PART X: MATERIALS LUANNA CAMBAS

DISTRICT LAB ENGINEER

PART X: MATERIALS

Committee

General Changes

Specific Materials

Part X Committee Members

Luanna Cambas

Casey Allen

Richie Charoenpap

Jason Davis

Clay Gottschalk

Mike Ricca

LJ Tullier

Bert Wintz

John Wells

Doc Zhang

Phil Arena

Hector Santiago

Dean Hughes

Don Weathers

Bailey Williams

Jeff Young

Contributors – 104 20 Sections

Chris Abadie

Peter Allain

Ronnie Allen

David Backsteadt

Mike Bailey

Alton Booth

Doug Chandler

Greg Charles

Jody Colvin

JR Conners

Jeff David

Ed Douglass

Roy Dupre

John Eggers

Glenn Eggers

Paul Fossier

Anthony Genaro

John George

Hossein Ghara

Fred Gholston

VJ Gopu

Francisco Guidiel

Stuart Hingle

Darrel Johnson

Jimmy Johnson

Kelly Kemp

Barry Lacy

Dan Lorio

Phil Macaluso

Steve McCarrol

Louay Mohammad

Brett Morgan

Justin Morris

Mark Morvant

Khiet Ngo

Tim Perault

Henry Reed

Tyson Rupnow

Stephen Sibley

Danny Smith

Frank Standige

Tim Thomas

Margaret Thompson

Tuan Tran

Chad Vosburg

Lei Wang

Randy Young

Brad Albin

Kyle Ardoin

Doug Arnold

Dick Barnes

Nicki Cammon

Tim Carey

Tim Cost

Oliver Delery

BJ Eckholdt

Darrel Elliot

Hollis Ervin

Brian Felder

Richie Follette

Robert Forlong

Ben Franklin

Lamar Freeman

Keith Gaines

Bob Gruber

Tim Guillory

Steve Holmes

Tom Irving

Mike Jackson

Gary Kellum

Larry Langenstein

Richie Largent

Chip Lawson

Mike Lebleu

Jeff Miller

Ed Milner

Tom Oleary

Chip Private

Sydney Pujol

Rick Richard

Russell Richardson

J Samson

Chuck Shaw

Don Siler

Bill Temple

Chip Travet

Bill Ullrich

Scott Watson

Contributors to Part X,

Materials 104 People

2

57 45

FHWA

DOTD

Private

Updated references to AASHTO and ASTM

QPL Approved Materials List

Passive voice, not active voice

Metric and English

Revamped and reorganized

Materials

Aggregates

Signs & Pavement Markings

Concrete

Paint

Pipe

Asphalt

Metals

Timber

Traffic Signals

Epoxy Resin Systems

Eliminated material use, where

possible

Contract Item Number

Specifications Section

Materials Section

AGGREGATES – SECTION 1003

Sand, Gravel, Stone

Recycled Portland Cement Concrete, RPCC

Reclaimed Asphalt Pavement, RAP

Blended Calcium Sulfate, BCS

Slag

Lightweight Aggregate

Aggregates Approved Producer Supplier / Approved Materials List

List of all Test Procedures

Property Test Procedure

Deleterious Materials DOTD TR 119

Flat and Elongated Particles ASTM D4791

Magnesium Sulfate Soundness AASHTO T 104

Los Angeles Abrasion AASHTO T 96

Alkali-Silica Reactivity (Chemical Method)

ASTM C289

Alkali Reactivity (Mortar-Bar Method) ASTM C1260

Aggregates

Deleterious Materials (wood, clay, iron)

Magnesium Sulfate Soundness

LA Abrasion

Friction Rating (Polish Value)

Alkali Silicate Reactivity

Alkali Carbonate Reactivity

Organic Impurities

Properties & Gradation

AGGREGATES – Deleterious Materials for

all aggregates in 1 table.

Deleterious Materials Max

%

Wood 0.05

Clay Lumps 0.5

Clay Lumps and Friable Particles 3.0

Coal and Lignite (0.00 - Bridge Rail) 1.0

Flat and Elongated Particles (5:1) (10-Asphalt, AST)(5-SMA) 15.0

Flat and Elongated Particles (3:1) (Coarse, OGFC, SMA) 25.0

Glassy Particles 10.0

Iron Ore 2.01

Total: Wood, Clay Lumps, Friable Particles, Iron Ore, Lignite and Other Foreign Matter

5.0

Aggregate Properties

Magnesium Sulfate Soundness (15% max)

LA Abrasion (40.1% max)

Friction Rating (concrete bridge decks, asphalt surface)

Friction Rating

Polish Value

I

> 37

II

35 to 37

III

30 to 34

IV

<30

The Materials Engineer may adjust based upon skid

tests. Gravel ≥ 75% double-faced crushed is tested.

Aggregates - General

Dedicated Stockpile

Sampled and approved. Don’t

add material.

Recycled Portland Cement

Concrete (RPCC) for Interstate

base course shall be in

dedicated stockpiles, for 1

project only.

If the RPCC came from an

interstate, the soundness test

may be waived.

Working Stockpile

Sampled and approved. Contractor

may take and add material, if

quality and gradation is maintained.

RPCC min 5000 CY

Reclaimed Asphalt Concrete is in

working stockpiles

On site samples may be taken to ensure

that material still meets specifications.

Aggregate

Gradation

Aggregate Gradations

Non Plastic Embankment

Sand

Sieve Size % Passing

No. 4 75 - 100

No. 200 0 - 15

Stone

Widened the 1” sieve, was 85 – 100. 95 lb/cf max

Blended Calcium

Sulfate (BCS)

Sieve Size % Passing

2” 100

1” 55 - 100

¾” 35 - 88

No. 4 0 - 10

Sieve Size % Passing

1 ½” 60 - 100

1” 40 - 80

¾” 30 - 70

No. 4 20 - 65

No. 200 0 - 25

Max organic is 4.0%.

Base Course

Stone

Sieve Size % Passing

2”

1 ½” 100

1” 90 – 100

¾” 70 – 100

No. 4 35 – 65

No. 40 12 – 32

No. 200 5 - 12

LL 25 max, PI 5 max for – No. 40

(PI was 4)

RPCC

Non-plastic for – No. 40.

BCS

Sieve Size % Passing

2”

1 ½” 100

1” 90 – 100

¾” 70 – 100

No. 4 35 – 65

No. 40 12 – 32

No. 200 0 - 8

Sieve Size % Passing

2” 100

1 ½” 85 – 100

1” 80 – 100

¾” 60 – 100

No. 4 10 – 40

No. 40 0 - 20

No. 200 0 - 15

Bedding

Stone / RPCC

Sieve Size % Passing

2”

1 ½” 100

1” 90 – 100

¾” 70 – 100

No. 4 35 – 65

No. 40 12 – 32

No. 200 5 – 12 / 0 - 8

Same PI and LL as Base

Course

Sand-Aggregate

Mixture 35%

Granular Material

Sieve Size % Passing

1 ½” 90 - 100

¾” 70 - 85

3/8” 40 - 60

No. 4 15 - 40

No. 16 3 - 15

No. 200 0 - 5

Sieve Size % Passing

½” 100

No. 10 75 - 100

No. 200 0 - 10

Sieve Size % Passing

1 ½” 95 - 100

No. 4 0 - 15

No. 200 0 - 2

Sieve Size % Passing

1 ½” 95 - 100

¾” 40 - 85

No. 4 0 - 15

65% Gravel or

65% RPCC or Stone

Section 1015 Signs and Pavement

Markings

Metals, Panels, Sheeting, Enamels, Paint, Silk Screen Paste,

Overlay Film

Temporary Pavement Markings, Raised Pavement Markings,

Thermoplastic Pavement Markings

Preformed Plastic Pavement Marking Tape, Traffic Paint

Glass Beads

Dead Man's Curve along the Marquette–

Negaunee Road in Michigan, shown in 1917 with

its hand-painted center line.

Signs & Pavement Markings

Square Tubing for small signs, markers

Bolt ASTM’s updated

Vandal-resistant fasteners

Allow recycled aluminum signs

Sign traceability records shall be

maintained 7 years.

Signs & Pavement Markings Updated retroreflection and

chromaticity coefficients, performance

standards and guaranty.

Added black thermoplastic spec.

Require PE night inspection for stop

bars, cross walks, etc…

Contractors have options on glass

beads.

CONCRETE

Portland Cement and

Cementitious Materials

Aggregate

Admixtures

Water

Water

Percent by Weight

(Max.)

Alkali

Solids (Organic)

Solids (Inorganic)

Salt (NaCl)

Sugar, Oil, or Acid

0.1

0.1

0.4

0.5

0.0

1018.01 WATER

Water shall be suitable for human consumption or shall

comply with the following when tested - AASHTO T 26

Admixtures in Section 1011

Chemical

Limit contribution of

chloride ions to 0.02 lbs/CY

Infrared Spectroscopy

% solids must be ± 10 % of

original

Physical

- compare samples with

admixture to that without

Air: 7 day compressive

strength ≥ 85% of control

Water Reducer: 7 day

strength ≥ 105% of control

Set Retarding WR: Initial set

must be delayed 1.5 – 3.5 hours

Section 1001 Portland Cement &

Cementitious Materials Cement - AASHTO M 85, with AASHTO’s process additions.

Blended Hydraulic Cement

IP - Up to 30% fly ash or bottom ash, if bottom ash is

interground with the cement clinker

IS – Up to 50% ground granulated blast furnace slag (Grade

100, 120)

IL – Portland Limestone Cement

Alkali content (sodium oxide equivalent) ≤ 0.6% by mass.

Fly Ash

Ground Granulated Blast-Furnace Slag (Slag Cement)

Microsilica (Silica Fume)

Fly Ash

Class C, Class F, Class N

Alkali content ≤ 2.5

Fly ash with alkali of 1.5 – 2.5 must be used only with

innocuous aggregates.

Concrete Aggregates

Sand & Gravel

Alkali Silica Reactivity (ASR) – test per ASTM C289

Innocuous (non-reactive) are good

“Potentially Deleterious” – test per ASTM C1260 modified

If still “Potentially Deleterious” then use the maximum fly ash or silica fume or slag cement allowed. If using fly ash, it must be Class F.

If “ASR Deleterious”, don’t use!

Section 1003

Concrete Aggregates

Limestone

Alkali Silica Reactivity (ASR) & Alkali Carbonate

Reactivity (ACR) – test per AASHTO PP-11

Innocuous (non-reactive) are good

“Potentially ASR Reactive” – use maximum fly ash or

silica fume or slag cement (Fly ash must be Class F)

If “ASR Deleterious” or “ACR Reactive”, don’t use.

Next, gradation…

Uncrushed Aggregates for Concrete

Sieve Size Size 57M Size 89M Size 67

1 ½” 100

1” 90 - 100 100

¾” 100 90 – 100 (was 80-100)

½” 25 - 60 90 - 100

3/8” 20 - 55

No. 4 0 - 10 15 - 60 0 - 10

No. 8 0 - 5 0 – 30 (was 0-15) 0 - 5

No. 16 0 - 5

No. 200 0 - 1 0 - 1 0 – 1

M means modified ASTM C33. For crushed, No. 200 is 2 or 3% max, in some cases.

No more Grade A, B, etc… for aggregates

Section 1008 Paint

Zinc Paint Systems – meet requirements of

Northeast Protective Coating Committee

(www.nepcoat.org)

Corrosion Inhibiting Alkyd System (3-

coat)

Maintenance Overcoating of Steel

Bridges – requires 3-year field trial over a red

lead paint. Check for blistering, rusting,

fading, chalking, and adhesion.

Eliminated the 3-coat waterborne system.

Pipe

Thermoplastic Pipe 1006

Metal Pipe 1007

Concrete Pipe 1016

CROSS DRAIN AND SIDE DRAIN

STORM DRAIN (CURB AND GUTTER)

Joint Types in 1018 Hydrostatic testing with water: straight pipe;

vertical manholes

Type I Joints – Soil Tight & no leaking when filled

with water (for side drains under drives)

Type II Joints – No leaking with 5 psi for 10

minutes (cross drains under roadways, turnouts)

Type III Joints – No leaking with 10 psi for 10

minutes; No leaking when deflected with 10 psi

for 10 minutes. (closed storm drain systems)

Section 1006 Thermoplastic Pipe

Polyvinyl Chloride

(PVCP)

Polyethylene

Can be ribbed

(RPVCP)

Open profile

(concentric or spiral

ribs) or dual wall

Resin has a cell classificaton

Section 1007 Metal Pipe

Corrugated Steel

Corrugated

Aluminum

Bituminous Coated

Steel

Cast Iron, Ductile

Iron

Black & Galvanized

Steel

Section 1016 Concrete Pipe and

Precast Reinforced Concrete Drainage

Units

Concrete Pipe

Box Culverts

Three-sided Structures

Manholes

Junction Boxes

Safety Ends

Lot - 1 Day’s Production

Strength is required before shipping

Concrete Pipe 5 Cylinders / Lot

Can go to 3 days/300 sections.

Core Test may be used in lieu of cylinders, with approval

3 Edge Bearing Test may be used w/approval

Concrete Drainage Units

5 Cylinders / Lot

Core Test may be

used in lieu of

cylinders, with

approval

Paint or indent – manufacturer, date of casting, structure #/station # from plans

Asphalt

Asphalt Cement

Tack, Prime, Curing

Aggregates

Section 1002 Asphalt Cement

Performance Graded Asphalt Cement PG 82-22m PG 76-22m PG 70 –22m PG 67-22 PG 58-28

Rot Visc 3.0- 3.0- 3.0- 3.0- 3.0-

Dynamic

Shear

1.00+ @ 82°C 1.00+ @ 76°C 1.00+ @ 70°C 1.00+ @ 67°C 1.00+ @ 58°C

Crumb Rubber -- 30 mesh crumb, 10% max. no

cryogenic

Tack, Prime, Curing in 1002 Tack

NTSS-1HM

(Trackless Tack)

CRS-2P

CSS-1H

SS-1H

SS-1L

PET

Prime

MC-30

MC-70

AEP

Curing

ERP-1

Tack Eliminated --- CRS-2, CMS-2, CSS-1, SS-1, MC 250, SS-1P

Asphalt Aggregates in 1003 Stone, gravel, slag, lightweight aggregates, and coarse

and manufactured sand sources from the Approved

Materials List.

RAP and fine natural sand are required to be from an

approved Producer/Supplier.

Stone Matrix Asphalt aggregates must be crushed

stone with manufactured sand.

Mineral Filler is limestone dust,

pulverized hydrated lime,

portland cement,

cement stack dust, lime kiln dust.

Asphalt Chip Seal

Asphalt Surface Treatment

Stone Size 1A, Slag or Size 2, All Size 3, All

Sieve % Passing % Passing % Passing

1 ½” 100

1” 100

¾” 85 - 100 100

½” 25 - 40 95 – 100 (was 90-100) 100

3/8” 5 - 15 60 – 80 (was 40-80) 95 – 100(was 85-100)

No. 4 0 – 5 (was 0-15) 20 – 50 (was 10-40)

No. 8 0 – 2 (was 0-5) 0 – 2 (was 0-10)

No. 200 0 - 1

CRS-2P with Cold Application PAC-15 with Hot Application

Section 1009 Reinforcing Steel,

Strand & Wire Rope

Comply with “Buy America” provisions in Section 104.

Use Grade 60 in structures; use Grade 40 in pavements.

Billet-Steel, Rail-Steel, Axle-Steel, Cold-Drawn Steel

Steel Welded Wire Reinforcement

Stainless Deformed, Galvanized Deformed, and Epoxy

Coated Reinforcing Steel

Dowel Bars, Steel Strand, Wire Rope

Changed “pretensioning” to “prestressing and post-tensioning.” Removed post-tensioning subsections for bars, parallel wire assemblies and anchorages.

Section 1013 Metals

Comply with “Buy America Provisions”

Provide

Certificate of Analysis

Fabricator’s Material Statement

Certificate of Compliance

Structural steel shall comply with AASHTO M 270.

Main load-carrying structural members have longitudinal

Charpy V-Notch requirements

Metals - Castings From Section 1016 (Manholes, Catch Basins)… Castings

for frames, grates and covers shall comply with 1013.05

for steel and shall comply with 1013.06 for gray iron or

malleable iron castings. Galvanization shall conform to

ASTM A123.

From (Metals)…

1013.05 STEEL CASTINGS

1013.06 CAST IRON CASTINGS

1013.06.1 Gray Iron and Ductile Castings

1013.06.2 Malleable Castings

Metals -Bolts, Nuts and

Washers

Carbon Steel

High Strength

Added Direct Tension Indicators

Added Stainless Steel

Added Anchor Bolts

Bridge Hardware requires galvanizing

Added new eyebolt spec

Metals

Added spec for galvanized pipe railings

Check the environment for steel stay-in-place

form requirements.

Updated sheet pile spec.

Section 1014 Timber

Updated Grading Rules Reference

Southern Pine Lumber

Western Lumber

Specified Class B for timber piles.

Added preservative option of Ammoniacal Copper Zinc Arsenate (ACZA).

Added timber connectors from 1018

Section 1020 Traffic Signals

Signal housing color is black, with polycarbonate

New Approved Products List for traffic signal LED’s, pedestrian LED modules, junction boxes.

Added open spec for video systems, LED blank out sign spec, and 60’ and over mast arm spec

Updated pedestrian push button, flashing switch, signal strain pole, 55’ and under mast are, and anchor bolt specs.

Section 1017 Epoxy Resin

Systems

Added viscosity for Grade B systems.

Revised gel times, max water absorption, min shear bond strength.

Enough said!