in SP

and permanently incorporated

Laminated Elastomeric Pad

Steel shims used to reinforce elastomeric

pads Yes Yes FHWA memo dated 12/21/12

rescinded

PCI Beam Lifting Strand

Device for moving beams Yes Yes FHWA memo dated 12/21/12

rescinded

Culvert Lifting Device

Device for moving culverts Yes Yes FHWA memo dated 12/21/12

rescinded

MSEW Lifting Device

Device for moving MSEW panels, posts, and

copings Yes Yes FHWA memo dated 12/21/12

rescinded

Sound Wall Lifting Device

Device for moving sound wall panels and

posts Yes Yes FHWA memo dated 12/21/12

rescinded

STRUCTURAL FABRICATION UNIT V092717

BUY AMERICA PAGE 4 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

Table 1 (continued). Steel and iron components used in fabricating structural precast concrete elements.

STRUCTURAL PRECAST CONCRETE FABRICATION

Component Description Buy America

Step Cert

Why Buy America is/is not Required

Tie Wire Secures bar reinforcement Yes No FHWA memo dated 12/21/12

rescinded

Bar Chair Supports bar reinforcement Yes No FHWA memo dated 12/21/12

rescinded

Screed Supporting

Frame (pipe)

Supports screed machine Yes No FHWA memo dated 12/21/12

rescinded

SIP Deck Clip Support location for attaching SIP decking Yes No FHWA memo dated 12/21/12

rescinded

Half Hanger Anchor Supports false work Yes No FHWA memo dated 12/21/12

rescinded

False Work Insert Supports false work Yes No FHWA memo dated 12/21/12 rescinded

Safety Line Embed Provides tie off Yes No FHWA memo dated 12/21/12

rescinded

Spun Pole Structural Steel

Mounts cameras, etc. to pole Yes No FHWA memo dated 12/21/12

rescinded

Spun Pole Hardware

Mounts cameras, etc. to pole Yes No FHWA memo dated 12/21/12

rescinded

Concrete Insert Attach threaded bar reinforcement or bolt Yes No FHWA memo dated 12/21/12

rescinded

STRUCTURAL FABRICATION UNIT V092717

BUY AMERICA PAGE 5 of 5

MICHIGAN DEPARTMENT OF TRANSPORTATION

Table 2. Steel and iron components used in fabricating structural steel elements.

STRUCTURAL STEEL FABRICATION

Component Description Buy America

Step Cert

Why Buy America is/is not Required

Structural Steel Rolled

Shape/Plate

Structural steel used for fabrication of bridge or

highway elements Yes Yes

Structural steel is specified in contract documents and

permanently incorporated

Hollow Structural Sections (HSS)

Structural steel used for fabrication of bridge or

highway elements Yes Yes

Structural steel is specified in contract documents and

permanently incorporated

High Strength Bolts

Bolts for structural steel connections Yes Yes

Bolts are specified in the contract documents and permanently

incorporated

Anchor Bolts Bolts for anchoring structural elements Yes Yes

Bolts are specified in the contract documents and permanently

incorporated

Laminated Elastomeric Pad

Steel shims used to reinforce elastomeric

pads Yes Yes FHWA memo dated 12/21/12

rescinded

Welding Rod Weld metal used in SMAW process Yes Yes FHWA memo dated 12/21/12

rescinded

Welding Wire Weld metal used in

GMAW, SAW, or FCAW processes

Yes Yes FHWA memo dated 12/21/12 rescinded

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Date

Company Name Company Address City, State, Zip Subject: Buy America Certification for Project (Structure No-XXXXX-XXXXXX)

I, (company representative), certify that the following pay items shipped/provided to the subject project are in full compliance with the Federal Highway Administration (FHWA) Buy America requirements as specified in Title 23 of the Federal Code of Regulations (CFR) Section 635.410.

Pay Item

Please see below example pay items. Delete and enter the project specific pay items.

Culv, Precast Conc Box, 20 foot by 8 foot

Prest Conc Box Beam, Furn, 21 inch

Prest Conc Bulb-Tee Beam, Furn, 48 inch by 49 inch

Spun Conc Pole, Type A

Structural Steel, Mixed, Furn and Fab

Structural Steel, Plate, Furn, Fab, and Erect

Mast Arm Pole, Cat I

If any of the above compliance statements change while providing material to this project we will immediately notify the prime contractor and the engineer.

Signature Delete this text prior to converting to pdf and place your e-signature here.

Date

Company Name Company Address City, State, Zip Subject: Buy America Step Certification for Project (Structure No-XXXXX-XXXXXX)

I, (company representative), certify that the (melting and manufacturing, bending, welding, cutting, coating, galvanizing), process for manufacturing or fabricating, the following material shipped or provided to the subject project are in full compliance with the Federal Highway Administration (FHWA) Buy America requirements as specified in Title 23 of the Federal Code of Regulations (CFR) Section 635.410.

Material: (Delete this text and all materials not being step certified for Buy America compliance. Fill in the company name for the process of the materia, and modify the listed processes as needed).

- Prestressing Strand

Company Name, Prestressing Strand, Buy America Compliance for melting and manufacturing into wire (mill)

Company Name, Prestressing Strand, Buy America Compliance for manufacturing into strand and cutting (manufacturer)

Company Name, Prestressing Strand, Buy America Compliance for cutting, grinding, and coating strand end (fabricator)

- Bar Reinforcement

Company Name, Bar Reinforcement, Buy America Compliance for melting and manufacturing into bar reinforcement (mill)

Company Name, Bar Reinforcement, Buy America Compliance for cutting, bending, and coating (manufacturer)

Company Name, Bar Reinforcement, Buy America Compliance for cutting, bending, and coating repairs (fabricator, if applicable)

- Structural Steel Plate

Company Name, Steel for Structural Steel Plate, Buy America Compliance for melting and manufacturing into steel plate (mill)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for cutting, bending, drilling, punching, shearing, and welding (service vendor, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for cutting, bending, drilling, punching, shearing, and welding (fabricator, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for machining (machine shop, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for galvanizing (galvanizer, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for coating (painter, if applicable)

If any of the above compliance statements change while providing material to this project we will immediately notify the prime contractor and the engineer.

Signature Delete this text prior to converting to pdf and place your e-signature here.

It should be noted that a complete list of the associated manufacturing and/or fabricating steps is to be provided with the step certification documentation along with which steps the respective letter(s) are addressing. This will allow MDOT to document the steps in the process to ensure documentation with federal regulations.

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5

STRUCTURAL FABRICATION UNIT V092517

METALS LABORATORY SAMPLING GUIDANCE PAGE 1 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

Metals Laboratory Sampling Guidance Document Description The following procedures provide step by step instruction on sampling all materials required to be tested by the Michigan Department of Transportation Metals Laboratory.

Sampling Instructions 1. Samples must be selected randomly without bias, must be representative of the material

sampled, and can only represent the population of material available at the time of sampling (e.g. makeup material must be resampled since the original sample cannot statistically represent material not available at the time of sampling). Specific sample size and frequency can be found in the Materials Acceptance Requirements table located in the MDOT Materials Source Guide.

2. All samples must be securely tagged with a numbered zip tie. Zip ties are provided by MDOT and are uniquely numbered for sample identification purposes. High strength bolt samples must be placed in plastic bags and closed with zip ties. All other samples must have zip ties placed directly on the sample.

3. Population of material sampled must be tagged or marked in accordance with subsection 108 of the MDOT Materials Quality Assurance Procedures (MQAP) Manual.

4. Sample Identification (Form 1923) must be electronically prepared and filled out in detail for each sample, placing the zip tie number in the remarks section. All available information for proper identification of the sample must be provided, including the heat number, lot number, tag number, batch number, serial number, and any other unique identification marks.

5. All material documentation for the sample must be electronically combined with Form 1923 as the first page into one Adobe portable document format (PDF) file and submitted to the testing lab via email to MDOT-MetalsLab@michigan.gov. The email must have the zip tie number in the subject line. The Contractor is responsible for providing all material certification and test data reports to the MDOT inspector in PDF.

6. If the MDOT Standard Specifications for Construction do not apply to the sample, applicable plan sheets, special provisions, or shop drawings must be included in the PDF submittal.

A. Material Sample File Naming Conventions:

• Acceptance or QA Sample: Control Section_Job Number_Material_Size_Date Example: 63172 123143 Anchor Bolt 2in 07-09-2015

• Tested Stock Sample: TS_Material_Size_Date Example: TS Extruded 12in 07-09-2015

• Certification Verification Sample: CV_CV Number_Material_Size_Date Example: CV 2015-31 Rebar #5 07-09-2015

• A glossary of standard material names is included on page 2 of this document.

STRUCTURAL FABRICATION UNIT V092517

METALS LABORATORY SAMPLING GUIDANCE PAGE 2 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

7. Form 1923 must be securely attached to the sample using a method which would ensure the form remains with the sample and is readable when it arrives at the testing lab.

8. The method of transportation of the samples to the testing lab is at the discretion of the Contractor. The Contractor is responsible for all associated shipping costs and must determine shipment method in a manner deemed most appropriate. Non-MDOT employees dropping off samples must check in with security at the loading dock gate or south entrance of the C&T building prior to dropping samples off to the Metals Laboratory (room 122).

9. All samples must be consigned to:

MDOT Metals Lab C/o MDOT – Operations Field Services C&T Building – Mail Code E-020 8885 Ricks Road P.O. Box 30049 Lansing, MI 48909

10. Test results can typically be expected within 2 weeks after the sample arrives in the testing lab. Inquiries regarding test results may be directed to MDOT-MetalsLab@michigan.gov.

11. Test reports can be found in the project specific ProjectWise folder at the location shown below. Reports should not be placed in the fabrication inspection file or any other construction folder to avoid duplication: Region

o TSC Project Specific JN

• Construction o Field Services

Metals

STRUCTURAL FABRICATION UNIT V092517

METALS LABORATORY SAMPLING GUIDANCE PAGE 3 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

Glossary of Materials Tested by the MDOT Metals Laboratory Spec Reference Material Name *File Name 712.03.L Mechanical Splicing Splice 713.02.A Temporary Support Hanger Rod Hanger Rod 905.03 Rebar Rebar 905.06 Welded Wire Fabric Welded Wire 905.07 Prestressing Strand Prestressing Strand 906.07 High Strength Bolts HS Bolt 907.05 High Tensile Wire Tensile Wire 908.09.A Bridge Rail Post Rail Post 908.09.A Bridge Rail Plate Rail Plate 908.09.B Bridge Tube Railing Bridge Tube 908.09.C Railing Anchor Studs Anchor Stud 908.11.A Guardrail Beam Guardrail 908.12 Guardrail Post Guardrail Post 908.14 Anchor Base Plate Base Plate 908.14.B Sign Support and Light Standard Anchor Bolts Anchor Bolt 908.14.C Traffic Signal Strain Poles Strain Poles 908.14.D Anchor Bolts for Other Purposes Anchor Other 909.05.A.1 Corrugated Steel Pipe Corrugated 914.07 Dowel Bars Dowel 918.11.A Guy Wire Guy Wire 919.02.A Extruded Aluminum Sign Planks Extruded Aluminum 919.02.A.3 Aluminum Sheet Aluminum Sheet 919.07.A Cantilever Pipe Wall Tubing

* This is to be used as the naming convention to save the file.

STRUCTURAL FABRICATION UNIT V092517

METALS LABORATORY SAMPLING GUIDANCE PAGE 4 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

Samplemanager login instructions (you must have a login name and password): 1. Open up Sample ID and certification paperwork.

2. In Samplemanager, click on “MDOT/Sample Submission” and then pick sample type.

3. Click on “Contract” button to pull up list of job numbers to pick one.

4. Click on “Metals” radio button.

5. Click on pulldown labeled “Material” to pick type of material.

6. Click on “Spec Level” in order to pick size of sample.

7. If remarks are needed, enter them in the “Remarks” box.

8. If needed, under “Send Results To” you can pick a person and reason for sending results.

9. Click “OK” to go to the next page for sample details.

10. Click on “Date Sampled” to pick the dates sampled. You can type it in or pick from the calendar.

11. Pick the “Supplier” from the dropdown list.

12. Pick a location from the “Sampled From” list.

13. Put in a number for “Quantity Represented”, this usually comes from the Materials Source List.

14. If needed, pick “Quantity Units” from the list.

15. Pick the “Sampled By” person from the dropdown list.

16. Pick the “Submitted By” person from the dropdown list.

17. Fill in the zip tie tag number or deer tag number.

18. If applicable, pick the “Manufacturer” of the bolt, nut and washer.

19. Also fill out the lot and heat numbers of the bolt nut and washer. If one component is not present,

pick “Not Supplied” as the manufacturer name from the dropdown list. Use the certifications to

find lot and heat numbers.

20. If applicable, also attempt to identify the products markings and enter these. Common

manufacturer’s markings are listed following this page.

Note: You can view logged samples by expanding the “Metals Lab” icon at the left of Samplemanager.

From there you will see different folders showing the state of testing for the samples. Also, if a company or

employee needs to be added to Samplemanager or you have login questions, please email:

MDOT-MetalsLab@michigan.gov.

You can find Samplemanager training videos on the MDOT YouTube page or they are available via email

by request.

STRUCTURAL FABRICATION UNIT V092517

METALS LABORATORY SAMPLING GUIDANCE PAGE 5 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

Metals Product Markings Product, spec book

section and ASTM

Required markings Commonly seen

markings (and

manufacturer) Temporary Support Hanger Rod 712.02A, ASTM A193

15.1 See Specification A962/A962M. The grade symbol shall be as shown in Table 4. From Table 4: B7

Rebar 905.03, A706, A615

16.2 Each manufacturer shall identify the symbols of his marking system. For Grade 60 [420] bars, the marking shall be either the number 60 [4] or a single continuous longitudinal line through at least five spaces offset from the center of the bar. For Grade 80 [550] bars, the marking shall be either the number 80 [6] or three continuous longitudinal lines through at least five spaces.

See rebar markings list below (Appendix A). *If rebar is coated, then coating company is the manufacturer (ABC Coating Co.)

High Strength Bolts 906.07, ASTM F3125 grade A325

From Table 1: A325 5.1 At a minimum, all bolts shall be marked as required in Table 1. Marking shall be on the bolt head and may be raised or depressed at the manufacturer’s option. The marking shall be visible after coating. 5.2 Grade and Type marking, and the manufacturer’s mark shall be in separate and distinct locations on the head. Other markings, if used, such as private label distributor’s mark shall also be separate and distinct.

nA325 (Nucor) SLA325 (St. Louis Screw & Bolt) SLA325USA (St. Louis Screw & Bolt) GA325 (Gaffney Bolt Co.)

Nuts 906.07, 908.14, ASTM A563 gr. DH or ASTM A194 gr. 2H

14.5 Nuts made to the requirements of Grade DH shall be marked with the grade symbol, DH (or 2H) (Note 4) on one face. 14.7 In addition, nuts shall be marked with a symbol to identify the manufacturer or private label distributor, as appropriate.

DHU (Unytite) Dhn (Nucor) 2HU (Unytite) DHn (Nucor) TDC2H (Dyson) 2HDHD/N (Dyson) DMCDH (Dyson) FSADH/2H (Foundation Systems)

Washers 906.07, 908.14 ASTM F436

15.1 Washers shall be marked with a symbol, or other distinguishing marks, to identify the manufacturer or private label distributor, as appropriate.

TSIF436 (Technical Stamping) PF436 (Prestige Stamping) Ws (Wrought Washer)

STRUCTURAL FABRICATION UNIT V092517

METALS LABORATORY SAMPLING GUIDANCE PAGE 6 of 6

MICHIGAN DEPARTMENT OF TRANSPORTATION

Product, spec book

section and ASTM Required markings Commonly seen

markings (and

manufacturer) Anchor Bolts 908.14 ASTM F1554, grade 55 and 105

19.1 Unless otherwise specified (see Note 4), the end of each anchor bolt intended to project from the concrete shall be color coded to identify the grade as follows: Grade 36 Blue, grade 55 Yellow, grade 105 Red. S2. (not required by spec but informational) S2.1 The end of the anchor bolt intended to project from the concrete shall be steel die stamped with the manufacturer’s identification.

AVA 55 (AA Anchor Bolt) ASI 55 (Alton Steel) 27 (“XX”) (Gerdau Ameristeel) S41 (“XXX”) (Cardinal Fabricating) FSA105 (Foundation Systems)

Bridge Tube Railing 908.09B, ASTM A500 grade B

908.09B The manufacturer of the structural shape must identify the product as follows: 1. Place identification before galvanizing; 2. Include heat number or other code traceable to the heat number; 3. Include manufacturer’s unique identification code; 4. Place identification on only one section face; 5. Repeat identification a no more than 4-foot intervals; 6. Do not extend identification into the curved surface at corners of section; and 7. Do not place identification on side facing traffic or side opposite traffic.

BMT U65 (Bull Moose Tubing)

Railing Anchor Studs 908.09C, ASTM A449

16.1 Manufacturers Identification—All hex cap screws and bolts and one end of studs 3⁄8

in. and larger, and whenever feasible studs smaller than 3⁄8 in., shall be marked by the manufacturer with a unique identifier to identify the manufacturer or private label distributor, as appropriate. 16.2.1 Type 1 hex cap screws and bolts and one end of Type 1 studs 3⁄8 in. and larger, and whenever feasible studs smaller than 3⁄8 in., shall be marked “A449.”

BFA449 (Birmingham Fastener) SLA449 (St. Louis Screw & Bolt) JHBA449 (J.H. Botts)

Guardrail Beam 908.11A, AASHTO M180

11.1 Each beam element shall be identified by the following: Name or brand of manufacturer, identification symbols or code for heat, number and coating lot, AASHTO specification number, and class and type.

Michigan Department Of Transportation

1923 (05/13) SAMPLE

IDENTIFICATION Send sample to MDOT Construction Field Services

8885 Ricks Rd., Lansing, Michigan 48909 SEE INSTRUCTIONS BELOW

CONTROL SECTION

JOB NUMBER/PO NUMBER DATE SAMPLED

LAB NUMBER DATE RECEIVED

LAB: Aggregate AWI Concrete HMA Metals Soils/ Geotextiles

NAME OF MATERIAL

SOURCE / SUPPLIER / PIT NAME ADDRESS / PIT NUMBER

MANUFACTURER / PRODUCER ADDRESS

SAMPLED FROM

QUANTITY OF MATERIAL REPRESENTED BY SAMPLE

CONSIGNED TO ADDRESS

SAMPLED BY PHONE/EMAIL TITLE

SUBMITTED BY PHONE/EMAIL TITLE

INTENDED USE

SPECIFICATION SENDER’S SAMPLE I.D.

TYPE OF SAMPLE Acceptance Tested Stock Certification Verification # ______ New Source Information Q.A.

REMARKS

SEND RESULTS TO:

INSTRUCTIONS NOTE: This ID is the sole basis for identification and distribution of the report.

PLEASE BE ACCURATE CONTROL SECTION JOB NO. – As given or PURCHASE ORDER NO. – If applicable NAME OF MATERIAL – As shown in Standard Specifications – include dimensions for bolts, schedule # for conduit, cement type, etc. SOURCE – Contractor, supplier, producer, pit name, or location for naturally occurring materials ADDRESS – Address of source (city & state or county) SAMPLED FROM – Identifiable lot or batch number, and/or specific location, project site, source, etc. QUANTITY REPRESENTED – Number of pieces, feet, square feet, pounds, gallons, etc. CONSIGNED TO – If sampled at source other than project, state to whom and where the material is to be shipped SAMPLED BY – Name and Title if different from submitter INTENDED USE – State material’s use in general terms (e.g., SS-1h, CRS-2M, CSS-1h, etc. for bolts; geosynthetics for select backfill, embankment, 3ft. granular blanket, etc.) SPECIFICATION – Anchor Bolt, ASTM F1554, grade 55, 2012 Std. Spec. 908.14B Aluminum, ASTM B221, 2012 Std. Spec. 919.02A SENDERS SAMPLE ID – Lot, heat, roll, etc. number; sample dimensions; and any other details specific to the same (not sender’s name) REMARKS – State special tests to be run, if sample is rush or resample, and if results are to be phoned or emailed, state to whom (phone number or email)

File 302

Clear Form

Michigan Department Of Transportation

1923 (05/13) SAMPLE

IDENTIFICATION Send sample to MDOT Construction Field Services

8885 Ricks Rd., Lansing, Michigan 48909 SEE INSTRUCTIONS BELOW

CONTROL SECTION

JOB NUMBER/PO NUMBER DATE SAMPLED

LAB NUMBER DATE RECEIVED

LAB: Aggregate AWI Concrete HMA Metals Soils/ Geotextiles

NAME OF MATERIAL

SOURCE / SUPPLIER / PIT NAME ADDRESS / PIT NUMBER

MANUFACTURER / PRODUCER ADDRESS

SAMPLED FROM

QUANTITY OF MATERIAL REPRESENTED BY SAMPLE

CONSIGNED TO ADDRESS

SAMPLED BY PHONE/EMAIL TITLE

SUBMITTED BY PHONE/EMAIL TITLE

INTENDED USE

SPECIFICATION SENDER’S SAMPLE I.D.

TYPE OF SAMPLE Acceptance Tested Stock Certification Verification # ______ New Source Information Q.A.

REMARKS

SEND RESULTS TO:

INSTRUCTIONS NOTE: This ID is the sole basis for identification and distribution of the report.

PLEASE BE ACCURATE CONTROL SECTION JOB NO. – As given or PURCHASE ORDER NO. – If applicable NAME OF MATERIAL – As shown in Standard Specifications – include dimensions for bolts, schedule # for conduit, cement type, etc. SOURCE – Contractor, supplier, producer, pit name, or location for naturally occurring materials ADDRESS – Address of source (city & state or county) SAMPLED FROM – Identifiable lot or batch number, and/or specific location, project site, source, etc. QUANTITY REPRESENTED – Number of pieces, feet, square feet, pounds, gallons, etc. CONSIGNED TO – If sampled at source other than project, state to whom and where the material is to be shipped SAMPLED BY – Name and Title if different from submitter INTENDED USE – State material’s use in general terms (e.g., SS-1h, CRS-2M, CSS-1h, etc. for bolts; geosynthetics for select backfill, embankment, 3ft. granular blanket, etc.) SPECIFICATION – Anchor Bolt, ASTM F1554, grade 55, 2012 Std. Spec. 908.14B Aluminum, ASTM B221, 2012 Std. Spec. 919.02A SENDERS SAMPLE ID – Lot, heat, roll, etc. number; sample dimensions; and any other details specific to the same (not sender’s name) REMARKS – State special tests to be run, if sample is rush or resample, and if results are to be phoned or emailed, state to whom (phone number or email)

12345

123456 Oct 18, 2017

17A

Edward C. Levy Co. Aggregates/Ray Road 275 Ray Rd. Oxford, MI. 48371, 63-115

Structural Precast Concrete Fabrication Plant

Structural Precast Concrete Fabrication Plant

1000tons

person qualified to pull sample

person dropping off sample to lab

Coarse Aggregate used in fabrication of prestressed concrete beams

MTM 109, MTM 108, *MTM 110

natural aggregate must meet the physical properties of 6AA

papanekd@michigan.gov

Clear Form

EXAMPLE

6

STRUCTURAL FABRICATION UNIT V110515

E-CONSTRUCTION PROCESS PAGE 1 of 2

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication E-Construction Process Description The purpose of this document is to provide the Michigan Department of Transportation’s Structural Fabrication Unit with a process for implementing e-construction for structural fabrication inspection record retention. E-construction requires all fabrication inspection records to be provided by the contractor to MDOT in Adobe portable document format (PDF) files and for MDOT to store the records in ProjectWise.

1. Receiving Fabricator DocumentsThe fabricator must provide MDOT with electronic files in Adobe PDF. Documents are provided toMDOT’s quality assurance inspector (QAI) in a timely manner (within 24 hours after the datecovered by the report for structural concrete) for their review prior to stamping structural elementsapproved for use.

2. Creating Quality Assurance DocumentsThe QAI must convert all QA documents into PDF files. If fillable forms are used then the files mustbe “flattened” to embed all form fields, comments, and any other type of annotation into thepage content prior to combining the PDF files to prevent the fields in similar forms from merging.The stamped Bill of Lading must be scanned by the QAI for inclusion in the final documentationpackage. The paper copy can be discarded after scanning.

3. Assembling and Bookmarking Fabrication Inspection FilesThe QAI combines, arranges, and bookmarks all project QA and QC documents in one PDFfabrication inspection file using Adobe Acrobat. See MDOT document titled Structural FabricationBookmarking Template for instructions on bookmarking.

4. Sending Fabrication Inspection File to MDOTQAI sends the fabrication inspection file to the MDOT Structural Fabrication Unit using a file transferprotocol (FTP) program. The MDOT Structural Fabrication Unit randomly audits fabricationinspection files and follows up with QAI to address any deficiencies.

5. Placing Fabrication Inspection Files into ProjectWiseThe MDOT Structural Fabrication Unit places the fabrication inspection file into ProjectWise at thefollowing location (in red) and assigns project attributes to the file:

Xxxxx Regiono Xxxxx TSC or Region Projects

JN XXXXXX• Construction

o Field Services Structural Fabrication

STRUCTURAL FABRICATION UNIT V110515

E-CONSTRUCTION PROCESS PAGE 2 of 2

MICHIGAN DEPARTMENT OF TRANSPORTATION

6. MDOT Fabrication Inspection MemorandumThe MDOT Structural Fabrication Unit works with the MDOT Structure Technical SectionAdministrative Assistant to prepare the memorandum (memo) for the MDOT Structural FabricationEngineer’s digital signature. The assistant places a copy of the signed memo into ProjectWise atthe following location (in red below) and assigns project attributes to the files for the projectoffice’s records:

Xxxxx Regiono Xxxxx TSC or Region Projects

JN XXXXXX• Construction

o Field Services Structural Fabrication

A copy of the signed memo is also placed into the Structural Fabrication Unit’s ProjectWise storage folder for historical record.

7. Notification of Fabrication Inspection CompletionThe MDOT Structure Technical Section Administrative Assistant emails the ProjectWise link to thestructural fabrication folder (in red below) to the individuals listed on the fabrication inspectionmemo:

Xxxxx Regiono Xxxxx TSC or Region Projects

JN XXXXXX• Construction

o Field Services Structural Fabrication

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STRUCTURAL FABRICATION UNIT V110817

BOOKMARKING TEMPLATE PAGE 1 of 1

MICHIGAN DEPARTMENT OF TRANSPORTATION

Structural Fabrication Bookmarking Template Description Use this table of contents template for bookmarking final e-construction project documentation files. This document is both the instructions for assembling a fabrication inspection file and the template for bookmarking the file. It contains the bookmarks for structural concrete (prestressed and non-prestressed) and structural steel so the bookmarks not needed must be removed.

Inspection File Assembly Instructions 1. Assemble the inspection file by inserting QC and QA files in PDF format into this document.

2. Using this document as the first page in the inspection file, arrange the files using thebookmarks shown in this document.

3. Click on the Bookmarks Tab to display the default bookmarks. Scroll through your documentand locate the page (or first page of a section with multiple pages) that corresponds to thebookmark. Highlight the corresponding bookmark in the list, single right click, and select SetDestination. Repeat for each applicable bookmark until every section of the inspection file isbookmarked.

4. Delete any bookmarks that are not needed for your particular project.

5. Delete this document after the file is complete as it is no longer needed in the file.

6. Once document is complete, electronically sign the Inspector’s Project Folder Checklist.

File Naming Convention: “SN-CS-JN Element Inspected Date” • SN: Structure Number

• CS: MDOT Control Section

• JN: MDOT Job Number

• Element Inspected: Bearing-type, high mast tower, modular expansion joint, sign structure-type, structural steel-type, culvert-type, prestressed beam-type, precast bridge element-type, sound wall, spun concrete pole, etc.

• Date: Date file is completed

Examples of this naming convention are shown below: • B03-82117-112703 Structural Steel-Pin & Hanger 093013• W01-73022-156776 Sound Wall 111716• S17-09031-121776 Bearing-Disc 021514• C07-11015-126765 Culvert-Three Sided 070416

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STATE OF MICHIGAN

DEPARTMENT OF TRANSPORTATIONLANSING

Effects of Debonded Strands on the

Production and Performance of Prestressed Concrete Beams

will not

•

•

To Whom It May Concern Page 2 of 2 January 14, 2014

Matthew J. FilcekDigitally signed by Matthew J. Filcek DN: cn=Matthew J. Filcek, o=Michigan Department of Transportation, ou=Structural Fabrication Engineer, email=filcekm@michigan.gov, c=US Date: 2014.01.15 09:49:47 -05'00'

STRAND DEBONDING

a. Description.

b. Materials.

c. Construction.

d. Measurement and Payment.

STATE OF MICHIGAN

DEPARTMENT OF TRANSPORTATIONLANSING

••

••••

••••

Matthew J. FilcekDigitally signed by Matthew J. Filcek DN: cn=Matthew J. Filcek, o=Michigan Department of Transportation, ou=Structural Fabrication Engineer, email=filcekm@michigan.gov, c=US Date: 2014.01.15 09:43:34 -05'00'

RICK SNYDERGOVERNOR

STATE OF MICHIGAN

DEPARTMENT OF TRANSPORTATIONLANSING

KIRK T. STEUDLEDIRECTOR

BUREAU OF FIELD SERVICES • CONSTRUCTION & TECHNOLOGY BUILDING • P.O. BOX 30049 • LANSING, MICHIGAN 48917www.michigan.gov • (517)-322-1087

March 13, 2014

To Whom It May Concern:

The Michigan Department of Transportation (MDOT) is requiring a Material Source List (MSL) to be submitted for all MDOT and Local Agency projects with structural precast concrete elements. This requirement is effective for projects Let after April 1, 2014 and applies to all elements that require fabrication inspection as the basis of acceptance per the MDOT Materials Source Guide(MSG) or as determined by the Project Engineer. The Project Engineer will notify the contractor if fabrication inspection will be performed on elements not explicitly stated in the MSG so a MSL can be submitted.

The contractor must provide a completed and signed MSL (MDOT Form 0501) to the ProjectEngineer in accordance with subsection 105.01 of the Standard Specifications for Construction at or prior to the pre-construction meeting. The Project Engineer will forward the MSL for MDOT projects to the Structural Fabrication Unit to review and use during inspection. Information on completing the MSL can be found in the MDOT Materials Quality Assurance Procedures Manual (MQAP) chapter 1.04. The MQAP is a contract document per subsection 106.01 of the 2012 MDOT Standard Specifications for Construction and can be found on MDOT’s website using the following link:

http://www.michigan.gov/mdot/0,4616,7-151-9622_11044_11367-207980--,00.html

Historically, MDOT has not required fabricators to complete the MSL for materials incorporatedinto structural precast concrete elements; however, the Department’s goal is to reduce material nonconformance issues. MDOT encourages all fabricators to contact the Structural Fabrication Unit if they have any questions on completing the MSL or material acceptance.

Please contact me by phone at (517) 322-5709 or email at filcekm@michigan.gov withquestions or concerns. Thank you for your patience and understanding on this matter.

Sincerely,

Matthew J. Filcek, P.E.Structural Fabrication EngineerBridge Field Services – Structure Technical Section

Enclosure

MJF:jt

cc: M. Chynoweth J. Gutting P. Jansson D. PapanekJ. Weiler CRAM MITA MMLStructural Precast Concrete FabricatorsD. Frank, PCI – Director of Quality Control

Matthew J. FilcekDigitally signed by Matthew J. Filcek DN: cn=Matthew J. Filcek, o=Michigan Department of Transportion, ou=Bridge Field Services - Structure Technical Section, email=filcekm@michigan.gov, c=US Reason: I have reviewed this document Location: MDOT CFS Building Date: 2014.03.13 19:09:12 -04'00'

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RICK SNYDERGOVERNOR

STATE OF MICHIGAN

DEPARTMENT OF TRANSPORTATIONLANSING

KIRK T. STEUDLEDIRECTOR

BUREAU OF FIELD SERVICES • CONSTRUCTION & TECHNOLOGY BUILDING • P.O. BOX 30049 • LANSING, MICHIGAN 48917www.michigan.gov • (517)-322-1087

January 0, 2015

To Whom It May Concern:

It has recently come to the attention of the Michigan Department of Transportation (MDOT) that structural precast concrete fabricators have been providing sole plates for prestressed concrete beams shorter than what is detailed and required in the contract plans. In some cases, the shorter sole plates were approved via a Request for Information (RFI), email correspondence, or a note in the shop drawings. MDOT has discussed this issue with several structural fabricators that perform work for MDOT and their reasoning for providing the shorter sole plates is to avoid additional machining required to get the sole plates to properly fit-up in the forms. Most forms are fabricated with a radius in the bottom soffit corners and the sole plate edge would need to bechamfered to accommodate this radius (see attached MDOT Bridge Design Guides 8.43.01 and 8.43.01A). After thoroughly reviewing the design intent and contract details, MDOT’s position is that full-width sole plates are required when detailed in the contract plans.

MDOT currently designs and details sole plates for prestressed concrete beams when the geometry warrants their use. Over the years, MDOT has noted excessive spalling at the bottom ends of prestressed concrete beams without sole plates. Spalling typically occurs after the side forms have been removed and the strands are detensioned. The large eccentric compressive force from the de-tensioning operation creates large horizontal and vertical shearing forces at the beam ends from the friction between the beam and formwork and a rotation about the beam ends from the ensuring positive deflection (camber). Spalling is more severe on skewed beam ends since the rotation occurs at the tip of the skewed beam end resulting in a point load versus evenly along the entire beam end for beams with no skew. Beams detailed with sole plates do not typically experience beam end spalling since they are armored by the sole plate to resist the shear forces and point loads. To reduce the number of occurrences where the beam ends spall and the ensuing beam repairs, MDOT is requiring all prestressed concrete beams to be designed, detailed, and fabricated with sole plates. This should be effective starting with the March 2015 Letting. Fabricators are welcome to propose the addition of sole plates on current projects at no additional cost to MDOT.

TO WHOM IT MAY CONCERN Page 2 of 2 January 0, 2015

Please contact me by phone at (517) 322-5709 or email at filcekm@michigan.gov with questions or concerns. Thank you for your patience and understanding during this transition.

Sincerely,

Matthew J. Filcek, P.E. Operations Field Services Structural Fabrication Engineer

MJF: jt

Enclosure

cc: M. Chynoweth J. Gutting D. Juntunen P. Jansson D. Papanek J. WeilerACEC CRAM MITA MML Structural Precast Concrete Fabricators

Matthew J. Filcek

Digitally signed by Matthew J. Filcek DN: cn=Matthew J. Filcek, o=Michigan Department of Transportion, ou=Bridge Field Services - Structure Technical Section, email=filcekm@michigan.gov, c=US Reason: I have reviewed this document Location: MDOT CFS Building Date: 2015.01.30 15:04:17 -05'00'

Note sole plateextends to side ofbeam (typical).

Note sole plateextends to side ofbeam (typical).

RICK SNYDERGOVERNOR

STATE OF MICHIGAN

DEPARTMENT OF TRANSPORTATIONLANSING

KIRK T. STEUDLEDIRECTOR

BUREAU OF FIELD SERVICES • CONSTRUCTION & TECHNOLOGY BUILDING • P.O. BOX 30049 • LANSING, MICHIGAN 48917www.michigan.gov • (517)-322-1087

December 16, 2015

To Whom It May Concern:

It has recently come to the attention of the Michigan Department of Transportation (MDOT) that some structural precast concrete fabricators working on MDOT projects may not be properly handling and storing epoxy coated reinforcing steel. Subsection 905.03.C of the MDOT Standard Specifications for Construction (as modified by supplemental specification 12SS-001A-10, Errata to the 2012 Standard Specifications) requires epoxy coated reinforcement to meet the requirements of ASTM A 775. Below is an excerpt of clause 15 of ASTM A775-07b(2014):

15 | Handling and Identification

15.1 All systems for handling coated steel reinforcing bars shall have padded contact areas. All bundling bands shall be padded or suitable banding shall be used to prevent damage to the coating. All bundles of coated steel reinforcing bars shall be lifted with a strong back, spreader bar, multiple supports, or a platform bridge to prevent bar-to-bar abrasion from sags in the bundles of coated steel reinforcing bars. The bars or bundles shall not be dropped or dragged.

15.2 If circumstances require storing coated steel reinforcing bars outdoors for more than two months, protective storage measures shall be implemented to protect the material from sunlight, salt spray and weather exposure. If the manufacturer stores coated steel reinforcing bars outdoors without protective covering, the date on which the coated bars are placed outdoors shall be recorded on the identification tag on the bundled steel. Coated steel reinforcing bars, whether individual bars or bundles of bars, or both, shall be covered with opaque polyethylene sheeting or other suitable opaque protective material. For stacked bundles, the protective covering shall be draped around the perimeter of the stack. The covering shall be secured adequately, and allow for air circulation around the bars to minimize condensation under the covering.

15.3 Coated steel reinforcing bars, whether individual bars or bundles of bars, or both, shall be stored off the ground on protective cribbing.

15.4 The identification of all steel reinforcing bars shall be maintained throughout the coating and fabrication processes to the point of shipment.

The provision for two-months of exposure stated in ASTM A775 was developed from testing conducted by C-SHRP where bars were left exposed and then tested. The Epoxy Interest Group of the Concrete Reinforcing Steel Institute (CRSI) recommends epoxy-coated reinforcing

TO WHOM IT MAY CONCERNPage 2 of 2December 16, 2015

bars be covered if outdoor storage is to exceed 30 days. Fusion-bonded epoxy coatings mayundergo surface discoloration and chalking from exposure, which may require repair coating damage or localized corrosion. Epoxy coatings that exceed the maximum two-month exposure limit per ASTM A775 are subject to careful inspection by the Contractor prior to incorporationinto the project, repair of coating damage and localized corrosion, and subject to pricereductions per MDOT’s Structural Fabrication Nonconformance Policy.

Please contact me by phone at (517) 322-5709 or email at filcekm@michigan.gov with questions or concerns.

Sincerely,

Matthew J. Filcek, P.E.Operations Field ServicesStructural Fabrication Engineer

MJF:mjf

cc: C. RogersJ. GuttingP. JanssonD. PapanekJ. WeilerACECCRAMMITAMMLStructural Precast Concrete Fabricators

Matthew J. Filcek

Digitally signed by Matthew J. Filcek DN: cn=Matthew J. Filcek, o=Michigan Department of Transportion, ou=Bridge Field Services - Structure Technical Section, email=filcekm@michigan.gov, c=US Location: MDOT CFS Building Date: 2015.12.16 13:57:45 -05'00'

RICK SNYDERGOVERNOR

STATE OF MICHIGAN

DEPARTMENT OF TRANSPORTATIONLANSING

KIRK T. STEUDLEDIRECTOR

BUREAU OF FIELD SERVICES • CONSTRUCTION & TECHNOLOGY BUILDING • P.O. BOX 30049 • LANSING, MICHIGAN 48917www.michigan.gov • (517)-322-1087

December 17, 2015

To Whom It May Concern:

Just a reminder that work progress test specimens are required to be match cured in the same manner as the product in accordance with subsection c.5.F of the MDOT Special Provision for Quality Control and Acceptance of Portland Cement Concrete (12SP604G-05). The purpose of the match curing requirement is to ensure the work progress test specimens accurately represent the strength of the product at the time of testing. Listed below are common structural precast concrete work progress strength requirements:

• Form removal;• Release of prestressing;• Handling and shipping; and• Acceptance testing

MDOT can work with any fabricator that has questions on what is required to properly match cure work progress test specimens to the product. Please contact me by phone at (517) 322-5709 or email at filcekm@michigan.gov with questions or concerns.

Sincerely,

Matthew J. Filcek, P.E.Operations Field ServicesStructural Fabrication Engineer

MJF:mjf

cc: C. Rogers ACECJ. Gutting CRAMP. Jansson MITAD. Papanek MMLJ. Weiler Structural Precast Concrete Fabricators

Matthew J. Filcek

Digitally signed by Matthew J. Filcek DN: cn=Matthew J. Filcek, o=Michigan Department of Transportion, ou=Bridge Field Services - Structure Technical Section, email=filcekm@michigan.gov, c=US Location: MDOT CFS Building Date: 2015.12.17 09:44:56 -05'00'

RICK SNYDERGOVERNOR

STATE OF MICHIGAN

DEPARTMENT OF TRANSPORTATIONLANSING

KIRK T. STEUDLEDIRECTOR

CONSTRUCTION & TECHNOLOGY BUILDING • P.O. BOX 30049 • LANSING, MICHIGAN 48917www.michigan.gov • (517)-322-1087

September 12, 2017

To Whom It May Concern:

It has recently come to the attention of the Michigan Department of Transportation (MDOT) that some welded sole plates for prestressed concrete beams are not meeting project requirements. MDOT requires structural precast concrete plants to be certified by either the Precast/Prestressed Concrete Institute (PCI) or National Precast Concrete Association (NPCA) depending on the type of work being performed. The American Concrete Pipe Association (ACPA) is considered an approved equal to NPCA for concrete culverts. PCI and NPCA state structural steel component welding requirements that must be followed by the Contractor. Below are excerpts from PCI and NPCA on structural steel welding:

• The first paragraph of subsection 2.3.1 of PCI MNL-116, 1999, 4th Ed. states, “Welding of steel plates, angles, and other shapes shall be in accordance with AWS D1.1. Welders qualified in accordance with AWS D1.1 and D1.4 shall perform all welds. Qualified engineers or quality control personnel shall write welding procedure specifications (WPS) for structural steel”. See PCI MNL-116 the additional information.

• Subsection 4.2.3 of NPCA, 2016, 12th Ed. States, “Welding of steel assemblies which are cast into or attached to precast concrete products shall be performed in accordance with American Welding Society D1.1, Structural Welding Code – Structural Steel”.

Please review your welding procedures and ensure structural steel welding required for structural precast concrete pay items meets the project requirements. Additionally, it is important to note that MDOT does not permit welding of reinforcing steel unless approved by the engineer due to the difficulty with obtaining sound welds. A detailed welding plan would be required to be submitted for MDOT’s Structural Fabrication Unit’s review prior to approval.

Please contact me by phone at 517-322-5709 or email at filcekm@michigan.gov with questions or concerns.

Sincerely,

Matthew J. Filcek, P.E.Bureau of Bridges and StructuresStructural Fabrication Engineer

cc: M. ChynowethM. BellgowanP. JanssonD. Papanek

J. WeilerACECCRAMMITA

MMLStructural Precast Concrete Fabricators

Matthew J Filcek, PE

Digitally signed by Matthew J Filcek, PE DN: cn=Matthew J Filcek, PE, o=Michigan Department of Transportation, ou=Structural Fabrication Unit, email=filcekm@michigan.gov, c=US Date: 2017.09.12 13:55:05 -04'00'

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STRUCTURAL FABRICATION UNIT

V111417

COMMENTARY FOR PROJECT FOLDER CHECKLIST

PAGE 1 of 8

MICHIGAN DEPARTMENT OF TRANSPORTATION

Commentary for Project Folder Checklist Description The Inspector’s Project Folder Checklist is used to aid in the gathering and combining of fabrication documents for submittal to the Structural Fabrication Unit upon completion of fabrication. This document is intended to provide the inspector with additional information regarding different materials involved in precast concrete fabrication.

Fabrication work should not begin until all certifications, calibrations, materials (including coatings) and test reports are verified and visually inspected, stamped approved shop drawings are in hand and all required steel meets "Buy America" requirements. Notify MDOT-Structural Fabrication Unit (structural precast concrete specialist), via email, if there are any deficiencies at the time of the first concrete pour (when materials are incorporated into the fabricated elements). Be sure to allow enough time at the fabrication facility prior to fabrication to go through the entire checklist. The checklist is not all inclusive: there may be specifications of materials on the shop drawing or items in a special provision that may not be covered on the checklist. Be sure to get all required documentation and check what is given to you.

It is the responsibility of the inspector to know the basis of acceptance for all materials incorporated into the project. The information in this document may have changed after this document was written. If you have any questions the Structural Precast Concrete Fabrication Specialist is one resource you can get answers.

I. Forms/Certifications/Calibrations and other Non-Material Items Materials that have Approved Manufacturer listed as the “Basis of Acceptance” in the Materials Acceptance Requirements Table in chapter 7 of the Material Quality Assurance Procedures (MQAP) manual and in the Materials Source Guide (MSG) must have a General Certification accompany the material per the requirements of section 3.01.03 of the MQAP Manual (Suppliers and Contractors can write the General Certification). In addition, the quantity shipped is required on the certification. This is listed in section 3.02.04 of the MQAP manual. Some examples are steel reinforcement, cement, precast concrete box sections, precast concrete 3 sided or arch.

I have attached a link to our forms page for each form. Always be sure to use the most current forms. See the appropriate section of the MQAP for a thorough explanation of the forms.

A. Project Folder Checklist Form 2001

B. Shop Inspection Report Form 5617

C. Sample Identification Form 1923

D. Strand Tensioning Report (0513) Form 0513

E. Bar Reinforcement Report Form 1985

STRUCTURAL FABRICATION UNIT

V111417

COMMENTARY FOR PROJECT FOLDER CHECKLIST

PAGE 2 of 8

MICHIGAN DEPARTMENT OF TRANSPORTATION

F. Pre and Post Pour Inspection Checklist Form 5616

G. Field and Lab Test Report (forms 0590 and 0551 have been merged) Form 0590

H. Repair Observation Report Form 1981

I. Material Source List Form 0501 This form is required to be filled out by the fabricator. The fabricator submits the form to MDOT, MDOT/QAI then fills out the basis of acceptance requirements for the materials, and then distributes the completed form to the fabricator (the construction office must be copied if materials will need to be tested by the construction office –example: mechanical reinforcement splices). QAI should notify MDOT-Structural Fabrication Unit if there is any required acceptance testing needed.

J. Certifications 1. Plant Certification

a. Prestressed Concrete Institute (PCI) b. National Precast Concrete Association (NPCA)

2. Approved Manufacturers General Certification a. See 3.01 in the MDOT MQAP Manual for General Certification requirements b. Precast Concrete Box Sections (909.04D) c. Precast Concrete Tree-Sided Arch Culverts (909.04G)

3. QC Certifications a. ACI or MCA Level I or Level II certification (≤ 3 yrs.) for concrete testing b. MCA Level II certification for anyone making concrete mix adjustments c. PCI Level II certification, temporary cards are not acceptable certifications d. PCI Level III certification, temporary cards are not acceptable certifications e. ACI, Concrete Strength Testing Technician

4. QA Certifications a. ACI or MCA Level I Certification (≤ 3 yrs.) b. PCI Level II Certification (≤ 5 yrs.), required for any prestressing QA inspection c. MCAT Certification (≤ 5 yrs.)

K. Calibrations 1. Compression Testing Machine

a. Calibration Certificate (≤ 1 yr.)

2. Stressing Jacks a. Calibration Certificate (≤ 1 yr.)

3. Air Meter a. Calibration (≤ 3 months) b. QA & QC air meter calibration sheet

4. Scales used for Aggregate and Cement a. Calibration (≤ 6 months)

STRUCTURAL FABRICATION UNIT

V111417

COMMENTARY FOR PROJECT FOLDER CHECKLIST

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MICHIGAN DEPARTMENT OF TRANSPORTATION

b. Cement & Aggregates, measured on separate scales, follow 601.03.B.1. c. Cement, cement and aggregates measured cumulatively, follow 601.03.A.2.

5. Volumetric Admixture Dispensers, Water Batching Devices (incl. water meters) a. Calibration (≤ 90 days) b. Accuracy follow 601.03.B.5. c. If water is batched by weight then scales calibration ≤ 6 months is acceptable.

6. Mixers, ensure have an attached metal plate showing the following information: a. Serial number b. Maximum mixing capacity in volume of mixed concrete c. Mixing speed of the drum d. Maximum agitating capacity in volume of mixed concrete, or on truck mixers and

agitators, the agitating speed of the drum or blades.

Note: frequency of scales checks can be less than the above if it is published in documents from the plant certification organization (NPCA and PCI).

L. QC Documentation Documentation is required to be given to the Engineer within 24 hours of the date covered by the record in a format acceptable to the Engineer. The list below may not be all inclusive.

1. Fresh Concrete Test Reports 2. Tensioning Report 3. Cylinder Test Reports 4. Curing Charts/Graph 5. Pre and Post Pour Checklists

M. Shop Drawings 1. The shop drawings must have an approval stamp on all sheets. 2. All revised sheets must have an approval stamp. 3. The stamp must have a name and date. It can either be an MDOT stamp or a stamp

that reads “Approved for MDOT”. 4. Design Build Projects will have a company name on the approval stamp on the shop

drawing sheets and a stamp from MDOT “Released for Construction”

N. Stamped Bill of Ladings Stamped bill of ladings are required for all projects with full-time inspection. Before stamping the BOL’s the QA inspector should verify that the element mark listed on the BOL is unique to a specific piece; there should not be any elements listed using the same element mark. If there are any unstamped BOL’s, put them in the project folder and note why they are not stamped “Approved for Use”, then sign and date.

II. Concrete A. Fabricator Batched Concrete

1. Fabricator Mix Design

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MICHIGAN DEPARTMENT OF TRANSPORTATION

a. Cement (Approved Manufacturer) b. Air entraining admixtures (QPL)(Gen Cert) c. Water reducing and water reducing retarding admixtures (QPL)(Gen Cert) d. Concrete accelerators (QPL & General Certification) e. Fly ash and other pozzolanic admixtures (Approved Manufacturer) f. Ground granulated blast furnace slag (Approved Manufacturer) g. Verify batch to discharge times do not exceed allowable times. The time allowed

between charging mixer and placing concrete is in table 601-1 of the 2012 Standard Specifications for Construction

B. RediMix Plant Concrete 1. NRMCA Certification (≤ 2 yrs.) 2. Concrete Tickets

a. All tickets must contain batch weights. b. QAI Collects and signs all tickets when the trucks arrive. c. Verify batch discharge times do not exceed allowable times (table 601-1 of the SSC)

3. Weekly Summary of Cert. Concrete from Central Mix and Transit Mix Plants Form 1155 The 1155 is filled out and signed by a representative from the redimix plant. It is needed for all concrete pours for the project. The plant needs to know MDOT control section, job number and construction engineer name. The fabricator should be getting the information to the redimix plant, and if they don’t have the information then they can get it from the bridge contractor or they can look it up themselves. Construction Contract Inquiry (select General Contract Level Information and enter the project number). There is no need to check all materials for the concrete. Verify that the materials not listed on the 1155 meet the basis of acceptance. They are listed in the mix design that is required to be given by the fabricator.

III. Fine Aggregates Aggregates should be stockpiled at the fabrication facility so the stockpile is easily identifiable. Multiple piles with different aggregates not identified are not acceptable.

A. Prequalified Aggregate Source 1. Aggregate Tickets

a. Collect signed ticket with a certified statement from the prequalified source. b. Requirements of aggregate ticket can be found in Chapter 3 (MDOT Aggregate

Supplier Program) on page 32 of the Procedures for Aggregate Inspection MDOT Procedures for Aggregate Inspection

2. Testing Verify that a quality assurance (QA) test or an acceptance test has been completed by MDOT on the material (Form 1900 or 1901).

a. The sampling schedule for MDOT Acceptance tests set up at the fabrication plant by the Structural Fabrication Unit are 1 test per year on every aggregate being used at every fabrication location. This will be pulled at the beginning of the construction year to avoid any project delays.

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MICHIGAN DEPARTMENT OF TRANSPORTATION

b. If the inspector notices a stockpile management problem (segregated aggregates, contaminated aggregates) at the fabricator location, notify MDOT so additional testing (acceptance testing) can be set-up.

3. Alkali Silica Reactivity Test Alkali Silica Reactivity test, In addition to collecting the ASR information, you need to check that documentation submitted is acceptable (not required for fine aggregate used in R-2 mortar). ASR test results are valid for 2 years from completion of testing. If the ASR test expires after fabrication starts then the fabricator must stop incorporating the material until new acceptable test data is provided.

• The QAI must verify that an applicable ASTM has been submitted and results are

current. Check the special provision “QC & Acceptance of…”

B. Non-prequalified Aggregate Source 1. Acceptance Test

a. Required (1 test represents 1,000 tons). This needs to be done before the material is incorporated into the work.

2. If the inspector notices a stockpile management problem (segregated aggregates, contaminated aggregates) at the fabricator location then notify MDOT so additional testing (acceptance testing) can be set up.

3. Alkali Silica Reactivity Test In addition to collecting the ASR information, you need to check that what is submitted is acceptable. ASR test results are valid for 2 years from completion of testing.

• The QAI must verify that an applicable ASTM has been submitted and results are

current. Check the special provision “QC & Acceptance of…”

IV. Coarse Aggregates Aggregates should be stockpiled at the fabrication facility so the stockpile is easily identifiable. Multiple piles with different aggregates not identified are not acceptable.

A. Prequalified Aggregate Source 1. Aggregate Tickets

a. Collect signed ticket with a certified statement from the prequalified source. b. Requirements of aggregate ticket can be found in Chapter 3 (MDOT Aggregate Supplier

Program) on page 32 of the Procedures for Aggregate Inspection MDOT Procedures for Aggregate Inspection

2. Testing Verify that a quality assurance (QA) test or acceptance test has been completed by MDOT on the material (Form 1900 or 1901).

a. The sampling schedule for MDOT Acceptance tests set up at the fabrication plant by the Structural Fabrication Unit are 1 test per year on every aggregate being used at every

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fabrication location. This will be pulled at the beginning of the construction year to avoid any project delays.

b. If the inspector notices a stockpile management problem (segregated aggregates, contaminated aggregates) at the fabricator location, notify MDOT so additional testing (acceptance testing) can be set-up.

3. Alkali Silica Reactivity Test In addition to collecting the ASR information, you need to check that what is submitted is acceptable. ASR test results are valid for 2 years from completion of testing. If the ASR test expires after fabrication starts then the fabricator must stop incorporating the material until new acceptable test data is provided. This is not needed for any coarse aggregates sources from within the state of Michigan.

• The QAI must verify that an applicable ASTM has been submitted and results are

current. Check the special provision “QC & Acceptance of…”

4. Freeze Thaw Dilation (≤ 5 yrs.) a. Prestressed Elements: 0.010 percent per 100 cycles b. Concrete Spun Poles: 0.030 percent per 100 cycles c. Non-Prestressed Elements

• 0.030 percent per 100 cycles or less for box culverts and 3-sided culverts • 0.067 percent per 100 cycles or less for all others • A special provision may change the F.T. requirement (MSE walls requires 0.010 percent

per 100 cycles or less

B. Non-Prequalified Aggregate Source 1. Acceptance Test

a. Required (1 test represents 1,000 tons). This needs to be done before the material is incorporated into the work.

2. Alkali Silica Reactivity Test In addition to collecting the ASR information, you need to check that what is submitted is acceptable. ASR test results are valid for 2 years from completion of testing. If the ASR test expires after fabrication starts then the fabricator must stop incorporating the material until new acceptable test data is provided. This is not needed for any coarse aggregates sources from within the state of Michigan.

• The QAI must verify that an applicable ASTM has been submitted and results are

current. Check the special provision “QC & Acceptance of…”

3. Freeze Thaw Dilation (≤ 5 yrs.) a. Prestressed Beams: 0.010 percent per 100 cycles b. Concrete Spun Poles: 0.030 percent per 100 cycles c. Non-Prestressed Elements

• 0.030 percent per 100 cycles or less for box culverts and 3-sided culverts • 0.067 percent per 100 cycles or less for all others • A special provision may change the F.T. requirement (MSE walls requires 0.010 percent

per 100 cycles or less.

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4. Stockpile Management a. If the inspector notices a stockpile management problem (segregated aggregates,

contaminated aggregates) at the fabricator location then notify MDOT so additional testing (QA sample) can be set up.

V. Stockpiled Aggregates (Aggregate ticket is over 1 year old). In addition to Coarse and Fine Aggregate requirements stated above, an acceptance test needs to be run to verify that the material is still acceptable every year.

VI. All Steel (basis of acceptance)

A. Buy America The Buy America requirements for Structural Precast Concrete materials is summarized in the document “Structural Fabrication Buy America Guidance Document” located in the Structural Precast Concrete QAI Manual and the Structural Precast Concrete Fabrication Portfolio found in the Structure Technical Section website.

Structure Technical Section

Buy America Compliance Listing for Approved Manufacturers, Qualified Products List and Tested Stock Suppliers

Buy America-Compliance Listing The inspector is required to verify that all processes for steel that is required to meet “Buy America” requirements are checked. If you identify a QPL, Approved Manufacturer or Tested Stock Supplier listed on the “Buy America Compliance Listing document” list the material name, its source and the rating given on the site, then list it on the Shop Inspection of Precast Concrete (Form 5617). If the rating given is a BA- we require the fabricator to compile the invoice cost of the “non-USA made steel” to be submitted for acceptance by the Construction Engineer. No Buy America Step Certs are required of a BA+ manufacturer. Steel Materials 1-6 are required to be step certified if not from a BA+ manufacturer.

1. Strand for Prestressed Concrete a. Approved MFR, General Cert, and Test Data Certification: 0.6" Dia. ASTM A416 Grade 270

low relaxation with load elongation curve.

2. Steel Reinforcement a. Epoxy coating, QPL and General Cert. b. Steel reinforcement, Approved MFR and General Cert. c. Coating Company, Approved MFR and General Cert. The coating company needs to

provide a written certification that the coated reinforcing bars were cleaned, coated, and tested in accordance with ASTM A775 (see SSC 905.03C.3.).

3. Welded Steel Wire Reinforcement a. Approved MFR and General Cert.

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4. Steel Sole Plates a. Step Certification for Buy America: See Shop Drawings for requirements b. Shear Developers or Studs: QPL and General Certification

5. Position Dowels a. Step Certification for Buy America: See Shop Drawings for requirement

6. MSE Connection Lugs

a. Test Data Certification: See Special Provision for requirements

7. Anchor Bolts a. Test or General Cert for Anchor Bolts for Other Purposes (see special instructions in MSG)

8. High Strength Bolts a. Test

9. Mechanical Reinforcement Splices (QPL with General Cert and Test) a. The contractor must make test splices, witnessed by the Engineer, on the largest bar sizes

that are to be spliced. See Bridge Field Services Advisory (BFSA) 2012-03. BFS Advisory-Mechanical Reinforcement Splicing Test splice consists of 2 pieces of reinforcing bar joined by the coupler with 12 inches of bar exposed on each end of the coupler. This is witnessed by the construction field office staff.

10. Concrete Design Inserts: a. Verify that the design inserts meet electro-galvanizing to ASTM B633 Service Condition 4

11. Contractor Add-Ons a. Visual Inspection of coating (be sure to VI and Accept the coating on form 5617)

VII. Elastomeric Bearing Pads The entire section of 914.12 of the SSC is replaced entirely with the frequently used special provision “Elastomeric Bearings”. Must have a Certification and Test Data Certificate.

VIII. Curing Compound Test Data Certification & verification by the inspector that the cure being applied is ≤ 1 year from date of manufacture (be sure to VI and Accept the curing compound [list the date of manufacturer] on form 5617)

7

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Michigan Department of Transportation

2001 (01/18) PROJECT FOLDER CHECKLIST

To be completed by the QA inspector, combined with all other fabrication documentation, and electronically submitted to the MDOT Structural Fabrication Unit.

Naming Convention: SN-CS-JN Element Inspected MMDDYY

GENERAL INFORMATION INSPECTION AGENCY INSPECTOR

FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION JOB NUMBER

1. Forms, Certifications, Calibrations and Non-Material ItemsProject Folder Checklist (Form 2001) QA Documentation Certifications (Plant and Personnel) All Equipment Calibrations QC Documentation

Approved Shop Drawings Important Emails Non-Conformance Reports (NCRs) Request For Information Reports (RFIs) Unique Special Provisions Annual Repair Reports

Stamped Bill of Ladings

2. ConcreteA. Fabricator Batched Mix: Check all mix design components

i. Cementii. Wateriii. Air Entrainment Admixtures

iv. Water Reducing and Retarding Admixturesv. Concrete Acceleratorsvi. Fly Ash, Pozzolanic admixtures for concretevii. Slag Cementviii. Aggregate Correction Factor

B. NRMCA Redi-Mix Plant:

i. NRMCA Certificationii. Concrete Tickets with Batch Weightsiii. Form 1155iv. Waterv. Admixturesvi. Accelerators

vii. Aggregate Correction Factor

3. Fine AggregatesA. Prequalified Aggregate Source

i. Test Result/Documentation

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ii. ASR Test Resultiii. Signed Delivery Tickets

B. Non-Prequalified Aggregate Source

i. Acceptance Test Resultsii. ASR Test Resultiii. Delivery Tickets

4. Coarse AggregatesA. Prequalified Aggregate Source

i. Test Result/Documentation

ii. ASR Test Result (Pit Outside MI)iii. FT Dilation and LA Abrasion Test Resultsiv. Signed Delivery Tickets

B. Non-Prequalified Aggregate Source i. Acceptance Test Resultii. ASR Test Result (Pit Outside MI)

iii. FT Dilation and LA Abrasion Test Resultsiv. Delivery Tickets

5. Stockpiled AggregatesA. Acceptance Test Result B. ASR Test Result C. FT Dilation and LA Abrasion Test Results D. Delivery Ticket

6. SteelA. Cable, Strand for Prestressed Concrete B. Uncoated Steel Reinforcement C. Epoxy Coated Steel Reinforcement

i. Epoxy Coating Materialii. Steel Reinforcement Company

iii. Epoxy Coating CompanyD. Welded Wire Reinforcement E. Sole Plates (and Shear Developer/Studs if used) F. Position Dowels G. MSE Connection Lugs H. Anchor Bolts

I. Mechanical Reinforcement Splices J. Design Inserts (Coated to ASTM B633 SC4) K. Contractor Add-Ons (VI coating)

7. Rigid Debonding

8. Elastomeric Bearing Pads

9. Curing Compound

10. Carbon Fiber Composite Cable (CFCC)

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Comments:

Inspector’s Signature: _________________________________________

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Michigan Department of Transportation

5617 (01/18) FABRICATION INSPECTION REPORTTo be completed by the QA inspector, combined with all other fabrication

documentation, and electronically submitted to the MDOT Structural Fabrication Unit. REPORT #

GENERAL INFORMATION INSPECTION AGENCY INSPECTOR DATE

FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION SIZE AND ELEMENT TYPE JOB NUMBER

STATUS OF FABRICATION FOR PERIOD ENDING REQUESTED DELIVERY DATE FABRICATED %

COMMENTS:

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Michigan Department of Transportation

0513 (01/18) STRAND TENSIONING REPORT To be completed by the QA inspector, combined with all other fabrication

documentation, and electronically submitted to the MDOT Structural Fabrication Unit. REPORT # GENERAL INFORMATION

INSPECTION AGENCY INSPECTOR DATE

FABRICATOR / LOCATION STRUCTURE #

JOB DESCRIPTION CONTROL SECTION

STRAND MANUFACTURER ELEMENT MARK(S) JOB NUMBER

HEAT # REEL #(s)

HEAT # REEL #(s)

SEQUENCE LOCATION MEASURED ELONGATION

ACTUAL GAUGE READING

TENSIONING CALCULATIONS

INPUTS

1 INITIAL FORCE LB

2 FINAL FORCE LB

3 STRAND AREA (A) IN2

4 STRAND LENGTH (L) IN

5 MODULUS OF ELASTICITY PSI

6 STRAND TEMPERATURE F

7 CONCRETE TEMPERATURE F

8 DEAD END SEATING IN

9 LIVE END SEATING IN

10 BED SHORTENING IN

11 OUTPUTS

12 APPLIED FORCE (P) LB

13 * DIFFERENTIAL TEMPERATURE F

14 BASIC ELONGATION IN

15 LIVE END SEATING (OVERPULL) LB

16 BED SHORTENING (OVERPULL) LB

17 ** THERMAL FORCE CORRECTION LB

18 ** THERMAL ELONGATION CORRECTION IN

19 GROSS ELONGATION IN

20 NET ELONGATION IN

21 GROSS FORCE LB

22 NOTES

23 Basic Elongation is calculated using the applied force.

Gross Elongation is the elongation before live end seating.

Net Elongation is the elongation after live end seating and bedshortening (if applicable).

Strand Location is numbered from left to right, and from bottomto top.

* Positive value denotes positive elongation and pull correction.

** Thermal Correction applies when differential temperature is greater than 25 F (positive or negative).

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25

26

27

28

29

30

31

32

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MDOT 0513 (01/18)

SEQUENCE LOCATION MEASURED ELONGATION

ACTUAL GAUGE READING COMMENTS

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MDOT 0513 (01/18)

STRAND TYPE SYMBOL QUANTITY DESCRIPTION

STRAIGHT A

DRAPED B

SUPPORT C

DEBONDED

D

E

F

G

H

I

TOTAL STRANDS

Not to Scale

Michigan Department of Transportation

1985 (10/17) BAR REINFORCEMENT REPORT To be completed by the QA inspector, combined with all other fabrication documentation,

and electronically submitted to the MDOT Structural Fabrication Unit. REPORT # GENERAL INFORMATION

INSPECTION AGENCY INSPECTOR DATE

FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION SIZE AND ELEMENT TYPE JOB NUMBER

BAR TYPE SIZE NUMBER LENGTH SPLICE BARSPACING REMARK

COMMENTS:

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Michigan Department of Transportation

5616 (01/18) PRE AND POST POUR INSPECTION CHECKLIST

To be completed by the QA inspector, combined with all other fabrication documentation, and electronically submitted to the MDOT Structural

Fabrication Unit. REPORT #

GENERAL INFORMATION INSPECTION AGENCY INSPECTOR DATE

FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION SIZE AND ELEMENT TYPE JOB NUMBER

INSPECTION ITEM PRE POST

FOR

M/D

IME

NS

ION

S

Cleanliness

Form Oil

Bulkhead Plan End Square/Skew

Bulkhead Vertical Deviation

Side Plum Vertical Deviation

Sweep (Stringline)

Length Final

Width

Depth

Camber/Haunch

CO

VE

R

Reinforcing Steel

Box Beam Top Slab Thickness

MIL

D R

EIN

FOR

CEM

ENT

Size

Location

Number

Lap Length

Epoxy Coating

Slab Tie (count and spacing)

Slab Tie Projection

Approved Manufacturer Mark (spot verify)

Confinement Reinforcement

STR

AN

D R

EIN

FOR

CEM

ENT

Size

Location

Number

Pattern

Debonding Location

Debonding Length

Debonding Material

Mid-Span Top Cable Pocket

Mid-Span Top Cable Debond

Draped Strands

EN

DS

Bearing Assembly Orientation

Pavement Seat Size & Orientation

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Dowel Pin & Slot Location

Blockout Provided

INSPECTION ITEM PRE POST

CO

NC

RE

TE

Mix Design Fresh Concrete Tests Consolidation Tining Maximum Cure Temperature Cylinder Tests

EM

BE

DED

ITE

MS

Lift Loop Location/Projection PT Duct Size/Location PT Duct Recess/Blockout Keyway Size/Location Styrofoam Void Size/Location Drain Tube Installation Drain Tubes Open After Casting Insert Locations Insert Size/Coating Insert Threading (Coil/NC) Deck Clip Spacing/Location Forming Hanger Spacing/Location Screen Pipe Spacing/Projection Safety Line Bolt Spacing/Projection

INSPECTION ITEM AFTER LOADING

SH

IPIN

G A

PP

RO

VA

L

Face Finish Back Finish Cracks Strands Cut Flush/Treated Marked End Top Finish Provided Chamfers Forms Seams Clean/Smooth Surface Voids/Cracks Keyways Sealer Application Stamped Approval For MDOT Use

COMMENTS:

Michigan Department of Transportation

0590 (01/18) FIELD AND LAB TEST REPORTTo be completed by the QA inspector and included in the final project documentation.

REPORT # GENERAL INFORMATION

INSPECTION AGENCY INSPECTOR DATE

FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION SIZE AND ELEMENT TYPE JOB NUMBER

STRENGTH REQUIRED SERIES *TRANSFER STRENGTH (PSI) **STRIPPING STRENGTH (PSI) 28-DAY STRENGTH (PSI)

FIELD TEST DATA ELEMENT MARK CYL MARK TIME AIR (%) SLUMP (IN) CONCRETE (F) AIR (F)

QC QA

QA TESTER: TRANSFER/STRIPPING CYLINDERS RESULTS

ELEMENT MARK CYL MARK TEST DATE TEST AGE CYL 1 (PSI) CYL 2 (PSI) CYL 3 (PSI) AVG (PSI) APPROVED

28-DAY CYLINDER RESULTS ELEMENT MARK CYL MARK TEST DATE TEST AGE CYL 1 (PSI) CYL 2 (PSI) CYL 3 (PSI) AVG (PSI) APPROVED

SHIPPING INFORMATION ELEMENT MARK DATE SHIPPED INSPECTOR APPROVED COMMENTS

COMMENTS:

*DO NOT AVERAGE STRENGTH TESTS FOR TRANSFER CYLINDERS. **STRIPPING STRENGTH IS NOT REQUIRED FOR CULVERTS.

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Michigan Department of Transportation

1981 (01/18) REPAIR OBSERVATION REPORT To be completed by the QA inspector, combined with all other fabrication

documentation, and electronically submitted to the MDOT Structural Fabrication Unit. REPORT # GENERAL INFORMATION

INSPECTION AGENCY INSPECTOR DATE

FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION SIZE AND ELEMENT TYPE JOB NUMBER

FIELD TEST DATA ELEMENT MARK CYL MARK TIME AIR % SLUMP (IN) CONCRETE (F) AIR (F)

COMMENTS:

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