STANDARD 

SPECIFICATIONS 

FOR CONSTRUCTION OF 

ROADS AND BRIDGES 

ON FEDERAL HIGHWAY 

PROJECTS

 FP-24 

U.S. Department 

of Transportation

Federal Highway 

Administration

Federal Lands 

Highway
Standard Specifications 

for Construction of 

Roads and Bridges on 

Federal Highway Projects 

FP-24 

UNITED STATES DEPARTMENT 

OF TRANSPORTATION

Federal Highway Administration


i 

PREFACE

These Standard Specifications for the Construction of Roads and Bridges on Federal Highway Projects 

are issued primarily for constructing roads and bridges on Federal Highway projects under the direct 

administration of the Federal Highway Administration. These specifications are cited as "FP-24" 

indicating "Federal Project" Standard Specifications issued in 2024. 

When designated in a contract, the FP-24 becomes part of the contract and binding upon all parties to the 

contract. Construction contracts of the Federal Highway Administration are also governed by the 

following regulations: 

• Federal Acquisition Regulation (FAR), Title 48, Code of Federal Regulations, Chapter 1; and 

• Transportation Acquisition Regulation (TAR), Title 48, Code of Federal Regulations, Chapter 12.

The FAR and TAR regulations are not included in the FP-24. A complete copy of the FAR is available 

from the Superintendent of Documents, Congressional Sales Office, U.S. Government Publishing Office, 

Washington, DC 20402. 

U.S. Customary units of measure are used in the FP-24. The references to Metric or Metric units apply

only where standardized testing requires Metric units of measure. 
ii

METRIC TO U.S. CUSTOMARY CONVERSION FACTORS (approximate)

Symbol When You Know Multiply By To Find Symbol

LENGTH

μm micrometers 3.9 × 10-5 inches in

mm millimeters 0.039 inches in

m meters 3.28 feet ft

m meters 1.09 yards yd

km kilometers 0.621 miles mi

AREA

mm2 square millimeters 0.0016 square inches in2

m2 square meters 10.764 square feet ft2

m2 square meters 1.195 square yards yd2

ha hectares 2.47 acres ac

km2 square kilometers 0.386 square miles mi2

VOLUME

mL milliliters 0.034 fluid ounces fl oz

L liters 0.264 gallons gal

m3 cubic meters 35.31 cubic feet ft3

m3 cubic meters 1.308 cubic yards yd3

MASS

g grams 0.035 ounces oz

kg kilograms 2.2046 pounds lb

Mg megagrams 1.1023 short tons T 

(or "t") (or "metric ton") (2000 lb)

TEMPERATURE (exact)

°C Celsius

temperature

1.8C +32 Fahrenheit

temperature

°F

ILLUMINATION

lx lux 0.0929 foot-candles fc

cd/m2 candela/m2 0.2919 foot-Lamberts fl

MISCELLANEOUS

J joule 0.7376 foot·poundforce ft·lbf

N newtons 0.225 poundforce lbf

kPa kilopascals 0.145 Poundforce

per square inch

lbf/in2
iii

Table of Contents

DIVISION 100 GENERAL REQUIREMENTS ..................................................................................1

Section 101. — TERMS, FORMAT, AND DEFINITIONS .................................................................2

Section 102. — BID, AWARD, AND EXECUTION OF CONTRACT ............................................12

Section 103. — SCOPE OF WORK ....................................................................................................14

Section 104. — CONTROL OF WORK .............................................................................................16

Section 105. — CONTROL OF MATERIAL .....................................................................................26

Section 106. — ACCEPTANCE OF WORK ......................................................................................29

Section 107. — LEGAL RELATIONS AND RESPONSIBILITY TO THE PUBLIC ......................40

Section 108. — PROSECUTION AND PROGRESS .........................................................................45

Section 109. — MEASUREMENT AND PAYMENT .......................................................................48

DIVISION 150 PROJECT REQUIREMENTS .................................................................................60

Section 151. — MOBILIZATION ......................................................................................................61

Section 152. — CONSTRUCTION SURVEY AND STAKING .......................................................62

Section 153. — CONTRACTOR QUALITY CONTROL ..................................................................69

Section 154. — CONTRACTOR SAMPLING AND TESTING ........................................................73

Section 155. — SCHEDULES FOR CONSTRUCTION CONTRACTS ...........................................75

Section 156. — PUBLIC TRAFFIC ....................................................................................................84

Section 157. — SOIL EROSION AND SEDIMENT CONTROL......................................................88

Section 158. — WATERING FOR DUST CONTROL ......................................................................93

DIVISION 200 EARTHWORK ...........................................................................................................94

Section 201. — CLEARING AND GRUBBING ................................................................................95

Section 202. — ADDITIONAL CLEARING AND GRUBBING ......................................................97

Section 203. — REMOVAL OF STRUCTURES AND OBSTRUCTIONS ......................................98

Section 204. — EXCAVATION AND EMBANKMENT ................................................................102

Section 205. — ROCK BLASTING ..................................................................................................113

Section 206. — RESERVED .............................................................................................................122

Section 207. — EARTHWORK GEOSYNTHETICS ......................................................................123

Section 208. — STRUCTURE EXCAVATION AND BACKFILL FOR SELECTED MAJOR 

STRUCTURES ........................................................................................................127

Section 209. — STRUCTURE EXCAVATION AND BACKFILL .................................................133

Section 210. — RESERVED .............................................................................................................137

Section 211. — ROADWAY OBLITERATION ..............................................................................138
iv

Section 212. — LINEAR AND SITE GRADING ............................................................................139

Section 213. — SUBGRADE STABILIZATION .............................................................................141

DIVISION 250 EARTH RETAINING SYSTEMS AND SLOPES ................................................146

Section 251. — RIPRAP....................................................................................................................147

Section 252. — ROCKERY, SPECIAL ROCK EMBANKMENT, AND ROCK BUTTRESS .......150

Section 253. — GABIONS AND REVET MATTRESSES ..............................................................155

Section 254. — SOLDIER PILE RETAINING WALLS ..................................................................158

Section 255. — MECHANICALLY-STABILIZED EARTH WALLS ............................................162

Section 256. — PERMANENT GROUND ANCHORS ...................................................................168

Section 257. — CONTRACTOR-DESIGNED RETAINING STRUCTURES ................................177

Section 258. — REINFORCED CONCRETE RETAINING WALLS .............................................182

Section 259. — SOIL NAIL RETAINING WALLS .........................................................................184

Section 260. — ROCK BOLTS AND DOWELS .............................................................................194

Section 261. — REINFORCED SOIL SLOPES ...............................................................................202

Section 262. — SLOPE SCALING ...................................................................................................204

Section 263. — DRAPED ROCKFALL PROTECTION .................................................................207

Section 264. — MIDSLOPE ROCKFALL ATTENUATOR ............................................................213

Section 265. — ROADSIDE ROCKFALL PROTECTION .............................................................219

Section 266. — ANCHORED WIRE MESH SYSTEM ...................................................................225

Section 267. — DRAIN HOLES IN ROCK......................................................................................231

Section 268. — HORIZONTAL DRAINS ........................................................................................233

DIVISION 300 AGGREGATE AND BASE COURSES .................................................................235

Section 301. — UNTREATED AGGREGATE COURSES .............................................................236

Section 302. — CRUSHED AGGREGATE .....................................................................................243

Section 303. — ROAD RECONDITIONING ...................................................................................246

Section 304. — FULL DEPTH RECLAMATION............................................................................249

Section 305. — FULL DEPTH RECLAMATION WITH CEMENT ...............................................252

Section 306. — FULL DEPTH RECLAMATION WITH ASPHALT .............................................258

Section 307. — RESERVED .............................................................................................................268

Section 308. — EMULSIFIED ASPHALT-TREATED BASE COURSE .......................................269

Section 309. — COLD CENTRAL PLANT RECYCLED ASPHALT BASE COURSE ................274

Section 310. — COLD IN-PLACE RECYCLED ASPHALT BASE COURSE ..............................280

Section 311. — STABILIZED AGGREGATE SURFACE COURSE .............................................289

Section 312. — DUST PALLIATIVE ...............................................................................................297
v 

Section 313. — AGGREGATE-TOPSOIL COURSE ......................................................................299

Section 314. — STOCKPILED AGGREGATES .............................................................................301

Section 315. — RECYCLED AGGREGATE ...................................................................................303

DIVISION 400 ASPHALT PAVEMENTS AND SURFACE TREATMENTS ............................306

Section 401. — ASPHALT CONCRETE PAVEMENT BY GYRATORY MIX DESIGN 

METHOD .................................................................................................................307

Section 402. — ASPHALT CONCRETE PAVEMENT BY HVEEM OR MARSHALL MIX 

DESIGN METHOD .................................................................................................334

Section 403. — ASPHALT CONCRETE .........................................................................................349

Section 404. — THIN LIFT ASPHALT CONCRETE PAVEMENT ...............................................353

Section 405. — OPEN-GRADED ASPHALT FRICTION COURSE ..............................................369

Section 406. — FOG SEAL...............................................................................................................376

Section 407. — CHIP SEAL .............................................................................................................379

Section 408. — ULTRATHIN BONDED WEARING COURSE ....................................................387

Section 409. — MICRO SURFACING .............................................................................................396

Section 410. — SLURRY SEAL .......................................................................................................402

Section 411. — ASPHALT PRIME COAT ......................................................................................407

Section 412. — ASPHALT TACK COAT ........................................................................................410

Section 413. — ASPHALT PAVEMENT MILLING .......................................................................413

Section 414. — ASPHALT PAVEMENT CRACK AND JOINT SEALING AND FILLING ........415

Section 415. — PAVING GEOTEXTILES .......................................................................................418

Section 416. — RESERVED .............................................................................................................420

Section 417. — RESERVED .............................................................................................................421

Section 418. — ASPHALT CONCRETE PAVEMENT PATCHING .............................................422

DIVISION 500 RIGID PAVEMENTS ..............................................................................................424

Section 501. — MINOR CONCRETE PAVEMENT .......................................................................425

Section 502. — CONCRETE PAVEMENT RESTORATION .........................................................436

DIVISION 550 BRIDGE CONSTRUCTION ..................................................................................447

Section 551. — DRIVEN PILES .......................................................................................................448

Section 552. — STRUCTURAL CONCRETE .................................................................................461

Section 553. — PRESTRESSED CONCRETE.................................................................................489

Section 554. — REINFORCING STEEL ..........................................................................................503

Section 555. — STEEL STRUCTURES ...........................................................................................507

Section 556. — BRIDGE RAILING .................................................................................................524

Section 557. — TIMBER STRUCTURES ........................................................................................527
vi

Section 558. — DAMPPROOFING ..................................................................................................532

Section 559. — WATERPROOFING AND SEALING....................................................................533

Section 560. — REMOVAL OF CONCRETE BY HYDRODEMOLITION ...................................539

Section 561. — CONCRETE CRACK REPAIR BY EPOXY INJECTION ....................................542

Section 562. — TEMPORARY WORKS .........................................................................................545

Section 563. — COATING................................................................................................................550

Section 564. — BEARING DEVICES ..............................................................................................561

Section 565. — DRILLED SHAFTS.................................................................................................565

Section 566. — SHOTCRETE ..........................................................................................................576

Section 567. — MICROPILES ..........................................................................................................586

Section 568. — SERVICE LIFE DESIGN CONCRETE ..................................................................594

Section 569. — CONCRETE OVERLAYS FOR BRIDGE DECKS ...............................................603

Section 570. — POLYESTER POLYMER CONCRETE OVERLAYS FOR BRIDGE DECKS....615

Section 571. — ULTRA-HIGH PERFORMANCE CONCRETE ....................................................625

Section 572. — CONCRETE REPAIR .............................................................................................634

Section 573. — HELICAL PILES .....................................................................................................649

Section 574. — GEOSYNTHETIC REINFORCED SOIL-INTEGRATED BRIDGE SYSTEM ....652

Section 575. — TEMPORARY BRIDGES .......................................................................................659

Section 576. — RESERVED .............................................................................................................661

Section 577. — FIBER-REINFORCED POLYMER STRUCTURES .............................................662

Section 578. — PRECAST CONCRETE ELEMENTS ....................................................................664

DIVISION 600 INCIDENTAL CONSTRUCTION .........................................................................671

Section 601. — MINOR CONCRETE ..............................................................................................672

Section 602. — CULVERTS AND DRAINS ...................................................................................677

Section 603. — STRUCTURAL PLATE STRUCTURES ...............................................................680

Section 604. — MANHOLES, INLETS, AND CATCH BASINS ...................................................682

Section 605. — UNDERDRAINS, SHEET DRAINS, AND PAVEMENT EDGE DRAINS .........685

Section 606. — CORRUGATED METAL SPILLWAYS ................................................................690

Section 607. — CLEANING, RELAYING, AND REPAIRING EXISTING DRAINAGE 

STRUCTURES ........................................................................................................691

Section 608. — PAVED WATERWAYS .........................................................................................692

Section 609. — CURB AND GUTTER ............................................................................................696

Section 610. — SIDEWALKS, PADS, AND MEDIANS ................................................................701
vii

Section 611. — WATER SYSTEMS ................................................................................................704

Section 612. — SANITARY SEWER SYSTEMS ............................................................................706

Section 613. — SIMULATED STONE MASONRY SURFACE.....................................................708

Section 614. — FLOWABLE BACKFILL .......................................................................................711

Section 615. — RESERVED .............................................................................................................713

Section 616. — SLOPE PAVING .....................................................................................................714

Section 617. — GUARDRAIL ..........................................................................................................716

Section 618. — CONCRETE BARRIERS ........................................................................................719

Section 619. — FENCES, GATES, CATTLE GUARDS, AND BOLLARDS ................................721

Section 620. — STONE MASONRY ................................................................................................727

Section 621. — MONUMENTS AND MARKERS ..........................................................................733

Section 622. — RENTAL EQUIPMENT ..........................................................................................734

Section 623. — GENERAL LABOR ................................................................................................735

Section 624. — TOPSOIL .................................................................................................................737

Section 625. — TURF ESTABLISHMENT .....................................................................................739

Section 626. — PLANTS, TREES, SHRUBS, VINES, AND GROUND COVERS .......................742

Section 627. — SOD..........................................................................................................................746

Section 628. — TEMPORARY STREAM DIVERSIONS ...............................................................748

Section 629. — ROLLED EROSION CONTROL PRODUCTS AND CELLULAR 

CONFINEMENT SYSTEMS ..................................................................................751

Section 630. — RESERVED .............................................................................................................754

Section 631. — RESERVED .............................................................................................................755

Section 632. — LOCATING UTILITIES .........................................................................................756

Section 633. — PERMANENT TRAFFIC CONTROL ....................................................................757

Section 634. — PERMANENT PAVEMENT MARKINGS ............................................................759

Section 635. — TEMPORARY TRAFFIC CONTROL ...................................................................763

Section 636. — TRAFFIC SIGNAL, TRAFFIC COUNTER, LIGHTING, AND ELECTRICAL 

SYSTEMS ................................................................................................................769

Section 637. — FACILITIES AND SERVICES ...............................................................................774

DIVISION 700 MATERIAL ..............................................................................................................780

Section 701. — CEMENTITIOUS MATERIAL ..............................................................................781

701.01 Hydraulic Cement. .............................................................................................................781

701.02 Reserved. ............................................................................................................................781

701.03 Pozzolans. ...........................................................................................................................781

701.04 Grout. .................................................................................................................................781
viii

701.05 Mortar. ................................................................................................................................782

Section 702. — ASPHALT MATERIAL AND ADDITIVES ..........................................................783

702.01 Asphalt Binder. ..................................................................................................................783

702.02 Emulsified Asphalt. ............................................................................................................783

702.03 Hot-Applied Asphalt Aggregate-Filled Mastic. .................................................................784

702.04 Asphalt Mastic. ..................................................................................................................784

702.05 Antistrip Additive. ..............................................................................................................784

Section 703. — AGGREGATE .........................................................................................................785

703.01 Fine Aggregate for Concrete. .............................................................................................785

703.02 Coarse Aggregate for Concrete. .........................................................................................785

703.03 Underdrain Backfill. ...........................................................................................................786

703.04 Reserved. ............................................................................................................................786

703.05 Subbase, Base, and Surface Course Aggregate. .................................................................786

703.06 Crushed Aggregate. ............................................................................................................788

703.07 Asphalt Concrete Aggregate. .............................................................................................788

703.08 Open-Graded Asphalt Friction Course Aggregate. ............................................................790

703.09 Chip Seal Aggregate. .........................................................................................................790

703.10 Slurry Seal and Micro Surfacing Aggregate. .....................................................................791

703.11 Reserved. ............................................................................................................................792

703.12 Blotter. ................................................................................................................................792

703.13 Aggregate for Aggregate-Topsoil Course. .........................................................................792

703.14 Sand. ...................................................................................................................................792

703.15 Flowable Backfill Aggregate. ............................................................................................792

703.16 Shotcrete Aggregate. ..........................................................................................................792

703.17 Granular Rock Backdrain. ..................................................................................................793

703.18 Ultrathin Bonded Wearing Aggregate. ..............................................................................794

703.19 Polyester Polymer Concrete Aggregate. ............................................................................795

703.20 Geosynthetic Reinforced Soil Open-graded Backfill. ........................................................795

Section 704. — SOIL .........................................................................................................................796

704.01 Soil and soil-aggregate materials. ......................................................................................796

704.02 Select Borrow. ....................................................................................................................796

704.03 Select Granular Backfill. ....................................................................................................797

Section 705. — ROCK ......................................................................................................................798

705.01 Gabion and Revet Mattress Rock. ......................................................................................798
ix

705.02 Rock for Riprap. .................................................................................................................798

705.03 Rock for Masonry Structures. ............................................................................................800

705.04 Rock for Special Rock Embankments................................................................................800

705.05 Rock for Buttresses. ...........................................................................................................801

705.06 Rock for Rockeries. ............................................................................................................801

705.07 Rock Mulch. .......................................................................................................................801

705.08 Filter Rock. .........................................................................................................................802

705.09 Wall Facing Fill. .................................................................................................................802

Section 706. — CONCRETE PIPE ...................................................................................................804

706.01 Non-Reinforced Concrete Pipe. .........................................................................................804

706.02 Reinforced Concrete Pipe. .................................................................................................804

706.03 Perforated Concrete Pipe. ...................................................................................................804

706.04 Reinforced Arch-Shaped Concrete Pipe. ...........................................................................804

706.05 Reinforced Elliptically-Shaped Concrete Pipe. ..................................................................804

706.06 Reinforced D-Load Concrete Pipe. ....................................................................................804

706.07 Precast Reinforced Concrete Box Sections. .......................................................................804

706.08 Gaskets for Concrete Pipe. .................................................................................................804

706.09 Supplemental Concrete Pipe Ties. .....................................................................................804

Section 707. — METAL PIPE...........................................................................................................805

707.01 Ductile Iron Culvert Pipe. ..................................................................................................805

707.02 Metallic-Coated Corrugated Steel Pipe. .............................................................................805

707.03 Aluminum-Alloy Corrugated Pipe. ....................................................................................805

707.04 Asphalt-Coated Pipe...........................................................................................................805

707.05 Steel Structural Plate Structures. ........................................................................................805

707.06 Aluminum-Alloy Structural Plate Structures. ....................................................................805

707.07 Asphalt-Coated Structural Plate Structures. .......................................................................805

707.08 Polymer-Coated Steel Pipe. ...............................................................................................805

707.09 Corrugated Metal Units. .....................................................................................................806

707.10 Metallic-Coated Slotted Drain Pipe. ..................................................................................806

707.11 Metallic-Coated Spiral Rib Pipe. .......................................................................................806

707.12 Aluminum-Alloy Spiral Rib Pipe.......................................................................................806

707.13 Concrete-Lined Corrugated Steel Pipe. ..............................................................................806

707.14 Invert-Paved Corrugated Steel Pipe. ..................................................................................806

707.15 Cast Iron Soil Pipe and Fittings. ........................................................................................806
x 

707.16 Seamless Copper Water Tube and Fittings. .......................................................................806

707.17 Gaskets for Metal Pipe. ......................................................................................................806

707.18 Gaskets for Ductile Iron Pipe. ............................................................................................807

Section 708. — PLASTIC PIPE ........................................................................................................808

708.01 Smooth Wall Polyethylene Pipe. ........................................................................................808

708.02 Corrugated Polyethylene Pipe. ...........................................................................................808

708.03 Profile Wall (Ribbed) Polyethylene Pipe. ..........................................................................808

708.04 Corrugated Polyethylene Drainage Tubing. .......................................................................808

708.05 Corrugated Polypropylene Pipe. ........................................................................................808

708.06 Smooth Wall Polyvinyl Chloride Pipe. ..............................................................................808

708.07 Profile Wall (Ribbed) Polyvinyl Chloride Pipe. ................................................................809

708.08 Acrylonitrile-Butadiene-Styrene (ABS) Pipe. ...................................................................809

708.09 Gaskets for Plastic Pipe. .....................................................................................................809

Section 709. — REINFORCING STEEL AND WIRE ROPE..........................................................810

709.01 Reinforcing Steel. ...............................................................................................................810

709.02 Prestressing Steel. ..............................................................................................................811

709.03 Wire Rope. .........................................................................................................................811

Section 710. — FENCING AND MESH FABRICS .........................................................................812

710.01 Barbed Wire. ......................................................................................................................812

710.02 Smooth Wire. .....................................................................................................................812

710.03 Woven Wire. ......................................................................................................................812

710.04 Chain Link Fence. ..............................................................................................................812

710.05 Fence Posts and Bollards. ..................................................................................................812

710.06 Split Rail.............................................................................................................................812

710.07 Fence Gates. .......................................................................................................................812

710.08 Temporary Plastic Fence. ...................................................................................................812

710.09 Draped Rockfall Protection Fabric.....................................................................................812

710.10 Midslope Rockfall Attenuator Materials. ...........................................................................813

Section 711. — CONCRETE CURING MATERIAL AND ADDITIVES ......................................815

711.01 Curing Material. .................................................................................................................815

711.02 Air-Entraining Admixtures. ...............................................................................................815

711.03 Chemical Admixtures. ........................................................................................................815

711.04 Latex Emulsion. .................................................................................................................815

711.05 Concrete Coloring Agents. .................................................................................................815
xi

711.06 Reinforcing Fibers. .............................................................................................................815

Section 712. — JOINT MATERIAL .................................................................................................817

712.01 Sealants, Fillers, and Seals. ................................................................................................817

Section 713. — ROADSIDE IMPROVEMENT MATERIAL .........................................................820

713.01 Topsoil................................................................................................................................820

713.02 Agricultural Limestone. .....................................................................................................820

713.03 Fertilizer. ............................................................................................................................820

713.04 Seed. ...................................................................................................................................821

713.05 Mulch. ................................................................................................................................821

713.06 Plant Material. ....................................................................................................................824

713.07 Cellular Confinement Systems. ..........................................................................................824

713.08 Miscellaneous Planting Material. .......................................................................................825

713.09 Sod. .....................................................................................................................................825

713.10 Pegs for Sod. ......................................................................................................................825

713.11 Tackifiers. ...........................................................................................................................826

713.12 Fiber Rolls. .........................................................................................................................826

713.13 Gravel Bags. .......................................................................................................................827

713.14 Sandbags. ...........................................................................................................................827

713.15 Temporary Culvert Pipe. ....................................................................................................827

713.16 Silt Fence. ...........................................................................................................................827

713.17 Rolled Erosion Control Products. ......................................................................................828

713.18 Turf Reinforcement Mats. ..................................................................................................830

713.19 Sediment Filter Bags. .........................................................................................................831

713.20 Prefabricated Filter Insert. ..................................................................................................831

713.21 Floating Turbidity Curtains. ...............................................................................................831

713.22 Plastic Lining. ....................................................................................................................832

Section 714. — GEOSYNTHETIC MATERIAL .............................................................................833

714.01 Geotextile. ..........................................................................................................................833

714.02 Geocomposite Drain...........................................................................................................833

714.03 Stabilization Geogrid. ........................................................................................................834

714.04 Reinforcement Geotextile and Geogrid .............................................................................834

714.05 Geomembrane. ...................................................................................................................835

714.06 Geosynthetic Reinforced Soil Reinforcement Geosynthetic. .............................................835

Section 715. — PILING ....................................................................................................................836
xii

715.01 Untreated Timber Piles. .....................................................................................................836

715.02 Treated Timber Piles. .........................................................................................................836

715.03 Steel Pipes. .........................................................................................................................836

715.04 Steel H-Piles. ......................................................................................................................836

715.05 Sheet Piles. .........................................................................................................................836

715.06 Pile Shoes. ..........................................................................................................................836

715.07 Splices. ...............................................................................................................................836

715.08 Helical Piles. ......................................................................................................................837

Section 716. — MATERIAL FOR TIMBER STRUCTURES .........................................................838

716.01 Untreated Structural Timber and Lumber. .........................................................................838

716.02 Treated Structural Timber and Lumber..............................................................................838

716.03 Structural Glued Laminated Timber. .................................................................................838

716.04 Wood-Plastic Composite. ...................................................................................................838

716.05 Hardware. ...........................................................................................................................838

Section 717. — STRUCTURAL METAL ........................................................................................840

717.01 Structural Steel. ..................................................................................................................840

717.02 Steel Forgings.....................................................................................................................841

717.03 Pins and Rollers. .................................................................................................................841

717.04 Castings. .............................................................................................................................841

717.05 Welded Stud Shear Connectors. .........................................................................................842

717.06 Steel Pipe. ...........................................................................................................................842

717.07 Galvanized Coatings. .........................................................................................................842

717.08 Steel Grid Floors. ...............................................................................................................842

717.09 Bearings. .............................................................................................................................842

717.10 Aluminum Alloy for Bridge Rail. ......................................................................................843

717.11 Aluminum Bolt Heads and Nuts. .......................................................................................843

717.12 Aluminum Welding Wire. ..................................................................................................843

Section 718. — TRAFFIC SIGNING AND MARKING MATERIAL ............................................844

718.01 Retroreflective Sheeting. ....................................................................................................844

718.02 Legends and Borders. .........................................................................................................844

718.03 Panels. ................................................................................................................................845

718.04 Sign Posts. ..........................................................................................................................847

718.05 Delineator and Object Marker Posts. .................................................................................847

718.06 Hardware. ...........................................................................................................................847
xiii

718.07 Delineator and Object Marker Retroreflectors. ..................................................................848

718.08 Solventborne Pavement Markings. ....................................................................................848

718.09 Waterborne Pavement Markings. .......................................................................................848

718.10 High-Build Waterborne Pavement Markings. ....................................................................849

718.11 Epoxy Pavement Markings. ...............................................................................................849

718.12 Thermoplastic Pavement Markings. ...................................................................................851

718.13 Preformed Pavement Marking Tape. .................................................................................851

718.14 Glass Beads. .......................................................................................................................851

718.15 Pavement Markers. .............................................................................................................851

718.16 Temporary Pavement Markings. ........................................................................................851

718.17 Epoxy Resin Adhesives. .....................................................................................................851

718.18 Methyl Methacrylate Pavement Markings. ........................................................................851

Section 719. — COATING MATERIAL ..........................................................................................853

719.01 General. ..............................................................................................................................853

719.02 Coating for Iron and Steel Structures. ................................................................................854

719.03 Coating for Aluminum Structures. .....................................................................................854

719.04 Coating for Other Structural Material. ...............................................................................854

719.05 Penetrating Stain for Concrete. ..........................................................................................854

Section 720. — STRUCTURAL WALL AND STABILIZED EMBANKMENT MATERIAL ......855

720.01 Mechanically-Stabilized Earth Wall Material. ...................................................................855

720.02 Gabion and Revet Mattress Material..................................................................................856

Section 721. — ELECTRICAL AND ILLUMINATION MATERIAL ...........................................857

721.01 Electrical Material. .............................................................................................................857

721.02 Lighting Material. ..............................................................................................................859

Section 722. — ANCHOR MATERIAL ...........................................................................................862

722.01 Anchorage Devices. ...........................................................................................................862

722.02 Anchor Tendons. ................................................................................................................862

722.03 Rock Bolts and Rock Dowels. ...........................................................................................863

722.04 Soil Nails. ...........................................................................................................................864

722.05 Anchor Nails. .....................................................................................................................864

722.06 Micropile Materials. ...........................................................................................................865

722.07 Rockfall Protection Anchor Materials. ..............................................................................865

Section 723. — DAMPPROOFING AND WATERPROOFING MATERIAL ...............................866

723.01 Dampproofing Material. .....................................................................................................866
xiv

723.02 Waterproofing Material. .....................................................................................................866

Section 724. — GUARDRAIL ..........................................................................................................869

724.01 Rail Elements. ....................................................................................................................869

724.02 Guardrail Posts. ..................................................................................................................869

724.03 Guardrail Blockouts. ..........................................................................................................870

724.04 Guardrail Hardware. ...........................................................................................................870

Section 725. — MISCELLANEOUS MATERIAL...........................................................................871

725.01 Water. .................................................................................................................................871

725.02 Calcium Chloride, Magnesium Chloride, and Lignosulfonate. .........................................871

725.03 Lime. ..................................................................................................................................871

725.04 Reserved. ............................................................................................................................872

725.05 Mineral Filler. ....................................................................................................................872

725.06 Concrete Building Brick. ...................................................................................................872

725.07 Concrete Masonry Units. ...................................................................................................872

725.08 Paving Brick. ......................................................................................................................872

725.09 Precast Concrete Units and Accessories. ...........................................................................872

725.10 Frames, Grates, Covers, and Ladder Rungs. ......................................................................872

725.11 Detectable Warning Tape. ..................................................................................................873

725.12 Epoxy Resin Adhesives......................................................................................................873

725.13 Slurry (Drilling Fluids). .....................................................................................................873

725.14 Polymer Concrete and Mortar. ...........................................................................................873

725.15 Color Coating. ....................................................................................................................874

725.16 Galvanic Anodes. ...............................................................................................................874

725.17 Polyester Resin Binder. ......................................................................................................875

725.18 High Molecular Weight Methacrylate. ..............................................................................875

725.19 Fiber-Reinforced Polymer. .................................................................................................876

725.20 Penetrating Sealant .............................................................................................................876
1 

DIVISION 100

GENERAL REQUIREMENTS 
Section 101

2 

Section 101. — TERMS, FORMAT, AND DEFINITIONS

101.01 Meaning of Terms. These specifications are generally written in the imperative mood. In 

sentences using the imperative mood, the subject, "the Contractor", is implied. Also implied in this 

language are "shall", "shall be", or similar words and phrases. In material specifications, the subject may 

also be the supplier, fabricator, or manufacturer supplying material, products, or equipment for use on the 

project. Wherever "directed", "required", "prescribed", "requested", or "ordered" are used, the 

"direction", "requirement", "prescription", or "order" of the Contracting Officer is intended. Wherever 

something is to be "submitted" or "submitting to", the Contracting Officer is intended. Similarly, wherever 

"approved", "acceptable", "suitable", "satisfactory", or similar words are used, the words mean "approved 

by", "acceptable to", or "satisfactory to" the Contracting Officer.

The word "will" generally pertains to decisions or actions of the Contracting Officer. 

101.02 Specifications Format. These specifications are divided into 10 Divisions. Division 100 consists 

of general contract requirements for which no direct payment is made. The requirements contained in 

Division 100 apply to all contracts. 

Division 150 consists of project contract requirements that apply to all contracts. Work under Division 150

is paid for directly or indirectly according to Subsection 109.05. If there is no pay item in the bid schedule, 

no direct payment is made. 

Divisions 200 through 600 consist of construction contract requirements for specific items of work. Work 

under these Divisions is paid for directly or indirectly according to Subsection 109.05. If there is no pay 

item in the bid schedule, no direct payment is made.

Division 700 contains the material requirements for Divisions 150 through 600. No direct payment is 

made in Division 700. Payment for material is included as part of the work required in Divisions 150

through 600. 

The first three digits of the pay item number in the bid schedule identify the Section under which the work 

is performed.

101.03 Abbreviations.When these abbreviations are used, they represent the following:

(a) Acronyms. 

3D — Three-Dimensional

AASHTO — American Association of State Highway and Transportation Officials 

ACI — American Concrete Institute

AISC — American Institute of Steel Construction

AITC — American Institute of Timber Construction

AMG — Automated Machine Guidance 
Section 101

3 

ANSI — American National Standards Institute

ASR — Alkali-Silica Reactivity

ASTM — American Society for Testing and Materials (ASTM International)

ATSSA — American Traffic Safety Services Association

AWG — American Wire Gauge

AWPA — American Wood Protection Association 

AWS — American Welding Society

AWWA — American Water Works Association

BMP — Best Management Practice

CFR — Code of Federal Regulations 

CO — Contracting Officer and authorized representatives

CPM — Critical Path Method

CRSI — Concrete Reinforcing Steel Institute

CTSM — Contingent Sum 

EPA — Environmental Protection Agency

FAR — Federal Acquisition Regulations (48 CFR Chapter 1)

FHWA — Federal Highway Administration

FLH — Federal Lands Highway

FRP — Fiber-Reinforced Polymer

GPS — Global Positioning System 

GRS — Geosynthetic Reinforced Soil 

GSA — General Services Administration

HDPE — High Density Polyethylene

HPC — High-Performance Concrete

HPS — High-Performance Steel

HMA — Hot Mix Asphalt 
Section 101

4 

HMWM — High Molecular Weight Methacrylate

IMSA — International Municipal Signal Association

ISO — International Organization for Standardization

ISSA — International Slurry Surfacing Association 

IWRC — Independent Wire Rope Core

JMF — Job-Mix Formula

LPSM — Lump Sum 

LRFD — Load and Resistance Factor Design

MASH — Manual for Assessing Safety Hardware

MPI — Master Painters Institute

MSE — Mechanically-Stabilized Earth

MTV — Material Transfer Vehicle

MUTCD — Manual on Uniform Traffic Control Devices for Streets and Highways

NACE — National Association of Corrosion Engineers 

NCHRP — National Cooperative Highway Research Program 

NEMA — National Electrical Manufacturers Association

NIST — National Institute of Standards and Technology 

NMSA — Nominal Maximum Size Aggregate

NPCA — National Precast Concrete Association

NTP — Notice to Proceed

OSHA — Occupational Safety and Health Administration

PCI — Precast/Prestressed Concrete Institute

PPC — Polyester Polymer Concrete

PTFE — Polytetrafluoroethylene

PTI — Post-Tensioning Institute

PVC — Polyvinyl Chloride 
Section 101

5 

QA — Quality Assurance

QC — Quality Control

QCM — Quality Control Manager 

QCP — Quality Control Plan

RAP — Recycled Asphalt Pavement

RECP — Rolled Erosion Control Product 

RSS — Reinforced Soil Slope 

SDS — Safety Data Sheet

SF — Standard Form 

SRWU — Segmental Retaining Wall Unit

SSPC — The Society for Protective Coatings

SWPPP — Storm Water Pollution Prevention Plan

S4S — Surfaced four sides (lumber)

TAR — Transportation Acquisition Regulations (48 CFR Chapter 12)

TSR — Tensile Strength Ratio

UL — Underwriter’s Laboratory

U.S. — United States

U.S.C. — United States Code

UV — Ultraviolet

VFA — Voids Filled with Asphalt 

VMA — Voids in Mineral Aggregate 

VOC — Volatile Organic Compounds 

WMA — Warm Mix Asphalt

(b) Unit abbreviations and symbols.

°F — degree Fahrenheit temperature

ft — feet length 
Section 101

6 

ft2 — square feet area

ft3 — cubic feet volume 

gal — gallon volume 

in — inches length 

in2 — square inches area

in3 — cubic inches volume 

kip — 1000 pounds mass

ksi — kilopound per square inch pressure

lb — pound mass

lbf — pound-force force

mi — mile length 

min — minute time

oz — ounces mass

ppm — parts per million concentration

psi — pounds per square inch pressure

sec — second time

V — volt electric potential

yd — yards length 

yd2 — square yards area

yd3 — cubic yards volume 

(c) Slope notation. Slopes are expressed as the ratio of vertical to horizontal (V:H).

101.04 Definitions. Unless otherwise specified, the following terms are defined as follows:

Automated Machine Guidance — An application that can be applied to highway construction projects 

to provide construction efficiencies through enhanced location referencing. AMG involves using 

construction equipment mounted with onboard computers. Using a combination of 3D modeling data 

along with GPS technology, AMG provides horizontal and vertical guidance in real time to construction 

equipment operators.

Award — The written acceptance of a bid by the CO. 
Section 101

7 

Backfill — Material used to replace or the act of replacing material removed during construction. Material 

placed or the act of placing material adjacent to structures.

Base — The lift or lifts of material placed on a subbase or subgrade to support a surface course.

Bid — A written offer by a bidder to perform work at a quoted price.

Bidder — An individual or legal entity submitting a bid. 

Bid Guarantee — A form of security assuring that the bidder will not withdraw a bid within the period 

specified for acceptance and will execute a written contract and provide required bonds. 

Bid Schedule — The prepared schedule included with the bid forms, containing the estimated quantities 

of pay items for which unit bid prices are invited.

Bridge — A structure including supports erected over a depression or an obstruction (such as water, 

highway, or railway), having a track or passageway for carrying traffic or other moving loads, and having 

an opening measured along the center of the roadway of more than 20 feet between undercopings of 

abutments or spring lines of arches, or extreme ends of openings for multiple boxes. It may also include 

multiple pipes, where the clear distance between openings is less than half of the smaller contiguous 

opening. 

Clear Zone — The portion of the roadside, including the shoulder, available for the safe use by an errant 

vehicle.

Commercial Certification — See Subsection 106.03. 

Completion Date — The date by which all contract work is to be complete.

Construction Limits — The limits that establish the area disturbed by construction operations and beyond 

which no disturbance is allowed. 

Contract — The written agreement between the Government and the Contractor setting forth the 

obligations of the parties for the performance of and payment for the prescribed work.

Contracting Officer — An official of the Government with the authority to execute, administer, and 

terminate contracts, and make related determinations and findings. The term includes authorized 

representatives of the CO acting within the limits of their authority as delegated by the CO.

Contract Modification — A written change in the terms of the contract. Contract modifications are of 

the following forms:

(a) Administrative change. A unilateral contract change, in writing, that does not affect the 

substantive rights of the parties (such as a change in the paying office or the appropriation data). 

(b) Change order. A written order, signed by the CO, directing the Contractor to make a change that 

FAR Clause 52.243-4 Changes authorizes the CO to order without the Contractor’s consent. 

(c) Supplemental agreement. A contract modification that is accomplished by the signature of the 

CO (unilateral contract modification) or by the signature of the CO and the Contractor (bilateral 

contract modification).
Section 101

8 

Contractor — The individual or legal entity contracting with the Government for performance of 

prescribed work.

Contract Time — The specified time allowed for completion of the contract work. 

Crashworthy — A highway feature that has been successfully crash tested under applicable standards 

defined in MASH, the NCHRP Report 350, Recommended Procedures for the Safety Performance 

Evaluation of Highway Features, or approved through analysis by FHWA based on similarity to other 

crashworthy features.

Cross-Section — A vertical section of the ground or structure at right angles to the centerline or baseline 

of the roadway or other work. 

Culvert — A structure, not classified as a bridge, that provides an opening under the roadway. 

Day — A calendar day starting and ending at midnight. 

Density — Mass per unit volume of material. Specific gravity multiplied by the density of water.

Detour — A temporary rerouting of public traffic onto alternate existing roadways to avoid the work or 

part of the work. 

Dewatering — Lowering and controlling water levels to allow excavation and construction to be 

performed. 

Drawings — Design sheets or fabrication, erection, shop drawing, or construction details submitted to 

the CO by the Contractor according to FAR Clause 52.236-21 Specifications and Drawings for 

Construction. Also refers to submissions and submittals. 

Federal Land Management Agencies — Federal agencies including, but not limited to, the National 

Park Service, U.S. Forest Service, U.S. Fish & Wildlife Service, U.S. Army Corps of Engineers, Bureau 

of Land Management, and Bureau of Reclamation. 

Final Acceptance — The point at which the Government formally accepts the work and relieves the 

Contractor of further responsibility for the maintenance of the project. This excludes warranties, which 

remain in effect until they expire. See FAR Clause 52.246-21 Warranty of Construction. 

Government — The Government of the United States of America.

Highway, Street, or Road — A general term denoting a public way primarily designed for purposes of 

multimodal travel.

Lane Mile — An area of pavement 1 mile long and 1 lane wide; not including turn lanes, turnouts, parking 

area lanes, or other auxiliary lanes.

Lift — When placing and compacting soils, aggregates, or pavement; a lift is a single, continuous layer 

of material that is uniformly compacted. 

Material — Substances specified or necessary to complete the contract work.
Section 101

9 

Measurement — The process of identifying the dimensions, quantity, or capacity of a pay item. See 

Section 109 for measurement methods, terms, and definitions.

Neat Line — A line defining the proposed or specified limits of excavation or structure element for 

purposes of calculating quantities. 

Notice to Proceed — Written notice to the Contractor to start the contract work. 

Offeror — An individual or legal entity submitting a bid. 

Pavement Structure — The combination of subbase, base, paving geotextiles, and surface courses placed 

on a subgrade to support and distribute the traffic load to the roadbed. 

Pay Item — A specific item of work consisting of a unit, quantity, and method of measurement furnished 

by the Government and a price established by the contract.

Payment Bond — The security executed by the Contractor and surety or sureties and provided to the CO 

to ensure payments as required by law to persons supplying labor or material according to the contract. 

Performance Bond — The security executed by the Contractor and surety or sureties and provided to the 

CO to guarantee completion of the contract work.

Plans — The contract plans furnished by the Government showing the location, type, dimensions, and 

details of the work.

Production Certification — See Subsection 106.03. 

Professional Engineer — Engineers holding valid state licenses permitting them to offer engineering 

services directly to the public. Engineers that are experienced in the work for which they are responsible, 

take legal responsibility for their engineering designs, and are bound by a code of ethics to protect the 

public health. 

Profile Grade — The trace of a vertical plane intersecting a particular surface of the proposed road 

construction located according to the plans, usually along the longitudinal centerline of the roadbed. 

Profile grade means either elevation or gradient of the trace according to the context. 

Project — The specific section of the highway or other property on which construction is to be performed 

under the contract.

Right-of-Way — Real property necessary for the project, including roadway, buffer areas, access, and 

drainage areas.

Roadbed — The graded portion of a highway prepared as a foundation for the pavement structure and 

shoulders. 

Roadside — The area between the outside shoulder edge and the right-of-way limits. The area between 

roadways of a divided highway may also be considered roadside. 

Roadway — In general, the portion of a highway, including shoulders, primarily for vehicular use. A 

divided highway has two or more roadways. In construction specifications, the portion of a highway within 

the construction limits.
Section 101

10

Roadway Prism — The area between the original and the final design cross-section. 

Roller Pass — One trip of a roller in one direction over one spot. 

Shop Drawings — See "Drawings"

Shoulder — A portion of the roadway contiguous with the traveled way that accommodates pedestrians, 

bicycles, stopped vehicles, and emergency use; and is used for lateral support of the subbase, base, and 

surface courses.

Sieve — See AASHTO M 92.

Solicitation — The complete assembly of documents (whether attached or incorporated by reference) 

furnished to prospective bidders.

Special Contract Requirement — An addition or revision to the Standard Specifications applicable to 

an individual project. 

Specifications — The written requirements for performing work.

Standard Form — Numbered form issued by the GSA for use as contract documents.

Standard Specifications — Standard Specifications for Construction of Roads and Bridges on Federal 

Highway Projects approved for general application and repetitive use. Also referred to as the FP.

Station — A precise location along a survey line.

Structures — Bridges, culverts, catch basins, drop inlets, retaining walls, cribbing, manholes, endwalls, 

buildings, sewers, service pipes, underdrains, foundation drains, and other constructed features that may 

be encountered in the work. 

Subbase — The lift or lifts of material placed on a subgrade to support a base. 

Subcontract — The written agreement between the Contractor and an individual or legal entity setting 

forth the obligations of the parties for the performance of and payment for a specific portion of the work 

to be performed by the subcontractor. 

Subcontractor — An individual or legal entity with which the Contractor sublets part of the work. This 

includes subcontractors and material suppliers in all tiers.

Subgrade — The top surface of a roadbed upon which the pavement structure, shoulders, and curbs are 

constructed. 

Substantial Completion — The point at which the project is complete and can be safely and effectively 

used by the public without further delays, disruption, or other impediments. For conventional bridge and 

highway work, the point at which bridge deck, parapet, pavement structure, shoulder, drainage, sidewalk, 

major demolition, roadway obliteration, permanent signing and markings, traffic barrier, safety 

appurtenance, utility, and lighting work is complete. 
Section 101

11

Substructure — Components of a bridge below the bearings of simple and continuous spans, skewbacks 

of arches, and tops of footings of rigid frames including backwalls, wingwalls, and wing protection 

railings.

Suitable Material — Rock or earth material that will provide stable foundations, embankments, or 

roadbeds, and is without organic matter, muck, frozen lumps, roots, sod, or other deleterious material. 

Suitable material may require drying or adding water, and other methods of manipulation before use. 

Suitable material includes the classifications of material for which the project was designed.

Superintendent — The Contractor’s on-site representative who has authority to act for the Contractor 

and is responsible for directing and supervising construction operations on behalf of the Contractor. 

Superstructure — The entire bridge, except the substructure. 

Surety — An individual or corporation legally liable for the debt, default, or failure of a Contractor to 

satisfy a contract obligation. 

Surface Course — The top lift or lifts of a pavement structure designed to accommodate the traffic load 

and resist skidding, traffic abrasion, and weathering. 

Target Value — A number established as a center for operating a given process. Once established, 

adjustments should be made in the process as necessary to maintain a central tendency about the target 

value. Test results obtained from a well-controlled process should cluster closely around the established 

target value and the mean of the test results should be equal to, or nearly equal to, the established target 

value. 

Temporary Stormwater Diversion — A temporary rerouting of stormwater runoff in a controlled, 

non-erosive manner.

Temporary Stream Diversion — A temporary rerouting of water into a temporary channel or through a 

system of structures within the construction limits to maintain water flow through or around the project.

Temporary Traffic Diversion — A temporary rerouting of public traffic onto a temporary alignment 

within the construction limits to bypass the work or part of the work.

Traveled Way — The portion of the roadway designated for the movement of vehicles, not including the

shoulders. 

Unsuitable Material — Material that cannot create stable foundations, embankments, or roadbeds. 

Unsuitable material includes muck, sod, and soils with high organic contents.

Well-graded — Graded from coarse to fine with a wide range of particle sizes and substantial amounts 

of the intermediate particle sizes.

Work — The providing of labor, material, equipment, and other incidentals necessary to complete the 

project according to the contract.
Section 102

12

Section 102. — BID, AWARD, AND EXECUTION OF CONTRACT

102.01 Acquisition Regulations. Bid, award, and execution of the contract is governed by the FAR and 

TAR. 

102.02 Preparation of Bids. Follow the requirements of FAR Provision 52.214-18 Preparation of 

Bids-Construction. 

Insert a numeric unit bid price for each pay item for which a quantity appears in the bid schedule. Multiply 

the unit bid price by the quantity for each pay item and show the amount bid. If mathematical checks made 

by the Government show a mistake in the amount bid, the corrected unit price extension governs. 

If "LPSM" appears as a unit of measure in the bid schedule, insert an amount bid for each lump sum pay 

item.

If "CTSM" appears as a unit of measure in the bid schedule, include the Government inserted amount for 

the pay item in the total bid amount. 

Total the amounts bid for each pay item and show the total bid amount. 

The quantities listed in the bid schedule are approximate, unless designated as a contract quantity, and are 

used for the comparison of bids. Payment will be made for the actual quantities of work performed and 

accepted or material provided according to the contract. The scheduled quantities may be increased, 

decreased, or deleted. Bid schedule quantities are considered the original contract quantities.

102.03 Bid Guarantee. Follow the requirements of FAR Clause 52.228-1 Bid Guarantee. 

102.04 Individual Surety. Follow the requirements of FAR Clause 52.228-11 Individual Surety-Pledge 

of Assets.

Complete and date the SF 28, Affidavit of Individual Surety after the solicitation date. The individual surety 

shall personally sign the SF 28. Bidders cannot serve as their own surety. See FAR 28.203 Individual 

Sureties.

After reviewing the SF 28, the CO may request the surety to submit further documentation with respect 

to its assets, debts, or encumbrances. The information may be required to be provided under oath. Failure 

of the surety to respond with the requested documentation within 7 days of receipt of the request is cause 

for rejection of the surety.

Any material misstatement by the surety, overstatement of assets (either as to ownership or value), or 

understatement of liabilities is cause for rejection of the surety. Substitution of individual sureties to 

support a bid bond after the bid opening will not be allowed. 

Provide documentary evidence as to the ownership and value of the assets pledged in support of the bond 

and details of the security interest in the assets by the individual sureties for the apparent low bidder within 

14 days after the opening of bids. Failure to submit evidence within the time required will be grounds for 

declaring the surety unacceptable.
Section 102 

13

After reviewing the SF 28 and documentary information on the security interest and the assets pledged, 

the CO may request the surety to submit further information and documents with respect to the documents 

submitted. The information may be required to be provided under oath. Failure of the surety to respond 

with the requested information or documents within 7 days of receipt of the request is cause for rejection 

of the surety.

102.05 Public Opening of Bids. Bids will be publicly opened at the time specified in the SF 1442, 

Solicitation, Offer, and Award. All bid openings will be conducted according to FAR Part 14 – Sealed 

Bidding. 

102.06 Performance and Payment Bonds. Follow the requirements of FAR Clause 52.228-15 

Performance and Payment Bonds – Construction. 

Use SF 25, Performance Bond and SF 25A, Payment Bond for submitting the bonds. 

Follow the requirements of Subsections 102.03 and 102.04. 

Submit the documentary evidence for individual sureties at the same time as the Affidavit of Individual 

Surety and security interest in assets pledged. A Contractor submitting an unacceptable individual surety 

in satisfaction of a performance or payment bond before the issuance of the NTP will be allowed one 

opportunity to substitute an acceptable surety or sureties within 7 days of receipt of notification that the 

surety is unacceptable.

The Government’s right to direct the substitution of sureties to ensure the continuing acceptability of the 

bonds during the performance of the contract according to FAR Clause 52.228-2 Additional Bond Security 

is not restricted.

The requirements of this Subsection are in addition to the requirements in FAR 28.203, except where in 

conflict with the requirements in the FAR, in which case the FAR supersedes the requirements of this 

Subsection. 
Section 103

14

Section 103. — SCOPE OF WORK

103.01 Intent of Contract. The intent of the contract is to provide for the construction and completion of 

the work described in the contract documents. The precise details of performing the work are not 

described, except as considered essential for the successful completion of the work. Provide labor, 

material, equipment, tools, transportation, and supplies necessary to complete the work according to the 

contract.

103.02 Disputes. Follow the requirements of FAR Clause 52.233-1 Disputes (Alternate I).

103.03 Value Engineering. Follow the requirements of FAR Clause 52.248-3 Value Engineering -

Construction. 

Before undertaking significant expenditures, submit a written description of the value engineering change 

proposal (VECP) concept. Within 14 days, the CO will inform the Contractor as to whether the concept 

appears to be viable or if the concept is unacceptable. If the CO indicates that the concept appears to be 

viable, then the Contractor can prepare and submit the formal VECP. 

103.04 Contractor Records. Follow the requirements of FAR Clause 52.222-8 Payrolls and Basic 

Records.

Upon request, provide records related to the contract to the Government for up to 3 years after final 

payment or for longer periods as provided by law. 

Include a provision in subcontracts at all tiers giving the Government the same rights as provided above 

with respect to the subcontractor’s records.

103.05 Partnering. To facilitate the contract, the CO offers to participate in a partnership with the 

Contractor. This partnership draws on the strengths of each organization to identify and achieve reciprocal 

goals. Partnering strives to resolve problems in a timely, professional, and non-adversarial manner. If 

problems result in disputes, partnering encourages, but does not require, alternative dispute resolution 

instead of the formal claim process. The objective is effective and efficient contract performance to 

achieve a quality project within budget and on schedule. 

Acceptance of this partnering offer by the Contractor is optional, and the partnership is bilateral.

If the partnering offer is accepted by the Contractor, mutually agree with the CO on the level of 

organizational involvement and the need for a professional to facilitate the partnering process. Engage the 

facilitator and other resources for key Contractor representatives and the CO to attend a partnership 

development and team-building workshop. Hold additional progress meetings upon mutual agreement. 

The direct cost of partnering facilities, professional facilitation, copying fees, and other miscellaneous 

costs directly related to partnering meetings will be shared by the Contractor and Government. Secure and 

pay for facilities, professional fees, and miscellaneous requirements. Submit invoices to the CO. The 

Government will reimburse the Contractor for 50 percent of the agreed costs incurred for the partnering 

process. The Government’s share will not exceed $5,000. 
Section 103

15

Each party is responsible for making and paying for its own travel, lodging, and meal arrangements. No 

time extension for the completion of the project will be made for the use of partnering. No changes to the 

contract can result from discussions during partnering sessions. 
Section 104

16

Section 104. — CONTROL OF WORK

104.01 Authority of the Contracting Officer. As stated in FAR 1.602-1(a), the CO has authority to 

execute, administer, or terminate contracts and make related determinations and findings. The CO may 

delegate authority to representatives to decide on acceptability, progress, and suspension of work, 

interpretation of the contract, and acceptable fulfillment of the contract.

104.02 Authority of Contracting Officer’s Representative. As stated in FAR 1.602-2(d), CORs will be 

designated in writing by the CO to act on behalf of the CO to administer the contract. The COR will 

administer the contract according to the contract documents and the FAR. The COR lacks authority to 

make commitments outside of the terms of the contract; issue changes that affect price, quality, quantity, 

delivery, or other terms and conditions of the contract; or direct the Contractor or its subcontractor to 

operate in conflict with the contract terms and conditions.

104.03 Authority of Inspectors. Inspectors are authorized to inspect work, including the preparation, 

fabrication, or manufacture of material for the project. Inspectors are not authorized to alter or waive 

contract requirements, issue instruction contrary to the contract, act as foreperson for the Contractor, or 

direct the Contractor’s operations. Inspectors have the authority to identify non-conforming work until the 

issue can be referred to and decided by the CO. An inspector is permitted to stop work in circumstances 

of imminent and substantial risk of death or injury.

104.04 Electronic Documentation. After award of the contract, provide documents in an approved 

electronic format.

Provide documents in their native file format (the format produced by the software that the document was 

created in) upon request. 

Provide a resolution quality with color, text, and lines clearly discernible. Submit each document in an 

individual file. Name files with a unique document name that includes the document date, document 

description, and project number, or as requested. 

Deliver electronic documents to the email address identified at the preconstruction conference or 

otherwise amended in writing by the CO. Documents delivered on removable media will not be accepted. 

Documents delivered after 5:00 p.m. local time will be considered received on the following business day.

In addition to electronic documents, provide paper copies of the following documents and other documents 

as directed: 

(a) Documents required under Section 102; 

(b) Weight records required under Subsection 109.03; 

(c) Receiving records required under Subsection 109.04; and 

(d) Concrete batch tickets required under Subsection 552.04. 

Provide one paper copy of each document upon request, unless more paper copies are specified. 
Section 104

17

The CO will reject without review documents that are unreadable, corrupted, illegible, or include 

malicious content.

104.05 Signatures for Electronic Documentation. Sign documents requiring a signature by electronic 

signature or by wet signature.

(a) Definitions. 

(1) Electronic signature. A computer data compilation of symbols or series of symbols executed, 

adopted, or authorized by an individual to be the legally binding equivalent of the individual’s 

handwritten signature.

(2) Wet signature. A signature of ink from pen, or a scanned copy of an actual signature of ink 

from pen. 

(b) Electronic signature. Unless the CO requests a wet signature, an electronic signature may be 

provided. Assume responsibility for the validity of electronic signatures. The Government will assume 

that the authorized individual’s electronic signature is authentic. 

Provide electronic signatures in the following formats:

(1) A digital signature from an encryption application;

(2) A digitized image of a paper signature; or

(3) A unique form or individual identification that can be used as a means of authenticating a 

record, record entry, or document. 

(c) Wet signature. After signing a document by wet signature, scan the complete document into an 

electronic format.

104.06 Specifications and Drawings. Follow the requirements of FAR Clause 52.236-21 Specifications 

and Drawings for Construction. 

(a) General. Submittals include both documents and drawings required to construct the work. Review 

submittals for accuracy, completeness, and compliance with the contract. Submittals that do not 

include evidence of Contractor review and verification may be returned for resubmission.

Time for approval starts over when submittals are returned for revision or when additional information 

is requested. Perform work related to submitted documents or drawings only after they are approved. 

Obtain written approval before changing or deviating from the approved submittals. 

Submit documents and drawings according to Subsection 104.04. 

(1) Drawings. Drawings include: 

(a) Layouts that show the relative position (vertical and horizontal as appropriate) of work to 

be performed; 

(b) Fabrication details for manufactured items and assemblies;
Section 104

18

(c) Installation and erection procedures; 

(d) Details of post-tensioning and other systems; 

(e) Detailed trench and excavation procedures that conform to OSHA standards; 

(f) Traffic control implementation drawings;

(g) Methods for performing work near existing structures or other areas to be protected; and

(h) Calculations that support each drawing. 

Show drawing dimensions in the same units as shown in the plans. Limit drawings to a maximum 

size of 24 by 36 inches. Include the project number, name, and other identification as shown in the 

contract on each drawing and calculation sheet. 

Drawings will be reviewed in the order they are received. Allow 30 days for approval of drawings 

and 40 days for approval of railroad structure drawings unless otherwise specified. Submit 

additional drawings for unique situations to clarify layout, construction details, or method if 

requested.

(2) Documents other than drawings. Documents other than drawings include descriptive 

literature, illustrations, schedules, performance and test data, certifications, and similar material 

submitted to certify or explain specific portions of the work required by the contract. Allow 

14 days for approval unless otherwise specified. 

(b) Specific requirements for concrete and miscellaneous structures.

(1) Submit drawings for the following: 

(a) Site-specific layouts and installation procedures for all wall types;

(b) Site-specific layouts and installation procedures for gabion and revet mattress installations; 

(c) Forms and falsework for cast-in-place non-bridge concrete structures and retaining walls 

less than or equal to 6 feet in height; 

(d) Shoring systems and cofferdams less than 6 feet in height; 

(e) Fabrication drawings for railings and parapets;

(f) Fabrication drawings for prestressed members;

(g) Fabrication and installation drawings for expansion joint assemblies; 

(h) Fabrication drawings for bearing assemblies;

(i) Construction joint location and concrete deck placement sequences not according to the 

plans; 

(j) Erection diagrams for structural plate structures (multi-plate structures);
Section 104

19

(k) Steel fabrication and assembly drawings; 

(l) Wood structure fabrication and assembly drawings; 

(m) Utility hanger details;

(n) Fabrication and installation drawings for precast items other than precast bridge elements; 

(o) Details and installation procedures for guardrail, guardrail terminal systems, and crash 

cushions; and

(p) Site-specific layouts for rockeries.

(2) Submit drawings and supporting calculations that bear the seal and signature of a professional 

engineer proficient in the applicable design field for the following:

(a) Forms and falsework for cast-in-place concrete structures greater than 6 feet in height;

(b) Forms and falsework for all cast-in-place bridge elements;

(c) Shoring systems and cofferdams greater than 6 feet in height; 

(d) Shoring systems that support traffic loadings; 

(e) Bridge concrete forms; 

(f) Containment system for bridge work;

(g) Girder erection plans;

(h) Partial or full demolition of structural bridge elements;

(i) Post-tensioning systems;

(j) Precast bridge elements;

(k) FRP bridges and structural components;

(l) Concrete box culvert details; 

(m) Concrete headwall and wingwall details;

(n) Reinforced soil slopes details;

(o) Ground anchors, soil nail, rock bolt, driven pile, drilled shaft, and micropile assembly 

details, layout, and installation and testing procedures; 

(p) MSE and tie back wall details;

(q) Alternate retaining wall details; 
Section 104

20

(r) Details and installation procedures for proprietary wall systems; and 

(s) Stream diversions. 

(3) Submit drawings and supporting calculations that bear the seal and signature of a professional 

engineer who is proficient in the applicable design field and licensed in the state where the project 

will be constructed for the following:

(a) Falsework for structures with spans exceeding 16 feet;

(b) Falsework for structures with heights exceeding 14 feet;

(c) Falsework for structures if traffic, other than workers involved in constructing the structure, 

will travel under the structure;

(d) Temporary bridge structures and load ratings for temporary bridge structures;

(e) New or existing bridges structures to be used as temporary work platforms and load ratings 

for new or existing bridges to be used as temporary work platforms conforming to AASHTO,

The Manual for Bridge Evaluation (MBE); 

(f) New prefabricated bridges or prefabricated bridge superstructures and load ratings for new 

prefabricated bridge superstructures conforming to AASHTO, MBE; 

(g) Helical piles; and 

(h) Contractor-designed retaining structures including walls, reinforced soil slopes, and 

rockeries.

(c) As-built drawings. Maintain a separate set of plans exclusively for as-built drawings. Use the 

color "red" to identify changes. Use approved methods to record changes accurately and neatly. 

Include details and notes on additional information discovered during construction. Note additions or 

revisions to the location, character, and dimensions of work. Strikeout details shown that are not 

applicable to the completed work. 

Retain as-built drawings at the project site or an alternate location as approved.

Keep as-built drawings current and maintain a revision log of changes made. Check and initial plan 

sheets that were incorporated in the completed work without change. Meet with the CO to jointly 

review as-built drawings and log for accuracy, completeness, and legibility before submission of each 

monthly invoice. The CO may retain a portion of the progress payment if as-built drawings are not 

current.

Submit as-built drawings and revision logs before the final inspection. Correct errors and omissions 

found during the final inspection and resubmit as-built drawings for approval within 7 days after the 

final inspection. 

When as-built drawings are approved, submit the final as-built drawings according to 

Subsection 104.04. 
Section 104

21

Include the following in the final as-built drawings:

(1) Title sheet.

(a) "AS-BUILT DRAWINGS" (bold text);

(b) Name of Contractor; 

(c) Project completion date; 

(d) Revisions to project length;

(e) Revisions to begin and end stations of project; 

(f) Revisions to index to sheets; 

(g) Strikeout schedules or options not awarded; 

(h) Plan notes; and 

(i) A note stating, "Work was constructed as designed unless otherwise noted."

(2) Typical section sheets.

(a) Revisions in dimensions;

(b) Revisions in material;

(c) Revisions in station range;

(d) Revisions to curve widening table; 

(e) Revisions to begin and end stations of project; and 

(f) Strikeout schedules or options not awarded. 

(3) Summary of quantities and tabulation sheets.

(a) Revisions to quantities, locations, notes, remarks, including totals; 

(b) Strikeout unused pay items; 

(c) Revisions to application rates; and

(d) Revisions to location, type, end treatments, riprap, and skew on the drainage summary.

(4) Plan and profile sheets. Note additions or revisions to the location, character, and dimensions 

of the following items:

(a) Plan.

(1) Alignment and curve and spiral information;
Section 104

22

(2) Equations; 

(3) Construction limits;

(4) Right-of-way;

(5) Road approaches; 

(6) Subexcavation and roadway obliteration; 

(7) Underdrains; 

(8) Trenches and drains;

(9) Channels and ditches; 

(10) Cut and fill slopes; 

(11) Monuments and permanent references, including revised or new Control Points; 

(12) Guardrail, guardwall, and end treatment; 

(13) Constructed, relocated, or encountered utilities; 

(14) Structures and obstructions abandoned in the roadbed; and 

(15) Walls.

(b) Profile.

(1) Grades, elevations, and stationing of points of intersection; 

(2) Equations; 

(3) Culvert diameter, length, type, skew, and stationing; 

(4) Culvert extension and length of existing culvert; 

(5) Walls;

(6) Limits of reinforced soil slopes, rock embankment; and 

(7) Guardrail, guardwall, and end treatment. 

(5) Bridge sheets. Note additions or revisions to the location, character, and dimensions of the 

following items:

(a) Stationing of bridge ends; 

(b) Elevations including footing, bearing pads, deck, and top of walls; 

(c) Pile records with pile length, size, type, and tip elevation; 
Section 104

23

(d) Modifications or repairs to drilled shafts or micropiles;

(e) Micropile installation records with drilling duration and observations, drill log, final 

location and inclination, final tip elevation, cut-off elevation, modification or repairs, grout 

pressures and quantities, and test records;

(f) Post-tensioning records including stressing sequence, jacking force, theoretical and actual 

tendon elongation measurements, and duct size and layout; 

(g) Construction and concrete placement sequences;

(h) Bearing details with orientation;

(i) Expansion joints including actual clearance with atmospheric temperature at time of setting 

joints;

(j) Changes in plan or dimensions including changes in reinforcing; 

(k) Location of construction joints; and

(l) Bridge railing.

(6) Miscellaneous sheets. Note additions or revisions to the location, character, and dimensions 

of the following items:

(a) Parking areas and turnouts; 

(b) Curbs and sidewalks; 

(c) Fencing; 

(d) Landscaping and planting; 

(e) Pavement markings;

(f) Signs; 

(g) Permanent erosion control measures;

(h) Rock bolts and dowels; 

(i) Draped rockfall protection; 

(j) Midslope rockfall attenuator;

(k) Roadside rockfall protection; 

(l) Anchored wire mesh; 

(m) Drain holes in rock; 
Section 104

24

(n) Horizontal drains; and 

(o) Plan notes. 

(7) Standard and detail sheets. Note the additions or revisions to the character and dimensions 

of details.

104.07 Coordination of Contract Documents. The FAR, TAR, Special Contract Requirements (SCR), 

plans, and Standard Specifications are contract documents. A requirement in one document is binding as 

though occurring in all the contract documents. The contract documents are intended to be complementary 

and to describe and provide for a complete contract. In case of discrepancy, calculated and shown 

dimensions govern over scaled dimensions. The contract documents govern in the following order: 

(a) FAR;

(b) TAR;

(c) SCR;

(d) Plans; and 

(e) Standard Specifications. 

104.08 Load Restrictions. Follow the requirements of FAR Clause 52.236-10 Operations and Storage 

Areas.

Comply with legal load restrictions while hauling material and equipment on public roads and bridges to 

and from the project. Regardless of the legal or posted load limit, control loads to prevent damage to 

existing and new infrastructure within the project limits.

Obtain necessary oversize or overweight vehicle permits and escorts for moving oversized or overweight 

loads. Provide a copy of the permits and associated loading calculations for roads and bridges within the 

project limits. A special permit does not relieve the Contractor of liability for damage resulting from 

moving or using material or equipment to or within the job site. 

Unless otherwise permitted, do not operate equipment or vehicles that exceed the legal load limits over 

new or existing structures, or pavements within the project. Ensure loads do not damage subgrade or 

utilities.

Replace or restore infrastructure damaged during operations to original condition. 

104.09 Construction Loading of Structures. Protect new and existing structures within the project limits 

from construction loads.

Construction loads include, but are not limited to, the weight of cranes, trucks, paving equipment, other 

heavy construction, or material delivery equipment, as well as the delivery or storage of materials placed 

on or adjacent to the structure or parts thereof during the various stages (phases) of the work.

If construction loads are planned to be located on or adjacent to a structure to be protected, determine the 

anticipated construction load, the construction loading capacity of the structure, and the effects the 
Section 104

25

construction load will have on the structure. Consider the sequencing of the work, including construction 

phasing. 

If the loading capacity of the structure is not provided, determine the appropriate loading capacity 

information. 

Submit drawings and calculations for approval according to Subsection 104.06(a)(1) that bear the seal and 

signature of a professional engineer who is proficient in the applicable design field before starting work.

104.10 Inspection at the Plant. Work may be inspected at the point of production or fabrication. 

Manufacturing plants may be inspected for compliance with specified manufacturing methods. Material 

samples may be obtained for laboratory testing for compliance with quality requirements. Allow entry at 

all times to the parts of the plant producing the work.

104.11 Other Contracts. Follow the requirements of FAR Clause 52.236-8 Other Contracts.
Section 105

26

Section 105. — CONTROL OF MATERIAL

105.01 Source of Supply and Quality Requirements. Follow the requirements of FAR Clause 52.236-

5 Material and Workmanship. Select sources and submit acceptable material. Notify the CO of proposed 

sources before delivery to the project to expedite material inspection and testing. Do not incorporate 

material requiring submittal into the work until approved.

Material may be approved at the source of supply before delivery to the project. Provide source quality 

test results dated within 12 months from NTP. Approval of a material source does not constitute 

acceptance of material submitted from the source. If an approved source fails to supply acceptable material 

during the life of the project, further use of that source may be denied. 

Submit samples of material for source quality verification testing for material if requested. 

105.02 Material Sources. 

(a) Government-furnished sources. The Government will acquire the permits and rights to 

remove material from furnished sources identified in the contract and to use such property for a 

plant site and stockpiles. Comply with permits and written agreements acquired by the 

Government. 

Test reports and available historical material data will be provided to the Contractor upon request.

Do not perform work within a source until a source development plan is approved. Allow 7 days 

for approval. Include the following as applicable:

(1) Source development details. Include requirements in Sections 107, 157, 204, and 205; 

(2) Restoration details. Include requirements in Sections 624, 625, and 626; and

(3) Abandonment details. Perform work necessary to produce acceptable material including 

work required by the approved source development plan. 

The quality of material is generally acceptable. Variations in quality should be expected as it is not 

feasible to ascertain the quality of material for an entire deposit from exploratory samples. 

Determine the quantity, type of equipment, and work necessary and produce acceptable material 

to be incorporated in the work. Do not perform aggregate source quality tests when using 

Government-furnished sources. Perform QC sampling and testing according to the approved 

Contractor QCP in Section 153 and acceptance testing for the required Section of work. Allow the 

CO the opportunity to witness sampling and splitting of the test material.

(b) Government-furnished material stockpile. The quality of the material in the stockpile has 

been preapproved unless otherwise noted and is considered acceptable for the application for 

which it has been designated. Perform QC sampling and testing according to the approved 

Contractor QCP in Section 153 and acceptance testing for the required Section of work. Allow the 

CO the opportunity to witness sampling and splitting of the test material.

(c) Contractor-located sources. The Contractor is responsible for Contractor-located material 

sources, including established commercial material sources. Use sources that fulfill the contract 
Section 105

27

quantity and quality requirements. Determine the quantity, type of equipment, and work necessary 

to select and produce an acceptable material. Secure permits and clearances for use of the source 

and submit copies of the documents to the CO. Follow the environmental requirements of 

Subsection 107.10(d). Submit available historical data indicating acceptable material can be 

produced from the source. Perform QC sampling and testing according to the approved Contractor 

QCP in Section 153, aggregate source quality tests, and acceptance testing for the required Section 

of work. Allow the CO the opportunity to witness sampling and splitting of the test material.

105.03 Material Source Management. Notify the CO at least 14 days before starting operations in the 

source. Develop and operate according to the approved source development plan for 

Government-furnished sources or written agreement for Contractor-located sources. 

Before developing a material source, measure the sediment content of bodies of water adjacent to the work 

area that will receive drainage from the work area. Perform erosion and sediment control according to the 

source development plan and Section 157. 

Do not remove material measured in-place from borrow sources or Government-furnished stockpiles until 

initial ground survey measurements have been taken according to Subsection 152.05(j) and approved. 

Perform final ground survey measurements according to Subsection 152.05(j). 

Dispose of rejected material in an approved manner.

105.04 Handling and Storing Material. Handle and store material to preserve its quality and fitness for 

the work. Stored material approved before storage may again be inspected before use in the work. Locate 

stored material to facilitate prompt inspection. 

Use only approved portions of the right-of-way for storing material or equipment. Provide additional space 

as needed. Do not use private property for storage without written permission of the owner or lessee. 

Submit copies of agreements and documents. 

Provide security for stored material.

Restore Government-furnished storage sites to their original condition.

105.05 Use of Material Found in the Work. Stone, gravel, sand, or other material found in the excavation 

may be used for another pay item, if approved. If material found in the excavation is used for another pay 

item, material will be paid both as excavation and as the other pay item for which it is used. Replace 

excavation used with acceptable material at no additional cost to the Government. Excavate or remove 

material only from within the grading limits, as indicated by the slope and grade lines. 

The right to use and process material found in the work excludes the use and processing of material for 

nongovernment contract work, except for the disposal of waste material. If the Contractor produces or 

processes more material from Government lands than the quantities required for the contract, the 

Government may: 

(a) Take possession of the excess material and direct its use, paying the Contractor only for the cost 

of production; or 

(b) Require removal of the material and restoration of the land to a satisfactory condition at no 

additional cost to the Government.
Section 105

28

105.06 Material Source Restoration. Restore Government-furnished sources according to the approved 

source development plan. Restack the unused portion of the Government-furnished stockpiles upon 

completion of the work at no additional cost to the Government. Do not measure restoration of material 

sources for payment. 
Section 106

29

Section 106. — ACCEPTANCE OF WORK

106.01 Conformity with Contract Requirements. Follow the requirements of FAR Clause 52.246-12 

Inspection of Construction. 

References to standard documents and test methods of AASHTO, ASTM, GSA, and other recognized 

standard authorities refer to the documents and methods in effect on the date of the Invitation for Bids 

(IFB) or Request for Proposal (RFP).

Use the FLH Testing Forms for reporting materials test results unless otherwise approved. Use the FLH 

Test Methods in effect on the date of the IFB or RFP for testing materials, when applicable.

Use ASTM E29, Absolute Method, for test results and related calculations.

Perform work to the lines, grades, cross-sections, dimensions, and processes or material requirements 

shown in the contract. 

Incorporate manufactured material into the work according to the manufacturer’s recommendations or to 

these specifications, whichever is stricter. 

If standard manufactured items are specified (such as fence, wire, plates, rolled shapes, and pipe conduits 

that are identified by gauge, density, or section dimensions) the tolerances for masses or dimensions will 

be established manufacturing tolerances unless otherwise noted. 

Plan dimensions and contract specification values are the values to be strived for and complied with as 

the design values from which deviations are allowed. Perform work and provide material that is uniform 

in character and reasonably close to the prescribed value or within the specified tolerance range. The 

purpose of a tolerance range is to accommodate occasional minor variations from the median zone that 

are unavoidable for practical reasons.

Perform process control testing as required. Do not rely on the availability of Government test results for 

process control.

The Government may inspect, sample, or test any work, at any time before acceptance of the entire work. 

If the Government tests work, copies of test reports will be provided to the Contractor upon request. 

Government tests may or may not be performed at the work site. 

Work will be evaluated for conformance to contract requirements and will be designated as follows: 

(a) Conforming work. Acceptable work conforming to the Contract will be paid for at the contract 

price per unit of measurement. Four methods of determining conformity and accepting work are 

described in Subsections 106.02 through 106.05. The primary method of acceptance is specified in the 

Acceptance Subsection of each Section, but work may be rejected if it is found not to comply with the 

contract. 

(b) Nonconforming work. Remove, repair, or replace work at no additional cost to the Government 

that does not conform to the contract or to prevailing industry standards where no specific contract 

requirements are noted. Provide temporary traffic control and perform other related work to correct 

nonconformities at no additional cost to the Government. 
Section 106

30

As an alternative to removal and replacement, the Contractor may submit a written request for approval 

that includes the following:

(1) Alternatives.

(a) Have the work accepted at a reduced price; or

(b) Perform corrective measures to bring the work into conformity.

(2) Supporting rationale and documentation. Include references or data justifying the proposal 

based on an evaluation of test results, effect on service life, value of material or work, quality, 

aesthetics, and other tangible engineering basis. 

The CO will determine disposition of the nonconforming work. 

106.02 Visual Inspection. Acceptance is based on visual inspection of the work for compliance with the 

contract. Use prevailing industry standards in the absence of specific contract requirements or tolerances.

Material accepted by visual inspection may be sampled and tested for conformance. 

106.03 Certification. For material manufactured off site, use a manufacturer with an ISO 9000 

certification or an approved testing and inspection system. Require the manufacturer to clearly mark the 

material or packaging with a unique product identification or specification standard to which it is 

produced. 

Other than references in or to the FAR or Federal Law, when the Standard Specifications or Special 

Contract Requirements reference certifications, certificates, certified documents, equipment, or 

individuals; the references refer to documentation of non-regulatory, peripheral contract requirements that 

are required to be validated by an individual or organization having unique knowledge or qualifications 

to perform such validation.

Check certifications before incorporating the material into the work to ensure that the requirements of the 

contract have been met. Mark the certifications with the following information: project number and name;

pay item number and description; contractor’s signature; and date.

Material accepted by certification may be sampled and tested for conformance.

Provide a commercial certification unless a production certification is identified in the Acceptance 

Subsection. 

(a) Commercial certification. A commercial certification is a manufacturer’s or Contractor’s 

representation that the material complies with the contract. The representation may be labels, catalog 

data, stamped specification standards, or supplier’s certifications indicating the material is produced 

to a commercial standard or specification.

Submit one commercial certification for similar material from the same manufacturer.

(b) Production certification. A production certification is a supplier’s certification that the material 

has been produced to a specific standard and is accompanied by test data performed within the past 
Section 106

31

12 months and other information as described below to support that the material complies with the 

contract.

Submit a production certification from the manufacturer for each shipment of material. Include the 

following:

(1) Date and place of manufacture;

(2) Lot number or other means of cross-referencing to the manufacturer’s inspection and testing 

system; and

(3) Substantiating evidence that the material conforms to the contract as required by 

FAR 46.105(a)(4), including the following: 

(a) Test results on material from the same lot and documentation of the inspection and testing 

system;

(b) A statement from the manufacturer that the material complies with the contract; and

(c) Manufacturer’s signature or other means of demonstrating accountability for the 

certification.

106.04 Measured or Tested Conformance. Perform necessary measurements and tests to ensure work 

complies with the contract. 

Use prevailing industry standards in the absence of contract requirements or tolerances. 

Submit measurements, tests, and supporting data for acceptance.

If Government testing is performed on work, the results may be used for acceptance purposes. 

106.05 Statistical Evaluation of Work and Determination of Pay Factor. Statistical evaluation of work 

is a method of analyzing inspection or test results to determine conformity with the contract.

Use the computer program, QL-Pay, to determine percent within limits and pay factors. The work will be 

accepted as follows:

(a) General. For work evaluated based on statistical evaluation, both the Government and Contractor 

assume some risk.

The Government’s risk is the probability that work of a rejectable quality level is accepted. The 

Contractor’s risk is either the probability that work produced at an acceptable quality level (AQL) is 

rejected (α) or the probability that the work produced at the AQL is accepted at less than the contract 

unit price. 

Acceptable quality level is the lowest percentage of work within the specification limits that is 

considered acceptable for payment at contract unit price. There are two categories: category I is based 

on an AQL of 95 percent and category II is based on an AQL of 90 percent. 

In both cases, the Contractor’s risk is 5 percent and the risk of rejection is significantly lower.
Section 106

32

As an incentive to produce uniform quality work and to offset the Contractor’s risk, a final payment 

greater than the contract unit price may be obtained under certain conditions. 

The quality characteristics to be evaluated, sampling frequency, sampling location, test methods, and 

category are listed in the Acceptance Subsection of each Section. The following applies: 

(1) Lot size. A lot is a discrete quantity of work to which the statistical evaluation procedure is 

applied. A lot normally represents the total quantity of work produced. More than one lot may 

occur if changes in the target values, material sources, or JMF are requested in writing and 

approved. 

(2) Sampling frequency. The frequency rate shown normally requires at least 5 samples. The 

minimum required to perform a statistical evaluation is 3 samples. The maximum obtainable pay 

factor with 3, 4, or 5 samples is 1.01. At least 8 samples are required to obtain a 1.05 pay factor. 

If the sampling frequencies and quantity of work would otherwise result in fewer than 8 samples, 

submit a written request to increase the sampling frequency to provide for at least 8 samples. 

Submit the request to increase the sampling frequency at least 48 hours before starting production. 

An increase in the sampling frequency may result in a reduced pay factor. 

(3) Sampling location. The exact location of sampling will be determined by the CO based on 

random numbers. 

(4) Specification limits. The specification limits for the quality characteristics are listed in the 

contract for the work in question. 

If Contractor testing and inspection are verified by the Government, the Contractor’s results may be 

used by the Government to evaluate work for acceptance. Contractor data will be verified using the Fand t-test statistics in comparison to Government test results at a significance level of 0.01. If the 

Contractor’s data is not verified and the CO determines it to be appropriate, the Government will 

perform tests associated for that discrete portion of work. In this situation, the Government test results 

will control in determining the acceptability and pay factor of the work. 

(b) Acceptance. The final pay factor for the work in a lot will not be determined until inspections and 

test results are completed and evaluated.

Before determining the final pay factor, the work may be incorporated in the project provided the 

current pay factor does not fall below 0.90. If a lot is concluded with fewer than 3 samples, the material 

will be evaluated under Subsection 106.04. 

If the current pay factor of a lot falls below 0.90, stop production. Resume production after effective 

and acceptable actions to improve quality have occurred. 

A lot containing an unsatisfactory percentage of non-specification material (less than 1.00 pay factor) 

is accepted provided the lowest single pay factor has not fallen into the reject portion shown in 

Table 106-2. 

A lot containing an unsatisfactory percentage of non-specification material with the lowest single pay 

factor falling into the reject portion shown in Table 106-2 is rejected. Remove rejected material from 

the work. 
Section 106

33

If approved, it is permissible to voluntarily remove non-specification material and replace it with new 

material to avoid or minimize a pay factor of less than 1.00. Sample and test new material according 

to this Subsection. New material will be evaluated according to this Subsection. 

Any quantity of material may be rejected based on visual inspection or test results. Do not incorporate 

rejected material in the work. The results of tests run on rejected material will be excluded from the 

lot.

(c) Statistical evaluation. The estimated percentage of work that is within the specification limits for 

each quality characteristic will be determined as follows:

(1) Calculate the arithmetic mean (xx̅) of the test values:

xx̅= ∑xx

nn

where: ∑ = summation of:

x = individual test value

n = total number of test values

(2) Calculate the standard deviations: 

 

where: ∑(x2) = summation of the squares of individual test values

(∑x)2 = summation of the individual test values squared

(3) Calculate the upper quality index (QU):

QU = UUUUUU  −   xx̅

ss

where: USL = upper specification limit

The USL is equal to the contract specification limit or the target value plus the allowable deviation.

(4) Calculate the lower quality index (QL):

QQLL = xx̅  −  UUUUUU

ss

where: LSL = lower specification limit

The LSL is equal to the contract specification limit or the target value minus the allowable deviation.
Section 106

34

(5) From Table 106-1, determine PU (the estimated percentage of work within the USL). PU

corresponds to a given QU. If a USL is not specified, PU is 100. 

(6) From Table 106-1, determine PL (the estimated percentage of work within the lot within the 

LSL). PL corresponds to a given QL. If an LSL is not specified, PL is 100. 

(7) Calculate the total estimated percentage of work within the USL and LSL: 

PU + PL - 100 

(8) Repeat steps 1 through 7 for each quality characteristic listed for statistical evaluation.
Section 106

35

Table 106-1 

Estimated Percent of Work Within Specification Limits

Estimated Percent within

Specification Limits

(PU or PL) 

Upper Quality Index QU or Lower Quality Index QL

n=3 n=4 n=5 n=6 n=7 n=8 n=9

n=10

to 

n=11

n=12

to 

n=14

100 1.16 1.49 1.72 1.88 1.99 2.07 2.13 2.20 2.28

99 – 1.46 1.64 1.75 1.82 1.88 1.91 1.96 2.01

98 – 1.43 1.58 1.66 1.72 1.75 1.78 1.81 1.84

97 1.15 1.40 1.52 1.59 1.63 1.66 1.68 1.71 1.73

96 – 1.37 1.47 1.52 1.56 1.58 1.60 1.62 1.64

95 1.14 1.34 1.42 1.47 1.49 1.51 1.52 1.54 1.55

94 – 1.31 1.38 1.41 1.43 1.45 1.46 1.47 1.48

93 1.13 1.28 1.33 1.36 1.38 1.39 1.40 1.41 1.41

92 1.12 1.25 1.29 1.31 1.33 1.33 1.34 1.35 1.35

91 1.11 1.22 1.25 1.27 1.28 1.28 1.29 1.29 1.30

90 1.10 1.19 1.21 1.23 1.23 1.24 1.24 1.24 1.25

89 1.09 1.16 1.18 1.18 1.19 1.19 1.19 1.19 1.20

88 1.07 1.13 1.14 1.14 1.15 1.15 1.15 1.15 1.15

87 1.06 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.11

86 1.04 1.07 1.07 1.07 1.07 1.06 1.06 1.06 1.06

85 1.03 1.04 1.03 1.03 1.03 1.03 1.02 1.02 1.02

84 1.01 1.01 1.00 0.99 0.99 0.99 0.99 0.98 0.98

83 0.99 0.98 0.97 0.96 0.95 0.95 0.95 0.95 0.94

82 0.97 0.95 0.93 0.92 0.92 0.92 0.91 0.91 0.91

81 0.95 0.92 0.90 0.89 0.88 0.88 0.88 0.87 0.87

80 0.93 0.89 0.87 0.86 0.85 0.85 0.84 0.84 0.84

79 0.91 0.86 0.84 0.82 0.82 0.81 0.81 0.81 0.80

78 0.88 0.83 0.81 0.79 0.79 0.78 0.78 0.77 0.77

77 0.86 0.80 0.77 0.76 0.75 0.75 0.74 0.74 0.74

76 0.83 0.77 0.74 0.73 0.72 0.72 0.71 0.71 0.70

75 0.81 0.74 0.71 0.70 0.69 0.69 0.68 0.68 0.67

74 0.78 0.71 0.68 0.67 0.67 0.65 0.65 0.65 0.64

73 0.75 0.68 0.65 0.64 0.63 0.62 0.62 0.62 0.61

72 0.73 0.65 0.62 0.61 0.60 0.59 0.59 0.59 0.58

71 0.70 0.62 0.59 0.58 0.57 0.57 0.56 0.56 0.55

70 0.67 0.59 0.56 0.55 0.54 0.54 0.53 0.53 0.52

69 0.64 0.56 0.53 0.52 0.51 0.51 0.50 0.50 0.50

68 0.61 0.53 0.50 0.49 0.48 0.48 0.48 0.47 0.47

67 0.58 0.50 0.47 0.46 0.45 0.45 0.45 0.44 0.44

66 0.55 0.47 0.45 0.43 0.43 0.42 0.42 0.42 0.41

65 0.51 0.44 0.42 0.40 0.40 0.39 0.39 0.39 0.38

64 0.48 0.41 0.39 0.38 0.37 0.37 0.36 0.36 0.36

63 0.45 0.38 0.36 0.35 0.34 0.34 0.34 0.33 0.33

62 0.41 0.35 0.33 0.32 0.32 0.31 0.31 0.31 0.30

61 0.38 0.30 0.30 0.30 0.29 0.28 0.28 0.28 0.28

60 0.34 0.28 0.28 0.25 0.25 0.25 0.25 0.25 0.25

59 0.31 0.27 0.25 0.23 0.23 0.23 0.23 0.23 0.23

58 0.30 0.25 0.23 0.20 0.20 0.20 0.20 0.20 0.20

57 0.25 0.20 0.18 0.18 0.18 0.18 0.18 0.18 0.18

56 0.20 0.18 0.16 0.15 0.15 0.15 0.15 0.15 0.15

55 0.18 0.15 0.13 0.13 0.13 0.13 0.13 0.13 0.13

54 0.15 0.13 0.10 0.10 0.10 0.10 0.10 0.10 0.10

53 0.10 0.10 0.08 0.08 0.08 0.08 0.08 0.08 0.08

52 0.08 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05

51 0.05 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03

50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Note: If the value of QU or QL does not correspond to a value in the table, use the next lower Q value. If QU

or QL are negative values, PU or PL is equal to 100 minus the table value for PU or PL. 
Section 106

36

Table 106-1 (continued)

Estimated Percent of Work Within Specification Limits

Estimated Percent

within

Specification Limits

(PU or PL) 

Upper Quality Index QU or Lower Quality Index QL

n=15

to 

n=17

n=18

to 

n=22

n=23

to 

n=29

n=30

to 

n=42

n=43

to 

n=66

n=67

to 

∞

100 2.34 2.39 2.44 2.48 2.51 2.56

99 2.04 2.07 2.09 2.12 2.14 2.16

98 1.87 1.89 1.91 1.93 1.94 1.95

97 1.75 1.76 1.78 1.79 1.80 1.81

96 1.65 1.66 1.67 1.68 1.69 1.70

95 1.56 1.57 1.58 1.59 1.59 1.60

94 1.49 1.50 1.50 1.51 1.51 1.52

93 1.42 1.43 1.43 1.44 1.44 1.44

92 1.36 1.36 1.37 1.37 1.37 1.38

91 1.30 1.30 1.31 1.31 1.31 1.31

90 1.25 1.25 1.25 1.25 1.26 1.26

89 1.20 1.20 1.20 1.20 1.20 1.20

88 1.15 1.15 1.15 1.15 1.15 1.15

87 1.11 1.11 1.11 1.11 1.11 1.11

86 1.06 1.06 1.06 1.06 1.06 1.06

85 1.02 1.02 1.02 1.02 1.02 1.02

84 0.98 0.98 0.98 0.98 0.98 0.98

83 0.94 0.94 0.94 0.94 0.94 0.94

82 0.91 0.90 0.90 0.90 0.90 0.90

81 0.87 0.87 0.87 0.87 0.87 0.87

80 0.83 0.83 0.83 0.83 0.83 0.83

79 0.80 0.80 0.80 0.80 0.80 0.79

78 0.77 0.76 0.76 0.76 0.76 0.76

77 0.73 0.73 0.73 0.73 0.73 0.73

76 0.70 0.70 0.70 0.70 0.70 0.70

75 0.67 0.67 0.67 0.67 0.67 0.66

74 0.64 0.64 0.64 0.64 0.64 0.63

73 0.61 0.61 0.61 0.61 0.61 0.60

72 0.58 0.58 0.58 0.58 0.58 0.57

71 0.55 0.55 0.55 0.55 0.55 0.54

70 0.52 0.52 0.52 0.52 0.52 0.52

69 0.49 0.49 0.49 0.49 0.49 0.49

68 0.47 0.46 0.46 0.46 0.46 0.46

67 0.44 0.44 0.43 0.43 0.43 0.43

66 0.41 0.41 0.41 0.41 0.41 0.40

65 0.38 0.38 0.38 0.38 0.38 0.38

64 0.36 0.35 0.35 0.35 0.35 0.35

63 0.33 0.33 0.33 0.33 0.33 0.32

62 0.30 0.30 0.30 0.30 0.30 0.30

61 0.28 0.28 0.28 0.28 0.28 0.28

60 0.25 0.25 0.25 0.25 0.25 0.25

59 0.23 0.23 0.23 0.23 0.23 0.23

58 0.20 0.20 0.20 0.20 0.20 0.20

57 0.18 0.18 0.18 0.18 0.18 0.18

56 0.15 0.15 0.15 0.15 0.15 0.15

55 0.13 0.13 0.13 0.13 0.13 0.13

54 0.10 0.10 0.10 0.10 0.10 0.10

53 0.08 0.08 0.08 0.08 0.08 0.08

52 0.05 0.05 0.05 0.05 0.05 0.05

51 0.03 0.03 0.03 0.03 0.03 0.03

50 0.00 0.00 0.00 0.00 0.00 0.00

Note: If the value of QU or QL does not correspond to a value in the table, use the next lower Q value. If QU

or QL are negative values, PU or PL is equal to 100 minus the table value for PU or PL.
Table 106-2 

Pay Factors

PAY FACTOR Minimum Required Percent of Work Within Specification Limits for a Given Pay Factor PU + PL - 100 

Category

n=3 n=4 n=5 n=6 n=7 n=8 n=9

n=10

to

n=11

n=12

to

n=14

n=15

to

n=17

n=18

to

n=22

n=23

to

n=29

n=30

to

n=42

n=43

to

n=66

n=67

to

∞ I II 

1.05 – – – – – – 100 100 100 100 100 100 100 100 100 100

1.04 – – – – – 100 99 97 95 96 96 96 97 97 97 97

1.03 – – – – 100 98 96 94 92 93 93 94 95 95 96 96

1.02 – – – – 99 97 94 91 89 90 91 92 93 93 94 94

1.01 – 100 100 100 98 95 92 89 87 88 89 90 91 92 92 93

1.00 – 69 75 78 80 82 83 84 85 86 87 88 89 90 91 92

0.99 – 66 72 76 78 80 81 82 83 84 85 86 87 89 90 91

0.98 – 64 70 74 76 78 79 80 81 82 84 85 86 87 88 90

0.97 – 63 68 72 74 76 77 78 79 81 82 83 84 86 87 88

0.96 – 61 67 70 72 74 75 76 78 79 81 82 83 84 86 87

0.95 1.00 59 65 68 71 72 74 75 76 78 79 80 82 83 84 86

0.94 0.99 58 63 67 69 71 72 73 75 76 78 79 80 82 83 85

0.93 0.98 57 62 65 67 69 71 72 73 75 76 78 79 80 82 84

0.92 0.97 55 60 63 66 68 69 70 72 73 75 76 78 79 81 82

0.91 0.96 54 59 62 64 66 68 69 70 72 74 75 76 78 79 81

0.90 0.95 53 57 61 63 65 66 67 69 71 72 74 75 77 78 80

0.89 0.94 51 56 59 62 63 65 66 68 69 71 72 74 75 77 79

0.88 0.93 50 55 58 60 62 64 65 66 68 70 71 73 74 76 78

0.87 0.92 49 53 57 59 61 62 63 65 67 68 70 71 73 75 77

0.86 0.91 48 52 55 58 59 61 62 64 66 67 69 70 72 74 76

Note: If the value of PU + PL - 100 does not correspond to a PU + PL - 100 value in this table, use the next smaller PU + PL - 100 value.
Table 106-2 (continued)

Pay Factors

PAY FACTOR Minimum Required Percent of Work Within Specification Limits for a Given Pay Factor PU + PL - 100

Category

n=3 n=4 n=5 n=6 n=7 n=8 n=9

n=10

to

n=11

n=12

to

n=14

n=15

to

n=17

n=18

to

n=22

n=23

to

n=29

n=30

to

n=42

n=43

to

n=66

n=67

to

∞ I II 

0.85 0.90 46 51 54 56 58 60 61 62 64 66 67 69 71 72 75

0.84 0.89 45 49 53 55 57 58 60 61 63 65 66 68 70 71 73

0.83 0.88 44 48 51 54 56 57 58 60 62 64 65 67 69 70 72

0.82 0.87 43 47 50 53 54 56 57 59 61 62 64 66 67 69 71

0.81 0.86 41 46 49 51 53 55 56 58 59 61 63 64 66 68 70

0.80 0.85 40 44 48 50 52 54 55 56 58 60 62 63 65 67 69

0.79 0.84 39 43 46 49 51 52 54 55 57 59 61 62 64 66 68

0.78 0.83 38 42 45 48 50 51 52 54 56 58 59 61 63 65 67

0.77 0.82 36 41 44 46 48 50 51 53 55 57 58 60 62 64 66

0.76 0.81 35 39 43 45 47 49 50 52 54 56 57 59 61 63 65

0.75 0.80 33 38 42 44 46 48 49 51 53 54 56 58 60 62 64

REJECT

0.79 32 37 40 43 45 47 48 49 52 53 55 57 59 60 63

0.78 30 36 39 42 44 45 47 48 50 52 54 56 57 59 62

0.77 28 34 38 41 43 44 46 47 49 51 53 55 56 58 61

0.76 27 33 37 39 42 43 45 46 48 50 52 53 55 57 60

0.75 25 32 36 38 40 42 43 45 47 49 51 52 54 56 59

Values less than those shown above

Note: If the value of PU + PL - 100 does not correspond to a PU + PL - 100 value in this table, use the next smaller PU + PL - 100 value.
Section 106

39

(d) Pay factor determination (value of the work). The pay factor for a lot will be determined as 

follows:

(1) The pay factor for each quality characteristic will be determined from Table 106-2 using the 

total number of test values and the total estimated percentage within the specification limits from 

Subsection 106.05(c)(7). 

(2) When all quality characteristics for a lot are Category I, the lot pay factor is based on the lowest 

single pay factor for any Category I quality characteristic. The maximum obtainable pay factor is 

1.05. 

(3) When quality characteristics for a lot are both Category I and II, the lot pay factor is based on 

the following:

(a) When all Category II quality characteristics are 1.00, the lot pay factor is based on the 

lowest single pay factor for all Category I characteristics. The maximum obtainable pay factor 

is 1.05. 

(b) When any Category II quality characteristic is less than 1.00, the lot pay factor is based on 

the lowest single pay factor for any Category I or II quality characteristic.

(4) When all quality characteristics for a lot are Category II, the lot pay factor is based on the 

lowest single pay factor for any Category II quality characteristic. The maximum obtainable pay 

factor is 1.00.

(5) Adjusted payment for material in a lot will be made at a price determined by multiplying the 

contract unit price by the lot pay factor as determined above, or as described in the Payment 

Subsection of the Section ordering the work. 

106.06 Partial and Final Acceptance. Maintain the work during construction and until the project is 

accepted. Repair damage before final acceptance of the entire project at no additional cost to the 

Government. See FAR Clause 52.236-11 Use and Possession Prior to Completion. 

(a) Partial acceptance. When a segment of the project is completed, a final inspection of that segment 

may be requested by the Contractor. If the segment is complete and in compliance with the contract, 

it may be accepted. If accepted, the CO may relieve the Contractor of further responsibility for 

maintenance of the completed segment.

When public traffic is accommodated through construction and starts using sections of roadway as 

they are completed, continue maintenance of such sections until final acceptance.

(b) Final acceptance. Notify the CO when the entire project is complete to schedule an inspection. If 

work is determined to be complete, the inspection will constitute the final inspection. The Contractor 

will be notified in writing of final acceptance as of the date of the final inspection. Final acceptance 

relieves the Contractor of further responsibility for the maintenance of the project.

If the inspection discloses unsatisfactory work, the CO will provide to the Contractor a list of the work 

that is incomplete or requires correction. Immediately complete or correct the work. Submit notification 

when the work has been completed. 
Section 107 

40

Section 107. — LEGAL RELATIONS

AND RESPONSIBILITY TO THE PUBLIC

107.01 Laws to be Observed. Follow the requirements of FAR Clause 52.236-7 Permits and 

Responsibilities. 

Comply with applicable laws, ordinances, safety codes, regulations, orders, and decrees. Protect and 

indemnify the Government and its representatives against claim or liability arising from or based on the 

alleged violation of the same.

Comply with permits and agreements obtained by the Government for performing the work that is 

included in the contract. Notify CO of proposed changes, including required revisions to Governmentobtained permits that are required by the Contractor’s methods of operation. Obtain additional permits or 

agreements that are required by the Contractor’s methods of operation. Submit copies of approved permits 

and finalized agreements upon receipt. 

107.02 Protection and Restoration of Property and Landscape. Follow the requirements of FAR 

Clause 52.236-9 Protection of Existing Vegetation, Structures, Equipment, Utilities, and Improvements. 

Do not disturb the area beyond the construction limits. 

(a) Property. Preserve public and private property. Protect monuments established for perpetuating 

horizontal, vertical, cadastral, or boundary control. If necessary to destroy a monument, reestablish 

the monument according to applicable state statute or by the direction of the agency or individual who 

established the monument.

(b) Vegetation. Replace trees, shrubs, or vegetated areas damaged by construction operations as 

directed and at no additional cost to the Government. Remove damaged limbs of existing trees by an 

approved arborist. 

(c) Archeological. Do not excavate, remove, damage, alter, or deface archeological or paleontological 

remains or specimens. Control the actions of employees and subcontractors on the project to ensure 

that protected sites are not disturbed or damaged. Should these items be encountered, suspend 

operations at the discovery site, notify the CO immediately and continue operations in other areas. The 

CO will inform the Contractor when operations may resume at the discovery site. 

(d) Utilities. Before starting work in an area, contact the local utility locating service to mark the 

utilities. Protect utilities from construction operations. Cooperate with utility owners to expedite the 

relocation or adjustment of their utilities to minimize interruption of service and duplication of work. 

If utility services are interrupted because of damage by the construction, immediately notify the utility 

owner, the CO, and other proper authorities. Cooperate with them until service is restored. Do not 

work around fire hydrants until provisions for continued service are made and approved by the local 

fire authority.

Notify the CO if utility work is required. Compensation for the work will be provided under applicable 

clauses of the contract. Satisfactorily repair damage due to the fault or negligence of the Contractor at 

no additional cost to the Government.
Section 107

41

Repair of damage to underground utilities not shown in the plans or identified before construction, 

and not caused by the fault or negligence of the Contractor will be paid for by the Government. 

107.03 Bulletin Board. Provide a weatherproof bulletin board of suitable size and construction for 

continuous display of posters and other information required by the contract. Erect and maintain the 

bulletin board at a conspicuously accessible location on the project and remove and dispose of it after 

project final acceptance. 

Display the following documents on the bulletin board: 

(a) Equal Employment Opportunity Commission (EEOC), Know Your Rights: Workplace 

Discrimination is Illegal poster according to FAR Clause 52.222-26 Equal Opportunity; 

(b) Form FHWA 1022, Notice that the project is subject to Title 18, U.S.C., Section 1020 poster; 

(c) Department of Labor, Wage and Hour Division (WHD), WHD 1321, Employee Rights Under The 

Davis-Bacon Act poster (regarding proper pay); 

(d) Department of Labor, OSHA, Job Safety and Health It’s The Law poster, according to CFR Title 

29, Part 1903; 

(e) "General Wage Decision" contained in the contract;

(f) Company equal employment opportunity policy, according to FAR Clause 52.222-27 Affirmative 

Action Compliance Requirements for Construction; 

(g) OSHA, Emergency telephone numbers (in areas where 911 is not available), according to CFR 

Title 29, Part 1926.50(f); 

(h) Department of Labor, WHD Publication, Employee Rights and Responsibilities Under the Family 

and Medical Leave Act poster according to CFR Title 29, Part 825.300(a); 

(i) WHD 1462, Employee Polygraph Protection Act poster; and 

(j) National Labor Relations Act (NLRA), Employee Rights Under The National Labor Relations Act 

poster according to Executive Order 13496.

107.04 Railroad Protection. The Government will obtain the necessary permits and agreements from the 

railroad for specified work for relocating railroads or for work at or adjacent to railroad crossings. If 

necessary, obtain additional permits and agreements for other work that, due to the method of operation, 

may also impact the railroad. Submit copies of permits and agreements. 

Do not interfere with railroad operations. If the construction damages railroad property, reimburse the 

railroad for damages, or at the railroad’s option, repair the damage at no additional cost to the Government.

Do not cross railroad tracks, with vehicles or equipment, except at existing and open public grade crossings 

or railroad approved temporary grade crossings. If there is a need for a temporary grade crossing, make 

the necessary arrangements with the railroad for its construction, protection, and removal. Reimburse the 

railroad for temporary grade crossing work or at the railroad’s option, perform the work. 
Section 107 

42

107.05 Responsibility for Damage Claims. Indemnify and hold harmless the Government, its employees, 

and its consultants from suits, actions, or claims brought for injuries or damage received or sustained by 

a person, persons, or property resulting from the construction operations or arising out of the negligent 

performance of the contract. 

Procure and maintain until final acceptance of the contract, liability insurance of the types and limits 

specified below. Obtain insurance from companies authorized to do business in the appropriate state. 

Ensure the insurance covers operations under the contract whether performed by the Contractor or by 

subcontractors. 

Before work starts, submit "certificates of insurance" certifying that the policies will not be changed or 

canceled until written notice has been given to the Government. Insurance coverage in the minimum 

amounts set forth below does not relieve the Contractor of liability in excess of the coverage. 

Carry insurance conforming to the following minimums:

(a) Worker’s compensation insurance. Minimum required by law. 

(b) Comprehensive or commercial general liability insurance. 

(1) Personal injury and property damage coverage; 

(2) Contractual liability coverage;

(3) Completed operations liability coverage; 

(4) $1,000,000 combined single limit for each occurrence; and 

(5) $2,000,000 general aggregate limit. 

(c) Automobile liability insurance. $1,000,000 combined single limit for each occurrence. 

107.06 Contractor’s Responsibility for Work. Assume responsibility for all work until final acceptance, 

except as provided in Subsection 106.06. This includes periods of suspended work. Protect the work 

against injury, loss, or damage from all causes whether arising from the execution or non-execution of the 

work. Maintain public traffic according to Section 156. 

Rebuild, repair, restore, and make good losses, injuries, or damages to any portion of the work. This 

includes losses, injuries, or damages caused by vandalism, theft, accommodation of public traffic, and 

weather that occurs during the contract. 

The Government will only be responsible for costs attributable to repairing or replacing damaged work 

caused by declared enemies and terrorists of the Government and cataclysmic natural phenomenon. The 

Government will not be responsible for delay costs, impact costs, or extended overhead costs. 

107.07 Furnishing Right-of-Way. The Government will obtain right-of-way. 

107.08 Sanitation, Health, and Safety. Follow the requirements of FAR Clause 52.236-13 Accident 

Prevention. 
Section 107

43

Observe rules and regulations of Federal, state, and local health officials. Do not allow workers to work 

in surroundings or under conditions that are unsanitary, hazardous, or dangerous. 

Admit OSHA inspectors or other legally responsible officials involved in safety and health administration 

to the project work site upon presentation of proper credentials. 

Report accidents on forms furnished by the Government or with prior approval, on forms used to report 

accidents to other agencies or insurance carriers. Maintain an OSHA Form 300, Log of Work-Related 

Injuries and Illnesses and make it available for inspection. 

Install a reverse signal alarm audible above the surrounding noise level on motorized vehicles having an 

obstructed view and on earth-moving and compaction equipment. 

107.09 Legal Relationship of the Parties. In the performance of the contract, the Contractor is an 

independent contractor. The Contractor’s independent contractor status does not limit the Government’s 

general rights under the contract. No Government employee or a business organization owned or 

substantially owned or controlled by one or more Government employees may be a contractor. 

107.10 Environmental Protection. Comply with the following: 

(a) Federal Water Pollution Control Act (Clean Water Act) 33 USC § 1251 et seq. 

(1) Do not operate equipment or discharge material within the boundaries of wetlands and the 

waters of the United States as defined by the Federal and state regulatory agencies. Permits are 

issued by the U.S. Army Corps of Engineers according to 33 USC § 1344 and delegated by the 

agency having jurisdiction. If an unauthorized discharge occurs: 

(a) Prevent further contamination;

(b) Notify appropriate authorities and the CO; and 

(c) Mitigate damages.

(2) Construct and maintain barriers in work areas and in material sources to prevent sediment, 

petroleum products, chemicals, and other liquids and solids from entering wetlands or waters of 

the United States. Remove and properly dispose of barrier collected material.

(3) Do not revise terms or conditions of permits without the approval of the issuing agency. 

(b) Oil and hazardous substances. Submit a hazardous spill plan as required by Federal, state, or 

local regulations at least 2 days before starting work. Where a hazardous spill plan is not required 

submit a "Spill Prevention, Control, and Countermeasure (SPCC) Plan". 

Describe preventative measures including the location of refueling and storage facilities and the 

handling of hazardous material. Describe actions to be taken in case of a spill. Identify personnel, 

equipment, and resources available to address spill prevention and response.

Do not use equipment with leaking fluids. Repair equipment fluid leaks immediately. Keep absorbent 

material manufactured for containment and cleanup of hazardous material on the job site. 

Notify the CO of hazardous spills.
Section 107 

44

(c) Dirt, plant, and foreign material. Remove dirt, plant, and foreign material from vehicles and 

equipment before mobilizing to work site. Prevent introduction of noxious weeds and non-native plant 

species into the work site. Follow applicable Federal land management agency and state rules and 

regulations. Maintain cleaning and inspection records.

(d) Clearances for Contractor-selected, noncommercial areas. Contractor-selected, 

noncommercial areas include material sources, disposal sites, waste areas, water sources, haul roads, 

and staging areas located outside project construction limits and permitted commercial areas. Allowed

commercial areas include enterprises or developed areas providing same type material or use over the 

last 2 years with appropriate permits and agreements. 

Before using a Contractor-selected, noncommercial areas, submit the following for approval: 

(1) Description, schedule, and map of area.

(2) Documentation of compliance with applicable laws, rules, and regulations.

(3) Owner approval for the area use. If use of Federal land is proposed, submit an approval letter 

or special use permit from the applicable Federal land management agency.

(4) Legal compliance for the area use. Submit documentation showing compliance with 

applicable tribal, state, and local laws including permits or other approvals issued for the area use.

107.11 Protection of Forests, Parks, and Public Lands. Comply with the rules and regulations of the 

state fire marshal, conservation commission, Federal land management agency, or other authority having 

jurisdiction governing the protection of land including or adjacent to the project. 
Section 108

45

Section 108. — PROSECUTION AND PROGRESS

108.01 Commencement, Prosecution, and Completion of Work. Follow the requirements of FAR 

Clause 52.211-10 Commencement, Prosecution, and Completion of Work. 

A preconstruction conference will be held after the contract is awarded and before starting work. Seven 

days before the preconstruction conference, submit copies of the preliminary work plan according to 

Section 155. 

108.02 Labor. Follow the requirements of FAR Clause 52.222-6 Construction Wage Rate Requirements.

Adjacent or virtually adjacent work sites are defined to be work sites within 1⁄2 mile of the project.

Application of Construction Wage Rate Requirements (Davis-Bacon Act) for work sites beyond 1⁄2 mile 

of the project will be determined by the CO. 

108.03 Subcontracting. Subcontracting does not relieve the Contractor of liability and responsibility 

under the contract and does not create any contractual relation between subcontractors and the 

Government. The Contractor is liable and responsible for actions or lack of action of subcontractors. 

Within 14 days of subcontract award, submit an SF 1413, Statement and Acknowledgment with Part I 

completed. Complete other forms that may be provided by the Government to show the work 

subcontracted and the total dollar amount of the subcontract. For subcontracts involving on-site labor, 

require the subcontractor to complete Part II of the SF 1413 and complete other forms that may be provided 

by the Government. Submit a separate statement documenting the cumulative number of on-site 

subcontracts to date as a percentage of the original contract amount. Submit this information on 

subcontracts at lower tiers.

In FAR Clause 52.219-8, Utilization of Small Business Concerns and FAR Clause 52.232-27 Prompt 

Payment for Construction Contracts, the term "subcontracts" includes on-site and off-site work and supply 

contracts.

108.04 Determination and Extension of Contract Time. Follow the requirements of FAR Clause 

52.211-10 Commencement, Prosecution, and Completion of Work. 

(a) Definitions. 

(1) Time impact analysis. The procedure by which the Contractor demonstrates the effect of 

specific time impacts on the overall construction schedule. Time impacts may result in an increase 

or decrease in contract time.

(2) Float. The amount of time between when an activity "can start" (the early start) and when an 

activity "must start" (the late start).

(b) Time impact analysis. Comply with the applicable contract clauses when requesting a time 

extension. Notify the CO in writing within 7 days after identifying a time impact.

Submit a time impact analysis and revised construction schedule within 14 days after the end of the 

time impact event for which notice has been given. Include the following: 
Section 108

46

(1) A title page or header block with: 

(a) Contract number; 

(b) Project number and name; 

(c) Contractor name;

(d) Current fixed completion date;

(e) Date of submittal; and

(f) Consecutive number for each analysis. 

(2) State the impact that requires a time impact analysis:

(a) CO proposed or directed contract modification; 

(b) Contractor proposed contract modification;

(c) Weather delay; or 

(d) Other Government caused delay. 

(3) A copy of the most current approved construction schedule existing before the impact.

(4) A detailed narrative describing each impact event. Describe impacts to each affected activity 

in the construction schedule. Include the following:

(a) Contract clauses under which the request is being made;

(b) Cause of the impact;

(c) Start date of the impact;

(d) Duration of the impact; and

(e) Methods to be employed to re-sequence or reschedule the work to mitigate the impact. 

Discuss the feasibility of re-sequencing future work to mitigate delay. Re-sequencing or 

rescheduling of work will be at no additional cost to the Government. Include corresponding 

rationale and assumptions of measures which increase the cost of mitigating the impact.

(5) A revised construction schedule to show the impact of the activities identified, including 

re-sequencing which would mitigate the delay. 

(c) Time extensions. Only delays or modifications that affect critical activities or cause noncritical 

activities to become critical will be considered for time extensions.

If a CPM schedule is used, no time extension will be made for delays or modifications that use 

available float as shown in the most current approved construction schedule existing before the impact.
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47

No time extension will be made for a claim that states insufficient time was provided.

For delays due to weather, demonstrate that the weather was unusually severe based on the most recent 

10 years of historical data according to FAR Clause 52.249-10 Default (Fixed-Price Construction).

(d) Execution of the time impact analysis. Incorporate accepted logic changes or time extensions 

into the construction schedule update by the next monthly submittal. 

108.05 Failure to Complete Work on Time. Follow the requirements of FAR Clause 52.211-12 

Liquidated Damages — Construction. 

Liquidated damages in the amount shown in Table 108-1 will be assessed for each calendar day beyond 

the time specified in the contract until substantial completion of the work. 

If a winter shutdown occurs during this period, liquidated damages in an amount equal to 10 percent of 

the amount shown in Table 108-1 will be assessed for each day until the winter shutdown ends at which 

time full liquidated damages will be assessed.

Table 108-1 

Charge for Liquidated Damages 

for Each Day Work Is Not Substantially Completed

Original Contract Price Daily

Charge(1)

Less than $1,000,000 $2,100

$1,000,000.00 to $4,000,000.00 $3,900

$4,000,000.01 to 10,000,000.00 $5,100

$10,000,000.01 to $20,000,000.00 $7,600

Greater than $20,000,000.00 $8,800

(1) Liquidated damages include Government costs and traffic control.

108.06 Stop Work Order. Follow the requirements of FAR Clause 52.236-13 Accident Prevention and 

FAR Clause 52.242-14 Suspension of Work. The CO may order the performance of the work to be 

stopped, either in whole or in part, for such periods deemed necessary including, but not limited to, the 

following:

(a) Weather or soil conditions considered unsuitable for prosecution of the work; or 

(b) Failure of the Contractor to:

(1) Correct conditions unsafe for the workers or the general public;

(2) Carry out written orders given by the CO; or 

(3) Perform provisions of the contract.
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48

Section 109. — MEASUREMENT AND PAYMENT

109.01 Measurement of Work. Take and record measurements and perform calculations to determine 

pay quantities for invoicing for work performed. Take or convert measurements of work according to U.S.

Customary measures. 

Unless otherwise specified, measure when the work is in-place and complete according to the contract. 

Measure the actual work performed, except do not measure work outside the design limits or other 

adjusted or specified limits (staked limits). Measure structures to the lines according to the plans or to 

approved lines adjusted to fit field conditions. 

Take measurements as described in Subsection 109.02 unless otherwise modified by the Measurement 

Subsection of the Section controlling the work being performed. 

Measurement of quantities for payment for the individual pay items will be based on the contract price for 

each pay item according to Table 109-1. 

Table 109-1 

Decimal Accuracy of Quantities for Payment

Contract Unit Price Decimal Accuracy of

Quantities for Payment

Less than $1.00 0 decimal

$1.00 to $100.00 1 decimal

Greater than $100.00 2 decimals

Decimal precision for measurement is one decimal beyond accuracy of quantities for payment.

Remeasure quantities if it has been determined that a portion of the work is acceptable, but has not been 

completed to the lines, grades, and dimensions shown in the plans or established by the CO. 

Prepare, sign, and submit measurement notes and supporting field note documentation using an approved 

format. Unacceptable measurement notes will be rejected and returned. Correct rejected measurement 

notes and resubmit. 

Submit measurement notes within 24 hours of completing work that is in-place and complete according 

to the contract. For on-going work, submit measurement notes weekly or as approved. When work is not 

complete, identify the measurement as being an interim measurement. Submit the final measurement when 

the work is completed. Measurement notes form the basis of the Government’s receiving reports described 

in Subsection 109.08(c). 

Include the following information in the measurement notes: 

(a) Project number and name; 

(b) Line item number, pay item number, and description; 

(c) Date the work was performed;

(d) Location of the work; 
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(e) Measured quantity;

(f) Calculations made to arrive at the quantity;

(g) Supporting sketches and details as needed to clearly define the work performed and the quantity 

measured;

(h) Names of persons measuring the work; 

(i) Identification as to whether the measurement is interim or final; and

(j) Signed certification statement by the persons taking the measurements and performing the 

calculations, that the measurements and calculations are correct.

109.02 Measurement Terms and Definitions. Unless otherwise specified, the following terms are 

defined as follows:

(a) Acre. 43,560 square feet. Make longitudinal and transverse measurements for area computations 

horizontally. Do not make deductions from the area computation for individual fixtures having an area 

of 500 square feet or less.

(b) Contingent sum. Perform only the work authorized by written order. The estimated cost of the 

contingent sum work is approximate and is considered the maximum cost for the required work. The 

quantity to be paid will be equivalent to the costs incurred. Submit paid invoice receipts as 

documentation. 

(c) Contract quantity. The quantity to be paid is the quantity listed in the bid schedule. The contract 

quantity will be adjusted for authorized changes that affect the quantity or for errors made in 

computing this quantity. If there is evidence that a quantity specified as a contract quantity is incorrect, 

submit calculations, drawings, or other evidence indicating why the quantity is in error and request in 

writing that the quantity be adjusted.

(d) Cubic foot and cubic yard. Measure by one of the following methods: 

(1) In place. Measure solid volumes by one of the following: 

(a) Average end area method. Take cross-sections of the original ground. Use design or staked 

templates to determine end areas. Do not measure work outside of the lines or slopes 

established by the CO.

If a portion of the work is acceptable but is not completed to the established lines and slopes, 

retake cross-sections or comparable measurements of that portion of the work. Use the 

remeasurements to calculate new end areas.

Compute the quantity using the average end areas multiplied by the horizontal distance along 

a centerline or reference line between the end areas. Deduct quantities outside the designed or 

staked limits.

(b) Finite element analysis method. Use digital terrain modeling to determine the difference 

between existing and constructed terrain surfaces.
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50

(2) In the hauling vehicle. Measure according to Subsections 109.03 and 109.04. 

Measure the cubic yard volume in the hauling vehicle using three-dimensional measurements at 

the point of delivery. Use vehicles bearing a legible identification mark with the body shaped so 

the actual contents may be readily and accurately determined. Before use, mutually agree in writing 

on the volume of material to be hauled by each vehicle. Vehicles carrying less than the agreed 

volume may be rejected or accepted at the reduced volume.

Level selected loads. If leveling reveals the vehicle was hauling less than the approved volume, 

reduce the quantity of all material received since the last leveled load by the same ratio as the 

current leveled load volume is to the agreed volume. Payment will not be made for more than the 

agreed volume.

Material measured in the hauling vehicle may be weighed and converted to cubic yards for 

payment purposes if the conversion factors are mutually agreed to in writing. 

(3) In the structure. Measure according to the lines of the structure as shown in the plans, except 

as altered by the CO to fit field conditions. Make no deduction for the volume occupied by 

reinforcing steel, anchors, weep holes, piling, or pipes less than 8 inches in diameter.

(4) By metering. Use an approved metering system. 

(e) Day. A 24-hour period starting and ending at midnight. Round portions of a day up to the full day.

(f) Each. One entire unit. Measure the actual number of units completed and accepted.

(g) Gallon. The quantity may be measured by the following methods: 

(1) Measured volume container. Use an approved container with a verified volume. 

(2) Metered volume. Use an approved metering system. 

(3) Commercially-packaged volumes. Use the volume as identified on the 

commercially-packaged product.

(4) Measured by mass. Use an approved weighing device. 

When asphalt material is measured by the gallon, measure the volume at 60 °F or correct the 

volume to 60 °F using recognized standard correction factors. 

(h) Hour. 60 minutes. Measure the actual number of hours ordered by the CO and performed by the 

Contractor. Round portions of an hour up to the next half hour. Measure time in excess of 40 hours 

per week at the same rate as the first 40 hours. 

(i) Linear foot. As applicable, measure the work along its length from end-to-end, parallel to the base 

or foundation, along the top, along the front face, or along the invert. Do not measure overlaps. 

(j) Lump sum. Do not measure directly. The bid amount is complete payment for all work described 

in the contract and necessary to complete the work for that pay item. The quantity is designated as 

"All". Estimated quantities of lump sum work shown are approximate. 
Section 109

51

(k) M-gallon. 1000 gallons. Measure according to Subsection 109.02(g).

(l) Mil. Thousandth of an inch. Use to measure thickness. 

(m) Mile. 5280 linear feet. Measure horizontally along the centerline of each roadway, approach road, 

or ramp.

(n) Month. A month as defined by the Gregorian calendar. Measure portions of a month by prorating 

based on the total days worked. 

(o) Pound. Measure according to Subsection 109.03 and 109.04. If sacked or packaged material is 

provided, the net weight as packed by the manufacturer may be used. 

(p) Square foot and square yard. 1 square yard equals 9 square feet. Measurements for area 

computations will be made horizontally or vertically to the surface being measured. No deductions 

from the area computation will be made for individual fixtures having area of 9 square feet or less. Do 

not measure overlaps.

(q) Thousand board feet measure. 1000 board feet. Measurement equal to 1000 feet of wood that is 

12 inches wide and 1 inch thick. 

(r) Ton. 2000 pounds. Measure according to Subsections 109.03 and 109.04. 

No adjustment in a contract price will be made for variations in quantity due to differences in the 

specific gravity or moisture content.

Use net-certified scale masses or masses based on certified volumes in the case of rail shipments as a 

basis of measurement subject to correction if asphalt material is lost from the car or the distributor, 

wasted, or otherwise not incorporated in the work. If asphalt material is shipped by truck or transport, 

net-certified masses, subject to correction for loss or foaming, may be used for computing quantities.

When emulsified asphalt is converted from volume to mass, use a factor of 240 gallons per ton 

regardless of temperature.

If the asphalt binder for asphalt concrete pavement is stored in tanks devoted exclusively to the project, 

base quantities on invoices. If asphalt binder for asphalt concrete pavement is not stored in tanks 

devoted exclusively to the project or if the validity of the quantity requested for payment is in question, 

base quantities on the asphalt content determined by testing. 

(s) Week. A 7-day period starting and ending at the same designated time. Measure portions of a week 

by prorating based on the total days worked.

109.03 Weighing Procedures and Devices. Batch masses may be acceptable for determination of pay 

quantities if an approved automatic weighing, cycling, and monitoring system is included as part of the 

batching equipment. 

If a weighing device is determined to indicate less than true mass, no additional payment will be made for 

material previously weighed and recorded. If a weighing device is determined to indicate more than true 

mass, material received after the last previously correct weighing accuracy test will be reduced by the 

percentage of error in excess of 0.5 percent.
Section 109

52

When material is proportioned or measured and paid for by mass, provide one of the following: 

(a) Commercial weighing system. Use permanently-installed and certified commercial scales.

(b) Invoices. If bulk material is shipped by truck or rail and is not passed through a mixing plant, 

submit a supplier’s invoice with net mass or volume converted to mass. Perform check weighing as 

requested.

(c) Project weighing system. Provide, erect, and maintain approved automatic digital scales. Provide 

scales that record mass at least to the nearest 100 pounds. Maintain the scale accuracy to within 

0.5 percent of the correct mass throughout the calibration range of the scale.

Do not use spring balances. Do not use scales mounted on non-stationary equipment.

Install and maintain platform scales with the platform level with rigid bulkheads at each end. Make 

the platform of sufficient length to allow simultaneous weighing of all axle loads of the hauling 

vehicle. Coupled vehicles may be weighed separately or together according to Subsection 2.20, 

paragraph UR.3.3, Single-Draft Vehicle Weighing of the NIST Handbook 44, Specifications, 

Tolerances, and Other Technical Requirements for Weighing and Measuring Devices. 

Install and maintain belt-conveyor scales according to Subsection 2.21, Belt-Conveyor Scale Systems

of the NIST Handbook 44, Specifications, Tolerances, and Other Technical Requirements for 

Weighing and Measuring Devices.

Before production on the project, after relocation, and at least once per year; have the weighing portion 

of the system checked and certified by the State bureau of weights and measures or a private scale 

service certified by the bureau of weights and measures. Seal the system to prevent tampering or other 

adjustment after certification.

Attach an automatic printer to the scale that is programmed or otherwise equipped to prevent manual 

override of mass information. For weighed pay quantities, program the printer to provide the following 

information for each weighing:

(1) Project number and name; 

(2) Line item number, pay item number, and description; 

(3) Date;

(4) Time;

(5) Ticket number;

(6) Haul unit number; 

(7) Net mass in load at least to the nearest 100 pounds; 

(8) Subtotal net mass for each haul unit since the start of the shift; and

(9) Accumulated total net mass for all haul units since the start of the shift.
Section 109

53

If a printer malfunctions or breaks down, the Contractor may manually weigh and record masses for up to 

24 hours provided the method of weighing meets other contract requirements. 

Provide competent scale operators to operate the system.

When platform scales are used, weigh empty haul units at least twice per day.

Use an approved format for the mass records. Submit the original records and a written certification as to 

the accuracy of the masses at the end of each shift.

109.04 Receiving Procedures. When the method of measurement requires weighing or volume 

measurement in the hauling vehicle, provide a person to direct the spreading and distribution of material 

and to record the location and placement of the material on the project. During the placement, maintain a 

record of each delivery and document it in an approved manner. Include the following as applicable: 

(a) Project number and name; 

(b) Line item number, pay item number, and description; 

(c) Location where placed;

(d) Date;

(e) Load number; 

(f) Truck identification;

(g) Time of arrival;

(h) Mass or volume; and

(i) Spread person’s signature. 

Submit the original records and a written certification of the delivery of the material at the end of each 

shift.

109.05 Scope of Payment. Payment for contract work is provided, either directly or indirectly, under the 

pay items listed in the bid schedule. 

(a) Direct payment. Payment is provided directly under a pay item listed in the bid schedule when 

one of the following applies:

(1) The work is measured in the Measurement Subsection of the Section ordering the work and 

the bid schedule contains a pay item for the work from the Section ordering the work. 

(2) The Section ordering the work references another Section for the work and the bid schedule 

contains a pay item for the work from the referenced Section.

(b) Indirect payment. Work for which direct payment is not provided is a subsidiary obligation of 

the Contractor. Payment for such work is indirectly included under other pay items listed in the bid 

schedule. This includes instances when the Section ordering the work references another Section for 
Section 109

54

performing the work and the work is not referenced in the Measurement Subsection of the Section 

ordering the work.

Compensation provided by the pay items included in the bid schedule is full payment for performing 

contract work in a complete and acceptable manner. Risk, loss, damage, or expense arising out of the 

nature or prosecution of the work is included in the compensation provided by the pay items. 

Work measured and paid for under one pay item will not be paid for under other pay items. 

The quantities listed in the bid schedule are approximate unless designated as a contract quantity. Limit 

pay quantities to the quantities staked, ordered, or otherwise authorized before performing the work. 

Payment will be made for the actual quantities of work performed and accepted or material provided 

according to the contract. No payment will be made for work performed in excess of that staked, ordered, 

or otherwise authorized. 

109.06 Pricing of Adjustments. Determine costs according to FAR Part 31 Contract Cost Principles and 

Procedures. Follow the requirements of FAR clauses providing for an equitable price adjustment. 

If agreement on price and time cannot be reached, the CO may make a unilateral determination.

If the work will delay contract completion, request a contract time extension according to 

Subsection 108.04.

(a) Contract modification standard rates. Provide the following information to the CO with contract 

modification proposals. 

(1) Overhead. Provide copies of the current job site and home office overhead rates for the 

Contractor and subcontractors that have been certified or audited by the Contractor’s controller or 

accountant. Provide supporting data, which justifies the rates. List each cost category that is

included in overhead and identify the cost pools to which overhead is applied. 

(2) Equipment. Provide a complete descriptive listing of equipment to be used by the Contractor 

and subcontractors, including the make, model, and year of manufacturer of each piece of 

equipment and attachments to the base equipment. Provide the following cost information:

(a) Rented equipment. Provide current invoices to support rented or leased equipment costs. 

(b) Owned equipment. Determine allowable ownership and operating costs for Contractor- and 

subcontractor-owned equipment using actual equipment cost data determined from the 

operating cost records and following the U.S. Army Corps of Engineers Construction 

Equipment Ownership and Operating Expense Schedule (CEOOES) method. If actual 

equipment cost data is not available, provide the CO with a statement signed by an individual 

that can bind the Contractor that such cost data is not available.

Provide a complete set of supporting documentation containing ownership records that are 

available, including purchase records, depreciation records, maintenance records, or other 

records that relate to the ownership and operating costs for each piece of equipment.

If actual costs cannot be determined, or are not provided at the preconstruction conference, use 

the rates shown in the CEOOES for the region where costs are incurred. Adjust the rates for 
Section 109

55

used equipment and for other variable parameters used in the schedules. Provide the CO with

supporting documentation.

Compute standby costs from approved ownership records or, if actual costs cannot be 

determined, according to CEOOES. Do not exceed 8 hours in a 24-hour period or 40 hours in 

a week. Do not include standby for periods when the equipment would have otherwise been in 

an idle status or for equipment that was not in operational condition.

(b) Proposal for forward priced work. Submit a written proposal, including price breakdown, for 

each line item of the work. Identify the major elements of the work, the quantity of the element, and 

its contribution to the proposed price. Submit additional information as requested to allow the CO to 

determine the reasonableness of the proposed price. Provide the following information:

(1) Direct costs.

(a) Material. Include estimated costs of material delivered to the work.

(b) Labor. Include a list of anticipated crew members and estimated work hours. Show basic 

hourly wage rates, fringe benefits, applicable payroll costs (such as FICA, FUTA, worker’s 

compensation, insurance, and tax levies), paid subsistence, and travel costs for each labor 

classification and foreperson employed in the work.

(c) Equipment. Include documentation or invoices to support equipment costs according to 

Subsection 109.06(a)(2).

(d) Other direct costs. Include documentation to support other estimated direct costs (such as

bonds, mobilization, demobilization, permits, and royalties).

(e) Production rates. Include estimated production rates for major elements of the work.

(f) Subcontract costs. Include supporting data as required.

(2) Overhead. Include overhead costs according to Subsection 109.06(a)(1). Limit Contractor

overhead applied to subcontractor payments to 5 percent unless a higher percentage is justified.

(3) Profit. Include a reasonable profit, except when precluded by the FAR.

(c) Post-work pricing. When a contract modification is not forward priced, it requires a change order 

and a supplemental agreement reflecting the resulting equitable adjustment. When negotiating the 

price of a contract modification after all or most of the work has been performed, submit the following:

(1) Direct costs.

(a) Material. Include invoices showing the cost of material delivered to the work.

(b) Labor. Include a list of crew members and actual hours worked. Show actual wage rates, 

fringe benefits, applicable payroll costs (such as FICA, FUTA, worker’s compensation, 

insurance, and tax levies), paid subsistence, and travel costs for each labor classification and 

foreperson employed in the adjusted work.
Section 109

56

(c) Equipment. Include documentation or invoices to support equipment costs according to 

Subsection 109.06(a)(2).

(d) Other direct costs. Include documentation to support other estimated direct costs (such as

bonds, mobilization, demobilization, permits, and royalties).

(e) Production rates. Include actual hours of performance daily for each labor classification 

and for each piece of equipment. Include production rate information reflecting the actual work 

occurring on an approved Contractor daily record document.

(f) Subcontract costs. Include supporting data as required.

(2) Overhead. Include overhead costs according to Subsection 109.06(a)(1). Limit Contractor

overhead applied to subcontractor payments to 5 percent unless a higher percentage is justified.

(3) Profit. Include a reasonable profit, except when precluded by the FAR. Limit profit to 

10 percent of the total cost. Due to the limited risk in post-work pricing, a lower profit percentage 

may be determined by a profit analysis according to FAR 15.404-4 Profit.

(d) Cost or pricing data. When the contract modification exceeds the amount indicated in FAR 

Clause 52.214-27 Price Reduction for Defective Cost or Pricing Data - Modifications - Sealed 

Bidding, FAR Clause 52.215-10 Price Reduction for Defective Certified Cost or Pricing Data, or FAR 

Clause 52.215-11 Price Reduction for Defective Cost or Pricing Data - Modifications, and the CO has 

determined that an exception does not apply, submit cost or pricing data according to 

Subsection 109.06(b) or (c) as applicable and as defined in FAR Subpart 2.1 Definitions, for the 

Contractor and each major subcontractor. See FAR Subpart 15.4 Contract Pricing and FAR Table 15-2 

Instructions for Submitting Cost/Price Proposals When Certified Cost or Pricing Data Are Required

for guidance.

Certify cost or pricing data according to FAR Subpart 15.4 Contract Pricing, upon completion of 

negotiations.

109.07 Eliminated Work. Follow the requirements of FAR Clause 52.243-4 Changes. 

Work may be eliminated from the contract without invalidating the contract. The Contractor is entitled to 

compensation for direct costs incurred before the date of elimination of work plus profit and overhead on 

the direct incurred costs. Anticipated profit and overhead expense on the eliminated work will not be 

compensated. 

109.08 Progress Payments. Follow the requirements of FAR Clause 52.232-5 Payments under FixedPrice Construction Contracts and FAR Clause 52.232-27 Prompt Payment for Construction Contracts.

(a) General. Only invoice payments will be made under this contract. Invoice payments include 

progress payments made monthly as work is accomplished and the final payment made upon final 

acceptance. Only one progress payment will be made each month. No progress payment will be made 

in a month in which the work accomplished results in a net payment of less than $1,000. The CO may 

withhold full or partial progress payment according to Subsection 109.08(h).
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(b) Invoice requirements. Submit the invoice to the Government’s designated billing office with the 

following items:

(1) The information required by FAR Clause 52.232-27(a)(2) Contractor’s invoice.

(2) A tabulation of total quantities and contract prices of work accomplished or completed on each 

pay item. Do not include quantities unless measurement notes for those quantities were submitted 

by the closing date. Do not include quantities of work involving material for which test reports 

required under Sections 153 and 154, or certifications required by Subsection 106.03 are, or will 

be, past due as of the closing date.

(3) The certification required by FAR Clause 52.232-5(c) and if applicable, the notice required by 

FAR Clause 52.232-5(d). 

(4) If applicable, a copy of the notices that are required by FAR Clause 52.232-27(e)(5) and (g).

(5) The amount included for work performed by each subcontractor under the contract. 

(6) The total amount of each subcontract under the contract. 

(7) The amounts previously paid to each subcontractor under the contract. 

(c) Government’s receiving report. The Government’s receiving report will be developed using the 

measurement notes received by the CO and determined acceptable.

(d) Closing date and invoice submittal date. The closing date for progress payments will be 

designated by the CO. Include work performed after the closing date in the following month's invoice.

Submit invoices to the designated billing office by the 7th day following the closing date. Invoices 

received by the designated billing office after the 16th day following the closing date will not be

accepted for payment processing that month. Include late, unprocessed invoice submittals in the 

following month’s invoice.

(e) Processing progress payment requests. No payment will be made for work unless measurement 

notes for the work are submitted by the closing date.

(1) Proper invoices. If the invoice meets the requirements of Subsection 109.08(b), and the 

quantities and unit prices shown on the Contractor’s invoice agree with the corresponding 

quantities and unit prices shown on the Government’s receiving report, the invoice will be paid. 

(2) Defective invoices. If the invoice does not meet the requirements of Subsection 109.08(b), or 

if any of the quantities or unit prices shown on the Contractor’s invoice exceed the corresponding 

quantities and unit prices shown on the Government’s receiving report, the invoice will be deemed 

defective and the Contractor notified according to FAR Clause 52.232-27(a)(2). Defective invoices 

will not be corrected by the Government and will be returned to the Contractor within 7 days after 

the Government’s designated billing office receives the invoice. Correct and resubmit returned 

invoices. If the defects are minor, the Contractor may elect, in writing, to accept the quantities and 

contract prices shown on the Government’s receiving report for payment. 
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(f) Partial payments. Progress payments may include partial payment for material to be incorporated 

in the work according to FAR Clause 52.232-5(b)(2), provided the material is delivered on or in the 

vicinity of the project, or stored in an approved storage location. 

Provide test results and material certifications for material when partial payment is requested.

Do not request partial payment for materials that do not meet the contract specifications according to

Subsections 106.03 and 106.04 or when the pay factor is less than 0.9 as calculated under 

Subsection 106.05. Partial payments will not be made for living or perishable material.

Submit measurement notes according to Subsection 109.01. Provide a price breakdown of the bid item 

components and submit invoices or other documents supporting the partial payment. Individual and 

cumulative partial payments for preparatory work and material will not exceed the lesser of:

(1) 80 percent of the contract bid price for the item; or

(2) 100 percent of amount supported by copies of invoices submitted. 

The quantity paid will not exceed the corresponding quantity estimated in the contract. Partial payment 

for preparatory work and materials does not constitute acceptance of work. The CO may adjust partial 

payments for protection of the Government. 

(g) Lump sum. If the basis for lump sum progress payments is not specified in the Section controlling 

the work, submit a price breakdown for use in making progress payments. Payments will be made 

based on the information in the price breakdown, and the work completed. 

(h) Retainage. Follow the requirements of FAR Clause 52.232-5 Payments under Fixed-Price 

Construction Contracts. The CO may withhold, retain, or adjust the invoice after validation of the 

invoice as follows:

(1) The CO may withhold full or partial progress payment until a construction schedule or schedule 

update is submitted according to Section 155, and according to FAR Clause 52.236-15 Schedules 

for Construction Contracts.

(2) The CO may withhold full or partial progress payment until certified payrolls are submitted 

according to FAR Clause 52.222-8 Payrolls and Basic Records.

(3) The CO may withhold a maximum of 10 percent of the amount the progress payment until 

satisfactory progress has been made according to FAR Clause 52.232-5 Payments under FixedPrice Construction Contracts. Satisfactory progress includes performance of all work under the 

contract including submittals, schedules, certifications, reports, test results, and drawings. 

(4) The CO may withhold Liquidated Damages for failure to complete work according to 

Subsection 108.05 and FAR Clause 52.211-12 Liquidated Damages – Construction. 

(5) After substantial completion of the contract, the CO may retain an amount adequate for 

protection of the Government according to FAR Clause 52.232-5 Payments under Fixed-Price 

Construction Contracts. 
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109.09 Final Payment. Follow the requirements of FAR Clause 52.232-5 Payments under Fixed-Price 

Construction Contracts and FAR Clause 52.232-27 Prompt Payment for Construction Contracts. 

Upon final acceptance and verification of final pay records, the Government will send an SF 1034, Public 

Voucher for Purchases and Services other than Personal (final voucher) and a release of claims document. 

Execute both the voucher and the release of claims and return the documents to the Government for 

payment. The date of approval by the Government of the final voucher for payment constitutes the date 

of final settlement of the contract. 

If unresolved claims exist or claims are proposed, reserve the right to the claims by listing a description 

of each claim and the amount being claimed on the release of claims document.

Failure to execute and return the voucher and release of claims document within 90 days after receipt will 

constitute execution of the documents and the release of claims against the Government arising by virtue 

of the contract. In this event, the day after 90 days from receipt constitutes the date of final settlement of 

the contract.
60

DIVISION 150 

PROJECT REQUIREMENTS 
Section 151

61

Section 151. — MOBILIZATION

Description

151.01 This work consists of moving personnel, equipment, material, and incidentals to the project and 

performing work necessary before starting work at the project site. This work also includes obtaining 

permits, insurance, and bonds.

Measurement

151.02 Measure the Section 151 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

151.03 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 151 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for mobilization by the lump sum will be paid as follows:

(a) Bond premiums will be reimbursed from the mobilization pay item according to FAR Clause 

52.232-5 Payments under Fixed-Price Construction Contracts, after receipt of the evidence of 

payment. 

(b) 50 percent of the pay item amount, less the amount paid under Subsection 151.03(a), will be paid 

after 5 percent of the original contract amount is earned from pay items (not including mobilization). 

The amount paid will not exceed 5 percent of the original contract amount.

(c) 100 percent of the pay item amount, less the amount paid under Subsections 151.03(a) and 

151.03(b), will be paid after 10 percent of the original contract amount is earned from pay items (not

including mobilization). The amount paid will not exceed 10 percent of the original contract amount.

(d) Any portion of the pay item amount more than 10 percent of the original contract amount will be 

paid after final acceptance.
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Section 152. — CONSTRUCTION SURVEY AND STAKING

Description

152.01 This work consists of surveying, staking, calculating, and recording data for the control of work. 

See FAR Clause 52.236-17 Layout of Work. 

Construction Requirements

152.02 Qualifications. Provide technically qualified survey crews experienced in highway construction 

survey and staking. Provide personnel who can perform in a timely and accurate manner. At least 14 days 

before starting survey and staking work, submit a résumé for each individual. 

Include the following if AMG methods are used: 

(a) The name, authority, relevant experience, and qualifications of the person with overall 

responsibility for the AMG system; and

(b) The names, authority, and relevant experience of personnel directly responsible for operating the 

AMG equipment. 

152.03 Submittals. At the preconstruction conference, submit a price breakdown by individual tasks if 

construction survey and staking is paid by the lump sum for use in making progress payments. 

Submit the following if AMG methods are used:

(a) Technology statement. A written statement that includes:

(1) The manufacturer, model, and software version of the AMG equipment; and 

(2) Certification that the final Government-furnished 3D data is compatible with the AMG 

equipment. 

(b) QCP. Describe procedures for checking, mechanical calibration, and maintenance of both survey 

and construction equipment. Include the frequency and types of checks performed. 

152.04 General. Provide a crew supervisor on-site when surveying and staking is in progress. Provide 

survey instruments and supporting equipment that can achieve the specified tolerances. If approved, 

construction equipment controlled with a GPS or Robotic Total Station (RTS) machine guidance system 

may be used in the construction of subgrade, subbase, and base aggregate courses, or other construction 

operations. 

Provide acceptable tools and supplies of the type and quality suitable for highway survey work. Provide 

stakes and hubs of sufficient length to provide a solid set in the ground with sufficient surface area above 

ground for necessary legible and durable markings. 

Include staking activities in the construction schedule according to Section 155. Include the dates and 

sequence of each staking activity.
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The Government may set initial horizontal and vertical control points for the project. If the Government 

sets initial horizontal and vertical control points, the Government will provide data for use in establishing 

control for completion of the work. If the Contractor is tasked with setting initial horizontal and vertical 

control for the project, provide the contractor-established control network to the Government for 

verification.

The Government will furnish data relating to horizontal and vertical alignment, theoretical slope stake 

catch points, and other miscellaneous design data. Reformatting and additional calculations may be 

required for the convenient use of the Government-furnished data. Provide immediate notification to the 

CO of apparent errors in the initial staking or in the Government-furnished data.

Record survey and measurement field data in an approved format. Submit as-staked data and corrections 

made to the Government-furnished survey data. Submit survey and measurement data at least weekly 

while surveys are being conducted. Field data and supporting documentation become the property of the 

Government upon completion of the work. 

Discuss and coordinate the following with the CO before surveying or staking: 

(a) Surveying and staking methods; 

(b) Stake marking; 

(c) Grade control for courses of material;

(d) Referencing;

(e) Structure control;

(f) Field staking data;

(g) Localization of the GPS systems to the Government-established control points; and

(h) Other procedures and controls necessary for the work. 

Do not start work until staking or 3D verification data for the affected work has been approved. 

Preserve initial reference and control points. Notify the CO of missing control points or stakes at least 

10 days before starting construction. Reestablish initial control points and obtain approval before starting 

construction. 

Acceptance of the construction staking does not relieve the Contractor of responsibility for correcting 

errors discovered during the work and for bearing additional costs associated with the error.

Maintain legibility of stake markings for the duration of the project or until notified in writing the stakes 

are no longer needed. Replace stakes as necessary to ensure markings are maintained.

Remove and dispose of flagging, paint, lath, stakes, and other staking material after the project is complete.

Compute and provide calculations supporting pay quantities. Measure quantities within the tolerances 

established by the CO according to Section 109. 
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152.05 Survey and Staking Requirements. Perform survey, staking, recording of data, and calculations 

as necessary to construct the project. Survey and set stakes to the tolerances shown in Table 152-1. Reset 

stakes and hubs as required and maintain in an acceptable condition for the duration of the project or until 

notified they can be removed. Notify the CO if errors are discovered. 

(a) Control points. Relocate initial horizontal and vertical control points in conflict with construction 

to areas that will not be disturbed by construction operations. Provide the coordinates, elevations, and 

supporting documentation for the relocated points before the initial points are disturbed. Set durable 

monuments for survey control that uniquely identify the points according to Subsection 107.02 and 

Section 621. Notify the CO at least 10 days before disturbing original monumentation to verify the 

newly set control.

Provide the GPS localization results or total station check shot data at least 10 days before starting 

construction layout work. The CO may order the GPS localization calibration and associated 3D model 

to be broken into two or more zones to maintain the localized relationship between control points and 

original ground. 

(b) Centerline establishment. Establish or reestablish centerline at roadway design cross-section 

locations and as necessary to construct the work. Reestablish the centerline if construction survey and 

staking work does not meet the tolerances. 

(c) Original ground topographic verification. Use an approved method to verify existing ground 

survey. In areas where theoretical and actual ground elevations do not meet a tolerance of ±0.5 feet, 

notify the CO as resurvey may be required. Re-measure 3D data to verify existing ground topography 

to mapping. Submit 3D data in electronic format.

Re-measure 3D data 10 feet beyond catch points to verify existing ground topography. 

(d) Slope and references stakes. Perform the following:

(1) AMG method. After clearing operations are completed, set centerline reference stakes and 

hubs on both sides of centerline at 100-foot intervals at the clearing limit locations. Where clearing 

limits are greater than 10 feet vertically, 25 feet horizontally, or both from subgrade hinge point; 

provide an additional reference stake and hub as approved. Label each centerline reference stake

with station, hub elevation, and offset from centerline.

Construct a 1000-foot-long test section using AMG at an approved location before starting grading 

operations. Select a test location with superelevation and curve widening transitions if applicable. 

Notify the CO 10 days before starting the test section. Demonstrate capability, knowledge, 

equipment, and experience to achieve work within tolerances. Allow 14 days to evaluate the test 

section. Do not start full grading operations until the test section is approved. 

Visibly delineate or mark the centerline reference stakes and hubs at cross-section locations for 

use in verifying grade and elevation. Use conventional survey methods at random locations 

specified by the CO, no more than 500-foot intervals. Submit 3D coordinates of centerline 

reference stakes and hubs QC checks. If QC checks do not meet the tolerances in 

Subsection 204.13(c), rework the section until the specified tolerances are achieved and provide 

additional cross-sections as directed.
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(2) Conventional survey methods. Verify and set slope stakes on both sides of centerline at the 

theoretical catch point. If the theoretical catch point is not within a tolerance of ±0.5 feet, perform 

original ground topographic verification according to Subsection 152.05(c). Set the slope stake at 

the actual intersection of the design roadway slope with the natural ground-line. Set reference 

stakes outside the clearing limits. Include reference points and slope stake information on the 

reference stakes. At minimum, label each slope stake with grade information to subgrade shoulder, 

station, hub elevation, and offset from centerline. Include other relevant information on the stakes 

if requested.

Establish slope stakes in the field as the actual point of intersection of the design roadway slope 

with the natural ground-line if theoretical catch point information is not available.

(e) Clearing and grubbing limits. Before ground disturbance occurs, set clearing and grubbing limits 

on both sides of centerline at least every 100 feet. Label each clearing and grubbing limit reference 

stake with station and offset from centerline. 

(f) Grade finishing stakes.

(1) AMG method. Construct a 1000-foot-long test section using AMG at an approved location 

before starting grading operations. Select a test location with superelevation and curve widening 

transitions if applicable. Notify the CO 10 days before starting the test section. Demonstrate the 

capability, knowledge, equipment, and experience to achieve work within tolerances. Allow 

14 days to evaluate the test section. Do not start full grading operations until the test section is 

approved. 

Visibly delineate or mark the centerline and shoulder catch point at cross-section locations for use 

in verifying grade and elevation. Verify the grade elevation and horizontal alignment of roadway 

grade-finishing operations. Use conventional survey methods at random locations specified by the 

CO, no more than 500-foot intervals. Submit 3D coordinates of grade finishing QC checks.

(2) Conventional survey methods. Set grade finishing stakes for grade elevations and horizontal 

alignment, on centerline and on each shoulder at design roadway cross-section locations. Set stakes 

at the top of subgrade and the top of aggregate course. Reset grade finishing stakes as many times 

as necessary to construct the subgrade and each aggregate course.

During turnout or pullout construction, set stakes on the centerline, on each normal shoulder, and 

on the shoulder of the turnout. In parking areas, set stakes at the center and along the edges of the 

parking area. Set stakes in ditches to be paved. 

If the centerline curve radius is less than or equal to 250 feet, use a maximum longitudinal spacing 

between stakes of 25 feet. If the centerline curve radius is greater than 250 feet, use a maximum 

longitudinal spacing between stakes of 50 feet. Use a maximum transverse spacing between stakes 

of 20 feet. Use brushes or guard stakes at each stake.

(g) Culverts. Verify and set culvert locations at the inlet, outlet, and inlet basin points as shown in the 

plans. Perform the following: 

(1) Survey and record the ground profile along the culvert centerline and additional channel profile 

for an appropriate offset to capture required information in Subsection 152.05(g)(4). 
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(2) Determine the slope catch points at the inlet and outlet.

(3) Set reference points and record information necessary to determine culvert length and end 

treatments.

(4) Plot to scale the profile along the culvert centerline. Show the natural ground, flow line, 

roadway section, culvert, end treatments, and other appurtenances. Show elevations, grade, culvert 

length, and degree of elbow. 

(a) For single skewed culverts, submit a plotted field-design cross-section normal to roadway 

centerline and at each end section. Plot the offset and elevation of natural ground at the end 

section and at proposed template break points between centerline and the end section. Ensure 

the template design embankment slope is not exceeded.

(b) For multiple skewed culverts, submit a plotted field-design cross-section normal to 

roadway centerline and at the end sections (left and right) nearest to the shoulder. Plot the 

offset and elevation of natural ground at the end section and at proposed template break points 

between centerline and the end section. Ensure the template design embankment slope is not 

exceeded.

(c) Submit the plotted field-design cross-section for approval of final culvert length and 

alignment. Plot at a clear and readable scale.

(d) Set inlet, outlet, and reference stakes after the field design has been approved. Stake inlet 

and outlet ditches to ensure the culvert and end treatments (such as drop inlets) are functional.

(e) Adjust slope, reference, and clearing stakes as necessary to provide for culvert inlet 

treatments in cut slopes. Readjust slope, reference, and clearing stakes as necessary if culvert 

inlets are moved from their plan locations. Review slope adjustments with the CO and obtain 

approval. 

(h) Bridges. Set adequate permanent horizontal and vertical control and reference points for bridge 

substructure and superstructure components to last through project construction. Establish and 

reference the bridge chord, bridge tangent, or control lines as shown in the bridge plans. Also establish 

and reference the centerline of each pier, bent, and abutment.

(i) Retaining walls, rockeries, special rock embankments, rock buttresses, gabion walls, and 

reinforced soil slopes. Survey and record profile measurements along the face of the proposed wall, 

rockery, embankment, buttress, or reinforced soil slope at 5 feet and 10 feet in front of the wall or 

slope face. Take cross-sections every 25 feet along the length of the wall or reinforced soil slope and 

at major breaks in terrain within the limits designated by the CO. Measure and record points every 

25 feet and at major breaks in terrain for each cross-section. Set reference and control points to perform 

the work. 

(j) Borrow and waste sites. Perform field work necessary for initial layout, baseline, and 

measurement of the borrow or waste site. Establish site limits and clearing limits. Measure both 

original and final ground conditions and submit survey data as directed. 
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(k) Permanent monuments and markers. Perform survey and staking work necessary to establish 

permanent monuments and markers as described in Section 621 or reestablish monuments as described 

in Subsection 107.02. 

(l) Miscellaneous survey and staking. Survey and stake other work as directed to the proper location 

and required tolerances. Propose staking increments and tolerances for approval if not shown in 

Table 152-1. 

Table 152-1

Construction Survey and Staking Tolerances(1)

Staking Phase Horizontal, 

feet (±)

Vertical, 

feet (±)

Control points set from existing control points 0.03 0.01 × √NN (2)

Mapping, topography, & cross-section points 0.16 0.16

Centerline points(3) & references 0.06 0.06

Slope stake and slope stake references(4) 0.16 0.16

Culverts, ditches, & minor drainage structures stakes 0.16 0.06

Retaining walls stakes 0.06 0.03

Curb & gutter stakes 0.06 0.03

Bridge substructures stakes 0.03(5) 0.03

Bridge superstructures stakes 0.03(5) 0.03

Clearing & grubbing limit stakes 1.00 – 

Roadway subgrade finish stakes(6) 0.16 0.03

Roadway finish grade stakes(6) 0.16 0.03

(1) At statistical 95 percent confidence level. Tolerances are relative to existing Government control points.

(2) N is the number of instrument setups.

(3) Centerline points: point of curve (PC), point of tangent (PT), point on tangent, point on curve (POC).

(4) Take the cross-sections normal to the centerline ±1 degree.

(5) Bridge control is established as a local network and the tolerances are relative to that network.

(6) Includes paved ditches. 

152.06 Acceptance. Construction survey and staking will be evaluated under Subsections 106.02 and 

106.04. 

Survey notes will be evaluated under Subsection 106.02. 

Permanent monuments and markers will be evaluated under Section 621. 

Measurement

152.07 Measure the Section 152 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring grade finishing by the mile, measure one time for the subgrade and one time for each 

aggregate course.
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When measuring survey and staking by the hour, do not measure time spent in making preparations, 

traveling to and from the project site, performing calculations, plotting cross-sections and other data, and 

processing computer data. 

Do not measure re-establishing missing control points or stakes after construction operations have begun.

Payment

152.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 152 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for lump sum pay items will be prorated based on total work completed under this 

Section. 
Section 153

69

Section 153. — CONTRACTOR QUALITY CONTROL

Description

153.01 This work consists of planning and implementing a construction quality process to ensure work 

conforms to the contract. This work also includes inspection and documentation, and process control 

sampling and testing. See FAR Clause 52.246-12 Inspection of Construction. 

Construction Requirements

153.02 Qualifications. At least 14 days before starting work, submit documentation of the following for 

approval: 

(a) QCM. Provide a QCM with documented authority to stop non-compliant work or work that results 

in non-compliance with contract requirements.

Provide a QCM with at least 3 years’ experience in areas of material testing, inspection, management, 

supervision, and QC on highway construction projects of similar type and scope; 

(b) Alternate QCM. Provide an alternate QCM, meeting QCM qualifications;

(c) Inspectors. Provide inspectors with at least 2 years’ experience inspecting work of similar type 

and scope; and

(d) Testers. Provide testers with at least 1 year’s experience in the type of sampling and testing 

required, and with one of the following for the type of sampling and testing performed: 

(1) National Institute for Certification in Engineering Technologies (NICET) Level II certification 

in construction materials testing for similar material types or equivalent state or industry 

certification;

(2) Certification by a state or regional certification program, such as Western Alliance for Quality 

Transportation Construction or Northeast Transportation Technician Certification Program; or 

(3) At least 1 year of employment by an AASHTO accredited laboratory performing equivalent 

sampling and testing with competence according to AASHTO R 18.

153.03 Quality Control Plan. Develop and submit a QCP for approval at least 14 days before starting a 

Section of work. Include the work of subcontractors, material suppliers, and technical services suppliers. 

Include the work required under Section 154. Do not perform work unless the QCP for that Section is 

approved. Approval does not imply that the QCP will result in contract compliance.

For each Section of work, include the following: 

(a) QC personnel. Provide the name, authority, responsibilities, and qualifications of the QCM and 

other personnel directly involved in inspection and testing. 
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(b) QC procedures. Describe the inspection, testing, and other activities to be performed for each 

phase of work in Subsection 153.06. Include methods, schedules, equipment, and laboratory facilities.

Include the following for materials to be tested:

(1) Pay item;

(2) Brief operational work plan including, but not limited to, the locations, crews, equipment, and 

proposed methods to complete the work. Describe the plan for staging, disposal, and storage areas.

Include the following in the plan for each Section of work: 

(a) The process to ensure the completed work conforms to contract requirements. 

(b) The inspection and testing frequency to ensure the process remains valid or work is being 

performed according to the established process.

(3) Sampling, testing, and acceptance requirements including the location of sampling, and the 

frequency of testing. At a minimum, perform testing according to the requirements in each 

applicable Section;

(4) Personnel responsible for performing the inspection, sampling, and testing; 

(5) Laboratory testing facilities to be used for process control and project acceptance testing; and

(6) Proposed reporting formats.

(c) Records. Describe the reporting format for inspection, testing, certification, and daily reports.

Revise the QCP if contract quality requirements are not achieved, or changes occur in the contract, work 

processes, or personnel. 

153.04 Quality Control Manager. Provide a QCM who is on site while contract work is being performed. 

Provide a QCM with no responsibilities for managing or superintending the project or performing 

operations other than managing QC. 

Do not use an alternate QCM for more than 3 consecutive days unless approved.

153.05 Certifications and Submittals. The QCM is required to review certifications and submittals to 

ensure compliance with the contract requirements. Provide a copy of the reviewed submittals and 

certifications signed by the QCM. Submit material certifications and submittals at least 7 days before the 

applicable work starts, unless otherwise specified.

153.06 Prosecution of Work. Complete the following:

(a) Preparatory and start-up phase.

(1) Before starting each Section of work, hold a preparatory phase meeting. Include the project 

superintendent, work foreperson, CO, QCM, inspectors, testers, and appropriate subcontractors. 

Discuss the following: 
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(a) Contract requirements for the work including, but not limited to, acceptance procedures, 

schedule, and control strip; 

(b) Process and equipment for constructing the work; and 

(c) Plan for inspection, process control, testing, measuring, and reporting the work.

(2) Review and coordinate certifications, submittals, plans, drawings, and permits. 

(3) Verify the capabilities of equipment, material, and personnel. Provide training as necessary.

(4) Establish a detailed testing schedule based on the production schedule.

(5) Report the required preparatory testing, calibration, and inspection results.

(6) Review accuracy of the surveying and staking. 

(7) Explain procedures to be followed if defective work is identified. 

(8) Describe the plan for staging, disposal, and storage areas. 

(9) Provide a brief operational work plan including, but not limited to, the locations, crews, 

equipment, and proposed methods to complete the work. 

(b) Production phase.

(1) Inspect, test, and report according to the QCP and evaluate the acceptability of the work 

produced. Meet with the CO weekly, or as requested, to discuss the status and effectiveness of the 

QC process. 

(2) Identify and correct deficiencies. Identify root causes and make changes to work processes to 

prevent repeated deficiencies.

(3) Request Government inspection. Allow 24 hours for inspection of the completed work after 

the Government has been notified. 

153.07 Sampling and Testing. At least 45 days before project use, ensure laboratory test equipment has 

been checked, calibrated, standardized, and verified according to AASHTO and ASTM standards by an 

individual qualified to perform the work. Keep laboratory facilities clean and maintain equipment in 

proper working condition. Certify that equipment conforms to testing requirements and submit evidence 

of current calibrations.

Inspect and calibrate mobile laboratory equipment after the laboratory is moved to the project, before 

using equipment, and every time it is moved thereafter. 

Allow the CO unrestricted access to the laboratory for inspection and review. Provide additional 

inspections and tests to demonstrate sampling and testing proficiency if requested. Submit proficiency 

sample test results within 48 hours of sample receipt.
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Perform QC sampling and testing according to the QCP and the Sampling, Testing, and Acceptance 

Requirements tables included at the end of each applicable Section. If no sampling frequencies are 

specified, submit the proposed sampling and testing frequencies. 

Allow the CO the opportunity to witness all sampling and testing. If requested, sample and split QC 

samples according to AASHTO or other acceptable procedures. Deliver and label split QC samples 

according to Subsection 154.03. 

Sample and test material that appears defective or inconsistent with similar material being produced, 

unless such material is voluntarily removed and replaced or otherwise corrected according to 

Subsection 106.01. 

153.08 Records and Control Charts. Maintain records and control charts by pay item. 

(a) QC and construction operations reports. Submit written QC and construction operations reports 

daily according to the QCP. Document meetings, work locations, labor and equipment used. Include 

actual hours worked, testing and measurement activities, inspection results, deficiencies observed, 

corrective actions taken, and process changes. Use Form FHWA 1413, Inspector’s Daily Record of 

Construction Operations or approved alternate forms. Include the following certification signed by 

the QCM on all reports: 

"I certify that the information contained in this record is accurate and that work documented herein 

complies with the contract. Exceptions to this certification are documented as a part of this record."

(b) Test Results. Label test results according to Subsection 154.03. Attach worksheets used to 

determine test values to the test result forms when submitted.

(c) Control charts. Maintain linear control charts that identify the test number, test parameter, upper 

and lower specification limit applicable to each test parameter, and test results for applicable material. 

Use the control charts to document variability of the process, to identify production and equipment 

problems, and to identify actions to improve processes or quality.

Update and post control charts daily in a location accessible to the CO. Stop production and correct 

the process when problems are evident. 

153.09 Acceptance. The Contractor’s QC process will be evaluated under Subsections 106.02 and 106.04

based on its demonstrated effectiveness to ensure work conforms to the contract. Performance of the work 

may be stopped according to Subsection 108.06, either in whole or in part, for failure to comply with the 

requirements of this Section. 

Measurement

153.10 Measure the Section 153 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

153.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 153 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 154

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Section 154. — CONTRACTOR SAMPLING AND TESTING

Description

154.01 This work consists of obtaining samples, testing, and reporting the required test results. It excludes 

Contractor process and QC sampling and testing required under Section 153. 

Construction Requirements

154.02 General. Sample and test material according to the Sampling, Testing, and Acceptance 

Requirements tables included at the end of each Section. Provide testers conforming to 

Subsection 153.02(d). Perform additional sampling and testing as directed if material does not meet 

requirements.

Provide the CO the opportunity to witness sampling, splitting, and testing of material. 

Where process control sampling and testing frequencies are identical to the sampling and testing 

frequencies for acceptance, the process control samples may be used for acceptance for the applicable 

work. 

154.03 Sampling. Sample and split samples according to AASHTO or other acceptable procedures. For 

statistical acceptance sampling, the exact location of sampling will be determined by the CO based on 

random numbers. Perform splits when required and deliver the Government’s portion of the sample or 

split sample in an acceptable container suitable for shipment. Label samples with the following: 

(a) Project number and name; 

(b) Pay item number and description;

(c) Source of material;

(d) Sample number; 

(e) Date sampled;

(f) Time sampled;

(g) Location sample taken;

(h) Name of person sampling; 

(i) Name of person witnessing sampling; and 

(j) Type of test required on sample.

154.04 Testing. Conform to Subsection 153.07 for sampling and testing. Demonstration of testing 

competence may be required.

154.05 Records. If tests are on material being incorporated in the work, report test results within 24 hours 

unless otherwise specified in the Sampling, Testing, and Acceptance Requirements tables. Report test 
Section 154

74

results on forms containing sample information required by Subsection 154.03. Label interim 

measurements used to determine the results. Attach worksheets used to determine test values to the test 

result forms. Payment for work may be delayed or the work stopped until test results are submitted. 

154.06 Acceptance. Contractor sampling and testing will be evaluated under Subsections 106.02 and 

106.04 based on Government verification testing. 

Measurement

154.07 Measure the Section 154 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

154.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 154 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for Contractor testing by the lump sum will be paid as follows:

(a) 25 percent of the pay item amount, no more than 0.5 percent of the original contract amount, will 

be paid after the testing facilities are in place, qualified sampling and testing personnel are identified, 

and the work being tested has started.

(b) The remaining portion of the pay item amount will be prorated based on total work completed 

under this Section. 

Payment may be retained if Government testing does not validate the Contractor testing or if it is 

determined that documentation of sampling and testing does not meet requirements. 
Section 155

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Section 155. — SCHEDULES FOR CONSTRUCTION CONTRACTS

Description

155.01 This work consists of scheduling, monitoring, and reporting the progress of construction activities.

155.02 Definitions. 

(a) Baseline construction schedule. The first approved construction schedule submitted after the 

preliminary work plan, showing the order to perform the work, and the dates for starting and 

completing the work. Once approved the baseline construction schedule cannot be changed. 

(b) Construction schedule. Designated as either a Bar Chart Method (BCM) or a Critical Path 

Method (CPM) schedule.

(1) BCM schedule. A BCM schedule includes a progress bar chart, written narrative, and a 

submittal list.

A progress bar chart is a time-scaled graphic representation of a project displaying the overall 

sequencing of work. Each activity includes an activity number, description, start and finish date, 

and duration. BCM schedules list predecessor activities that must be finished before each activity 

can be started.

(2) CPM schedule. A CPM schedule includes a time-scaled logic diagram, tabular schedule, 

written narrative, and a submittal list.

The time-scaled logic diagram is a computer-generated diagram showing the sequence in which 

the Contractor, in coordination with subcontractors, plans to perform the work; the 

interdependence of all activities and milestones; the work completed through the data date; and 

the remaining work necessary to complete the project.

(c) Construction schedule update. An update to the previously approved construction schedule that 

shows the completed work and the remaining work necessary to complete the project and includes 

progressing of the schedule, changes to the schedule logic, changes to the schedule activities, changes

to the activity durations, or any other modification to the schedule of planned work. A construction 

schedule update may show construction being completed at a date other than the contract completion 

date.

(d) Critical path. The longest sequence of activities in the CPM schedule that determines the project’s 

duration. If the duration of any activity on the critical path is changed, the time required to complete 

the project will change unless a separate CPM schedule adjustment is made. 

(e) Preliminary work plan. A narrative and schedule diagram of contract activities for the first 

60 days after the NTP.

Construction Requirements

155.03 General. Follow the requirements of FAR Clause 52.236-15 Schedules for Construction 

Contracts.
Section 155

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Designate an individual who will be the authorized representative responsible for the schedule. Submit 

the name of the authorized representative with the preliminary work plan. 

Failure to include elements of work in the schedule that are required for performance of the contract, even

if approved by the Government, will not excuse the Contractor from completing the work required by the 

contract completion date.

Approval of the construction schedule does not relieve the Contractor of the responsibility to schedule the 

work to meet the contract requirements. 

Do not suppress or sequester float. Do not alter planned durations and sequencing to give the appearance 

that activities do not have float. Float time within the construction schedule is not for use or benefit of 

either the Government or the Contractor but is a jointly owned project resource available to both parties 

as needed to meet the contract completion date. Either party has the full use of float until it is depleted. 

In case of discrepancy, the approved electronic format governs over native file format of the construction 

schedule.

155.04 Preliminary Work Plan. Do not start work, except mobilization, temporary traffic control, and 

Section 637 work, without an approved preliminary work plan. No progress payments will be made until 

a preliminary work plan has been approved. Include the following: 

(a) A title page stating contract number, project number, project name, Contractor name, contract 

completion date, date of submittal, submittal number, and "Preliminary Work Plan"; 

(b) A schedule diagram showing work activities; 

(c) Description of proposed work within each activity including the type and quantity of equipment, 

labor, and material to be used;

(d) Description of site mobilization; 

(e) Description of planned production rates for each applicable pay item by pay item quantities; 

(f) Description of the number of workdays per week, holidays, number of shifts per workday, and 

number of hours per shift. Include all calendars used in the schedule module;

(g) Estimate of idle and partially idle periods within each activity, showing start and finish dates;

(h) Description of expected and critical delivery dates for equipment and material that can affect 

completion of the project. Describe the fabrication and delivery of key and long-lead time procurement 

activities;

(i) Name of vendor, supplier, or subcontractor to perform an activity. State assumptions made in 

scheduling their work; 

(j) A list of shop drawings, sample submittals, and review times; and

(k) A list of drawings, permits, and other submittals by pay item number required for the entire 

contract period. 
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77

Submit a preliminary work plan at least 7 days before the preconstruction conference. Within 14 days of 

submission, the preliminary work plan will be approved or rejected. If rejected, submit a revised plan 

within 3 days. 

155.05 Baseline Construction Schedule. Submit a construction schedule within 45 days of the NTP. 

Include a title page or header block for each component with the contract number, project number, project 

name, Contractor name, contract completion date, date of submittal, and submittal number. Show all 

activities including those in the preliminary work plan.

Prepare and submit a CPM construction schedule unless otherwise specified.

(a) CPM schedule. Depict the order and interdependence of all activities and the sequence of the work 

that will be accomplished by the Contractor and subcontractors. 

Do not provide logic relationships between unrelated activities. Do not constrict start or finish dates 

without rationale. 

Obtain approval before using lags or leads in the construction schedule. Remove lags or leads and 

replace with an activity identifying the lag or lead upon request. 

(1) Time-scaled logic diagram.

(a) Show activity descriptions. Relate activities or groups of activities to pay items. Include 

activities for submittals, submittal reviews, fabrication, and deliveries. Do not include 

continuous activities (such as traffic control and QC).

(b) Show activity name or description with the activity bar on the diagram.

(c) Group activities by area (such as separate distinct bridges or roadways), and by type of 

work (such as submittals, utilities, roadway, or bridge). 

(d) Show original and remaining durations for construction activities. Break construction 

activities into subtasks with activity durations no longer than 20 workdays.

(e) Show original and remaining durations of non-construction activities (such as mobilization 

and submittals). Include pay item number, and the fabrication and delivery of key materials. 

Non-construction activities may have durations exceeding 20 workdays consistent with the 

contract. Indicate intended submittal dates and delivery dates for fabrication and delivery 

activities. Allow for review of each submittal.

(f) Start the construction schedule with the date of the NTP and conclude with a milestone that 

shows the contract completion date. 

(g) Show early start and finish dates.

(h) Show late start and finish dates.

(i) Show total float and free float.

(j) Show relationship lines. Include at least one predecessor and one successor activity for each 

activity, except for the NTP and contract completion date. 
Section 155

78

(k) Use a time scale to graphically show the work scheduled for performance.

(l) Show the sequence and interdependence of all activities.

(m) Identify the critical path.

(2) Tabular schedule. Submit a tabular schedule sorted by early start and total float. Include the 

following information in the tabular schedule:

(a) Activity number; 

(b) Activity description;

(c) Subcontractor and supplier activity codes; 

(d) Activity percent complete;

(e) Original and remaining duration;

(f) Early and late schedule dates;

(g) Total float;

(h) A predecessor/successor report; and 

(i) Other tabular schedule report formats for analyzing CPM schedule revisions or time 

impacts, if requested.

(3) Written narrative. Describe the rationale and assumptions used in the development of the 

construction schedule. Use the time-scaled logic diagram as the basis of schedule-related 

comments and reference specific activities by number and description. Ensure there are no 

conflicts between the diagram and the narrative. Include the following: 

(a) Description of the planned critical path and the general sequence of work.

(b) Information and references to adequately define the scope of work by pay item included in 

each major activity type (such as roadway excavation and aggregate base course). Include 

station numbers and location. 

(c) Description of the resource loading planned for use in the performance of the work for each 

major activity. Include manpower allocation by types of labor and crew size, types and number 

of equipment and special equipment, material, and subcontractors. 

(d) Description of the basis (including the resource loading above) for the calculation of the 

duration for major activities, to be stated as quantity production rates. 

(e) Description of workdays per week, number of shifts per workday, and number of hours per 

shift.

(f) A description of the assumptions used in converting workdays to calendar dates. Include 

anticipated holidays, non-workdays, winter shutdowns, and other constraints within the 
Section 155

79

contract. Describe calendars used in the schedule module and list the calendar used for each 

activity in the schedule module.

(g) Name of the subcontractor or supplier performing an activity and identify their activity 

codes used on the schedule diagram. State assumptions made in the scheduling of the 

subcontractor’s or supplier’s work. 

(h) Description of site mobilization and critical delivery dates for equipment and material that 

can affect completion of the project.

(i) A description of organizational limitations (such as resource constraints or subcontractor 

commitments) which limit scheduling flexibility.

(j) Estimate of idle and partially idle periods within each activity, showing start and finish

dates.

(k) A list and description of constraints used in the CPM scheduling software. 

(4) Submittal list. Provide a submittal list according to Subsection 155.05(b)(3). 

(b) BCM schedule. Include the following:

(1) Progress bar chart.

(a) Use a time scale to graphically show the percentage of work scheduled for completion 

during the contract time;

(b) Define and relate activities to the pay items;

(c) Show activities in the order the work will be performed, including submittals, submittal 

reviews, fabrication, and delivery; 

(d) Highlight activities that are controlling factors in the completion of the work;

(e) Show the time needed to perform each activity and its relationship in time to other 

activities;

(f) Show the total time to complete work; and

(g) Provide enough space for each activity to allow two additional plots parallel to the original 

time span plot. Use one space for revision of the planned time span, and one for showing actual 

time span achieved.

(2) Written narrative.

(a) Estimate start and finish dates of each activity;

(b) Describe work to be done within each activity including the type and quantity of equipment, 

labor, and material to be used;

(c) Describe the location on the project where each activity occurs;
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80

(d) Describe planned production rates for each applicable pay item by pay item quantities; 

(e) Describe the number of workdays per week, holidays, number of shifts per workday, and 

number of hours per shift. Include all calendars used in the schedule; 

(f) Estimate of idle and partially idle periods within each activity, showing start and finish 

dates; 

(g) Describe expected and critical delivery dates for equipment or material that can affect 

completion of the project. Describe the fabrication and delivery of key and long-lead time 

procurement activities;

(h) Identify the vendor, supplier, or subcontractor to perform the activity. State assumptions 

made in the scheduling their work; and

(i) Describe critical completion dates for maintaining the construction schedule.

(3) Submittal list. Submit a list of drawings and other submittals by pay item number required for 

the entire contract period. Include the following information for each drawing or submittal:

(a) Pay item number and description;

(b) Planned date of initial submittal; and

(c) Planned date of CO’s initial response.

Submit the construction schedule according to Subsection 104.04. 

Within 14 days of submission, the construction schedule will be approved or rejected. If rejected, submit 

a corrected schedule within 7 days. If rejected again, schedule a meeting within 3 days to discuss 

corrections and submit another construction schedule. 

If a construction schedule is not received within 45 days after the NTP is issued, the CO will withhold the 

progress payment according to Subsection 109.08(h) until the construction schedule is received.

The approved construction schedule with supporting documents becomes the baseline construction 

schedule. 

155.06 Construction Schedule Update. Submit a construction schedule update by the 15th day of each 

month, or on the date established by the CO. 

Submit the construction schedule update according to Subsection 104.04. 

Do not make changes to the schedule logic, activities, or critical path without prior approval. 

Within 7 days of submission, the construction schedule update will be approved or rejected. If rejected, 

submit a corrected construction schedule within 7 days. If rejected again, schedule a meeting within 3 days 

to discuss corrections and submit another construction schedule.

If an acceptable construction schedule update is not received by the 15th day of the month, or on the date 

established by the CO, the CO will withhold 10 percent of each progress payment according to 
Section 155

81

Subsection 109.08(h)(3), until a construction schedule update is approved. Failure to receive approval of 

a prior construction schedule update does not relieve the Contractor of the responsibility to meet the 

requirement to provide construction schedule updates each month. 

Submitting a proposed construction schedule update is not considered a notification of delay or of other 

basis for change. Continue to submit monthly construction schedule updates until a construction schedule 

update is approved. 

Approval of a construction schedule update showing completion past the fixed completion date will not 

alter the fixed completion date or affect the Government's rights under the contract.

(a) Update summary. Provide a summary of the changes and progressing made to the construction 

schedule since the last approved construction schedule update. 

(b) Written narrative. Submit an update of the written narrative identifying adjustments made to 

each operation since the last update. Include the following:

(1) Equipment added or removed from the project;

(2) Changes to labor (such as added crews or subcontractors); 

(3) Work shift adjustments (such as extended hours or added shifts); 

(4) Changes to anticipated periods of suspension or holiday; 

(5) Changes in material delivery;

(6) Early completion of individual work items; 

(7) Efficiency of operations; 

(8) Changes to the critical path and logic revisions; 

(9) Delays and disruptions that are ongoing as of the date of the proposed construction schedule 

update. If delays or disruptions have occurred, propose efforts to return the project to a schedule 

consistent with the contract requirements including the commitment of additional resources or 

other appropriate action; and

(10) Notification that completion date or other contract requirements will not be met, if applicable. 

(c) Submittal list. Provide an update to the submittal list. Include the following: 

(1) Actual dates for submittals;

(2) Proposed dates for anticipated submittals;

(3) CO’s responses (approved, rejected, or approved as noted); and 

(4) Comments.
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(d) CPM schedule updates.

(1) Tabular schedule. Update the tabular schedule. Include the following:

(a) Actual start and finish dates for completed activities;

(b) Remaining duration required to complete each activity started, or scheduled to start, but 

not completed; 

(c) Float remaining for each activity;

(d) Percentages for completed and partially completed activities; 

(e) Additional tabular schedules using different sort parameters if requested; and 

(f) Revised construction activities affected by impacts addressed with a time impact analysis. 

Include a revised completion date for the total work.

(2) Updated time-scaled logic diagram. Update the diagram and show the approved baseline 

construction schedule on the construction schedule update for comparison. Show the data date for 

the update. 

(e) BCM schedule updates.

(1) Progress bar chart. Update the progress bar chart. Include the following: 

(a) Actual start and planned finish dates of activities underway;

(b) Remaining duration of uncompleted activities;

(c) Actual finish dates of completed activities; 

(d) Revised construction activities affected by impacts addressed with a time impact analysis. 

Include a revised completion date for the total work; and 

(e) The initial time span plot adjacent to the updated time span plot for each work activity. 

155.07 Progress Meetings. Schedule and facilitate a weekly progress meeting. Invite the CO, 

superintendent, QCM, and other personnel directly supervising or managing the project. 

Provide a two-week look-ahead schedule one day before the meeting. Review actual progress as compared 

to the planned progress and review planned activities for the upcoming 2 weeks. Discuss the status of 

submittals, QC documentation, contract modifications, and requests for information.

155.08 Acceptance. Construction schedules and supporting documents will be evaluated under 

Subsection 106.02. 

Measurement

155.09 Measure the Section 155 pay items listed in the bid schedule according to Subsection 109.02. 
 

Section 155 

Payment 

155.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 155 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for construction schedule by the lump sum will be paid as follows: 

(a) 25 percent of the pay item amount, no more than 0.5 percent of the original contract amount, will 

be paid after the baseline construction schedule is approved. 

(b) The remaining portion of the pay item amount will be prorated based on the total work completed 

in the contract. 

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Section 156 

Section 156. — PUBLIC TRAFFIC 

Description 

156.01 This work consists of controlling and protecting public traffic adjacent to and within the project. 

See FAR Clause 52.236-13 Accident Prevention. 

Construction Requirements 

156.02 Qualifications. Provide a traffic control supervisor (TCS) certified by a state department of 

transportation, ATSSA, or other acceptable certification programs. At least 30 days before starting work, 

submit documentation of appropriate certifications for approval. 

156.03 Accommodating Traffic During Work. Accommodate traffic according to the MUTCD, 

Section 635, this Section, and as shown in the plans. At least 30 days before intended use, submit a 

temporary traffic control plan according to Subsection 104.06. 

Ensure the safety and convenience of the public and protect the residents and property adjacent to the 

project. Accommodate public traffic on roads adjacent to and within the project until the project is 

accepted according to Subsection 106.06(b). 

Immediately open the road to emergency vehicles. 

156.04 Maintaining Roadways During Work. Maintain roadways as follows: 

(a) Construct and remove temporary traffic diversions and bridges as required by the temporary traffic 

control plan. 

(b) Maintain intersections and provide access to trails, roads, streets, businesses, parking areas, 

residences, garages, farms, and other features at all times. 

(c) Snow removal to facilitate the work is the Contractor’s responsibility. Snow removal to provide 

public access is the responsibility of the maintaining agency and may be performed at the maintaining 

agency’s discretion. Allow the maintaining agency access to perform snow removal. 

(d) Provide dust control according to Section 158 or 312. Apply water or dust palliative as ordered to 

maintain visibility and eliminate hazardous conditions. 

(e) Remove accumulations of soil and other material from the traveled way. 

(f) Do not allow water to pond on the traveled way. 

(g) Maintain the roadway, detours, and temporary traffic diversions in a safe and acceptable condition. 

If corrective action is requested and the corrective action is not taken immediately, the condition may be 

corrected by the CO and the cost of the corrective action deducted from monies due the Contractor. 

156.05 Maintaining Roadways During Non-Work Periods. Maintain roadways and traffic control for 

public traffic during periods when work is not in progress. Snow removal to provide public access is the 

responsibility of the maintaining agency. 

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Section 156 

156.06 Limitations on Construction Operations. When the roadway is open to public traffic, perform 

the following: 

(a) Limit construction-caused delays to public traffic to no more than 30 minutes per passage through 

the project. 

(b) Operate equipment in the direction of traffic, where practical. 

(c) For shoulder drop-offs of 3 inches or less, provide "Low Shoulder" warning signs. For shoulder 

drop-offs more than 3 inches, provide a 1V:3H fillet with "Shoulder Drop-Off" warning signs. 

Complete the construction of shoulders adjacent to traffic lanes to the same elevation within 14 days. 

(d) Provide minimum lane widths of 10 feet. Use barricades, drums, or other approved devices to 

delineate traffic lanes through areas where the edge of pavement or intended path has been obliterated 

by construction operations. Notify and coordinate with the oversize load permitting authority for lane 

width limitations before reducing lane width or closing roadway shoulders. 

(e) Locate staging areas outside the clear zone or behind approved traffic barriers. Obtain approval of 

the location and access to staging areas. Store unused traffic control devices at staging areas. 

(f) Park equipment outside of the clear zone or behind approved traffic barriers. 

(g) Provide parking areas for employee’s personal vehicles in approved areas. 

(h) Provide uninterrupted two-way communications between flaggers and between flaggers and pilot 

cars unless flaggers can see each other and communicate. Citizen band radios are unacceptable. Make 

communication devices available to the CO as necessary or if requested. 

(i) Maintain existing guardrails, barriers, and bridge railings until removal is necessary for 

construction. Use a temporary barrier or appropriate channelizing devices while the guardrails and 

bridge rails are absent. Install permanent barriers, guardrails, and bridge rails as soon as possible. 

156.07 Nighttime Operations. Perform construction operations during the hours of daylight. Daylight 

hours are defined as one-half hour after sunrise to one-half hour before sunset. 

Where nighttime operations are allowed, submit a night lighting plan for approval. Include the number of 

lights, types, and locations. Submit the proposed plan at least 14 days before use. Do not use vehicle or 

incandescent lights for work zone lighting. 

Provide and install the approved system to illuminate the entire work area. Position the lights so they do 

not shine directly at motorists traveling from any direction. If the operation is moving, move the lighting 

with the operation. Describe how lighting system moves will be accomplished and designate a person 

responsible. Provide lighting at each flagger location. Equip vehicles with an exterior flashing yellow 

dome light. If arrow boards are used, reduce brightness by an acceptable level during nighttime. 

156.08 Traffic Control Supervisor. Provide a TCS according to Subsection 156.02 during construction 

operations and as necessary to inspect the devices as defined below. Provide the TCS’s name and 24-hour 

telephone numbers at the preconstruction conference. 

Do not designate the superintendent as the TCS. 

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Section 156 

During the contract, including periods of suspensions and work stoppages, perform the following: 

(a) Implement the temporary traffic control plan and monitor the effectiveness of the plan. 

(b) Coordinate traffic control operations. Include those of subcontractors and suppliers. 

(c) Ensure the condition, position, and applicability of traffic control devices in use. 

(d) Immediately correct traffic control deficiencies. 

(e) Coordinate and ensure that traffic control devices are provided, installed, maintained, removed, 

stored, replaced, relocated, and cleaned according to Section 635. Ensure unused traffic control 

devices are properly handled and stored. 

(f) Conduct weekly traffic safety meetings for construction workers and invite the CO to these weekly 

meetings. 

(g) Submit a weekly certification that inspections and reviews were conducted and that the traffic 

control devices meet contract requirements. Include the number and types of devices in use. Report 

with the weekly certification, changes or corrective actions taken to ensure the safe passage of public 

traffic through the project. 

(h) Inspect traffic control devices, including those in staging, storage, material source, and disposal 

areas, as follows: 

(1) Daily, during daylight hours and during hours of darkness; 

(2) Weekly during: 

(a) Daylight hours and hours of darkness when work is suspended for periods of more than 

one week; and 

(b) Periods of winter suspension. 

(3) Additional inspections, day or night, as directed; and 

(4) Submit reports of inspections within 24 hours. 

(i) Before winter suspension, conduct an inspection of the project with the CO to ensure proper 

provisions are made for winter travel during the period of suspension. 

(j) Provide temporary flagging assistance. 

156.09 Acceptance. Controlling and protecting public traffic work will be evaluated under 

Subsection 106.02. 

Dust control will be evaluated under Sections 158 and 312. 

Temporary traffic control devices and services will be evaluated under Section 635. 

86 
Section 156 

Measurement and Payment 

156.10 Do not measure controlling and protecting public traffic for payment. See Subsection 109.05. 

87 
 

 

 

Section 157 

Section 157. — SOIL EROSION AND SEDIMENT CONTROL 

Description 

157.01 This work consists of providing, constructing, maintaining, and removing soil erosion and 

sediment control measures to eliminate or minimize pollutants in stormwater discharges from the project. 

Material 

157.02 Conform to the following Subsections: 

Fiber rolls 713.12 

Filter rock 705.08 

Floating turbidity curtains 713.21 

General purpose tackifier 713.11(a) 

Geotextile 714.01 

Gravel bags 713.13 

Mulch 713.05 

Nonloadbearing concrete masonry units 725.07(c) 

Plastic lining 713.22 

Prefabricated filter insert 713.20 

Rock for riprap 705.02 

Rock mulch 705.07 

Rolled erosion control products 713.17 

Sandbags 713.14 

Sediment filter bags 713.19 

Seed 713.04 

Silt fence 713.16 

Soil and soil-aggregate materials 704.01 

Temporary culvert pipe 713.15 

Temporary plastic fence 710.08 

Turf reinforcement mats 713.18 

Water for vegetation 725.01(b) 

Construction Requirements 

157.03 Qualifications. Provide personnel with experience providing erosion and sediment control and 

pollution prevention. At least 14 days before starting earth disturbing work, submit a résumé for each 

individual describing at least 5 years’ experience providing erosion and sediment control and pollution 

prevention on highway or road construction projects for approval. Include certifications in those states 

where applicable. 

157.04 General. Provide and construct permanent and temporary soil erosion and sediment control 

measures according to the plans, contract permits, Section 107, and this Section. Contract permits amend 

the requirements of this Section. Do not modify the type, size, or location of measures or practices without 

approval. 

Manage SWPPP documentation and reporting requirements according to contract permits. An alternate 

erosion and sediment control plan or SWPPP, with necessary permits, may be submitted for approval 

88 
 

 

 

 

Section 157 

according to Subsection 104.06. Submit alternate erosion and sediment control proposals at least 30 days 

before their intended use. 

If soil erosion and sediment control measures are not functioning as intended, take corrective action to 

eliminate or minimize pollutants in stormwater discharges from the project. 

157.05 Controls and Limitations on Work. Mark clearing limits and construct sediment perimeter 

control measures before ground disturbing activities. 

Limit the combined grubbing and grading operations areas to 5 acres of exposed soil at one time. 

Construct and implement soil erosion and sediment control measures as follows: 

(a) Construct temporary measures in incremental stages as construction proceeds. 

(b) Following each day’s grading operations, shape earthwork to minimize and control soil erosion 

and sediment transport from stormwater runoff. 

(c) Divert runoff around exposed soils. 

(d) Stabilize areas of exposed soil where construction activities have permanently ceased or will be 

temporarily inactive for the next 14 days. Complete the installation of stabilization measures as soon 

as practical, but no later than 14 days since last disturbance. 

(e) Construct outlet protection as soon as culverts or other structures are complete. 

(f) Construct and maintain soil erosion and sediment controls on and around soil stockpiles. 

(g) Maintain stabilized construction exits to minimize tracking of soil onto existing roads. 

157.06 Filter Barriers. Construct silt fence, berms, and fiber rolls to reduce the velocity of runoff to allow 

sediment to settle. 

157.07 Sediment Retention Structures. Construct sediment retention structures of the following types: 

(a) Temporary sediment traps. Construct temporary sediment traps to detain runoff from disturbed 

areas and settle out sediment. Provide outlet protection. 

(b) Sediment basins. Construct sediment basins to store runoff and settle out sediment for large 

drainage areas. Excavate and construct sediment basins according to Section 204. Construct riser pipes 

according to Section 602. Provide outlet protection. 

157.08 Outlet Protection. Construct riprap aprons or basins to reduce water velocity and prevent scour 

at the outlet of permanent and temporary erosion and sediment control measures. Construct riprap 

according to Section 251. 

157.09 Water Crossings. Construct temporary culvert pipe or bridge at temporary crossings where 

construction vehicles cross a live waterway according to Section 107. 

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Section 157 

157.10 Temporary Stormwater Diversions. Construct temporary channels, temporary culverts, earth 

berms, or sandbags to divert stormwater around disturbed areas and slopes. Stabilize channels according 

to Subsection 157.11. Provide outlet protection. 

157.11 Channel and Slope Protection and Stabilization. Use the following: 

(a) Plastic lining. Use plastic lining to protect underlying soil from erosion. Place the plastic lining 

loosely on a smooth soil surface free of projections or depressions that may cause the liner to puncture 

or tear. Anchor the lining in place using riprap, gravel bags, or sandbags. If plastic liner is being used 

for a temporary stormwater diversion channel, place seams perpendicular to the direction of 

stormwater flow and overlap at least 18 inches.

(b) Riprap. Construct riprap according to Section 251. 

(c) Check dams. Construct riprap, filter rock, gravel bags, sandbags, and fiber rolls for check dams 

to reduce the velocity of runoff in ditches and swales. 

(d) Rolled erosion control products. Use rolled erosion control products before or after temporary 

or permanent seeding. Install according to Section 629. 

(e) Temporary slope drains. Use drain pipe, riprap, or plastic lined channel for temporary slope 

drains. Channel water into the slope drain with an earth berm, gravel bag, or sandbag headwall 

constructed at the top of a cut or fill. Anchor slope drains to the slope. Provide outlet protection. 

(f) Floating turbidity curtains. Install floating turbidity curtains within a body of water to minimize 

the migration of silt laden stormwater out of the construction area. 

157.12 Temporary Soil Stabilization. Control soil erosion on unprotected slopes. Do not import wood 

chips without approval. Use the following: 

(a) Temporary cover. Use mulch, plastic lining, RECP, or tackifier. Apply according to the 

manufacturer’s recommendations or as approved. 

(b) Temporary turf establishment. Apply seed and mulch for soil erosion protection at the rates 

shown in Table 157-1. Protect and care for seeded areas, including watering, until permanent turf 

establishment is in place. 

Table 157-1 

Application Rates for Temporary Turf Establishment 

Material Application Rate, 

pounds/acre 

Seed 45 

Wood fiber or grass straw cellulose fiber mulch 2000(1) 

(1) Apply mulch using hydraulic method according to Subsection 625.08(b). For other mulch products and 

application methods, use the manufacturer’s rate as approved. 

157.13 Permanent Soil Stabilization. Control soil erosion on completed permanent slopes. Use the 

following: 

(a) Turf establishment. Apply turf establishment according to Section 625. 

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Section 157 

(b) Plants, trees, shrubs, vines, groundcovers, and other plants. Plant trees, shrubs, vines, 

groundcovers, and other plants according to Section 626. 

(c) Sod. Place sod of perennial turf-forming grasses according to Section 627. 

(d) Rock mulch. Place rock on finished surfaces. 

157.14 Inspection and Reporting. Inspect erosion and sediment control measures according to contract 

permits. If no contract permits apply, inspect at least once every 7 days and within 24 hours of the 

occurrence of a storm event of 0.25 inch. 

Within 24 hours after each inspection, submit an inspection report. Include the following: 

(a) Date and time of the inspection; 

(b) Names and titles of persons making the inspection; 

(c) Summary of the inspection; 

(d) Weather since the last inspection or since the start of work, if the first inspection. For each storm 

event, include the starting date and time, duration, precipitation quantity in inches, and whether 

discharge occurred; 

(e) Weather and description of discharges occurring during the inspection; 

(f) Locations of discharges or other pollutants from the site; 

(g) Locations of erosion and sediment control measures that need maintenance; 

(h) Locations of erosion and sediment control measures that failed to operate as designated or proved 

inadequate for a particular location; 

(i) Locations where additional erosion and sediment control measures are needed; and 

(j) Other necessary corrective actions including action taken, locations, dates, and times. 

157.15 Maintenance and Cleanup. Maintain temporary and permanent erosion and sediment control 

measures in working condition until final acceptance or the measures are no longer needed. 

Remove sediment trapped in perimeter protection control measures before deposits reach 50 percent of 

the above ground height. Remove sediment from sediment retention structures when their capacity is 

reduced to 50 percent of design capacity. Use removed sediment in the work if approved or dispose of it 

according to Subsection 204.14. 

Replace erosion and sediment control measures that cannot be maintained and those that are damaged by 

construction operations. 

When vegetation coverage meets permit requirements, conforms to Subsection 625.09, and drainage 

ditches and channels are lined and stabilized, remove and dispose of temporary erosion and sediment 

control measures according to Subsections 203.05 and 203.07. 

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Section 157 

Restore the ground to its natural or intended condition and provide permanent erosion control measures. 

157.16 Acceptance. Material for erosion and sediment control measures will be evaluated under 

Subsections 106.02 and 106.03. 

Construction, maintenance, and removal of erosion and sediment control measures will be evaluated under 

Subsections 106.02 and 106.04. 

Measurement 

157.17 Measure the Section 157 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring soil stabilization by the acre, measure on the ground surface. 

Do not measure replacement items. 

Payment 

157.18 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 157 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for erosion control measures will be paid as follows: 

(a) 25 percent of the pay item amount will be paid after installation. 

(b) An additional 50 percent of the pay item amount will be prorated based on total work completed 

under this Section. 

(c) The remaining portion of the pay item amount will be paid after the temporary erosion control 

measure is removed from the project or at final acceptance. 

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Section 158 

Section 158. — WATERING FOR DUST CONTROL 

Description 

158.01 This work consists of providing and applying water for the control of dust caused by the work and 

public travel. 

Material 

158.02 Conform to the following Subsection: 

Water for construction 725.01(c) 

Construction Requirements 

158.03 General. Provide an adequate water supply and apply water uniformly across the traveled way as 

necessary to control dust. Uniformly apply water using pressure-type distributors, pipelines equipped with 

spray systems, or hoses with nozzles. Apply water at the locations, rates, and frequencies as necessary to 

control the dust, or as ordered. 

(a) Project dust control for public benefit. Control dust within the construction limits as necessary 

including nights, weekends, and periods of non-work when the project is open to public traffic. When 

the project is not open to public traffic, control dust in areas of the project that have adjacent residences 

or businesses. Control dust on approved, active detours established for the project. 

(b) Other dust control. Control dust on active haul roads, in pits and staging areas, and on the project 

during periods not covered in Subsection 158.03(a). 

158.04 Acceptance. Water will be evaluated under Subsection 106.02. 

Providing and applying water will be evaluated under Subsections 106.02 and 106.04. 

Measurement 

158.05 Measure the Section 158 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring water for dust control by volume or mass, measure in the hauling vehicle or by metering. 

Do not measure water for dust control applied according to Subsection 158.03(b). 

Payment 

158.06 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 158 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

93 
DIVISION 200 

EARTHWORK 

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Section 201 

Section 201. — CLEARING AND GRUBBING 

Description 

201.01 This work consists of clearing and grubbing within the clearing limits designated in the plans. 

Material 

201.02 Conform to the following Subsections: 

Soil and soil-aggregate materials 

Tree wound dressing 

704.01 

713.08(g) 

Construction Requirements 

201.03 General. Construct erosion and sediment control measures according to Section 157. Do not start 

clearing until the limits have been approved. Perform work within approved limits. Where possible, 

preserve vegetation adjacent to bodies of water. 

Do not damage vegetation designated to remain. If damage occurs, repair or replace the vegetation in an 

acceptable manner. Treat wounds or scarred surfaces of trees or shrubs with tree wound dressing. 

201.04 Clearing. Within the clearing limits, clear trees, brush, downed timber, and other vegetation as 

follows: 

(a) Cut trees so they fall within the clearing limits. 

(b) In areas of cut slope rounding, cut stumps flush with or below the final ground-line. 

(c) In areas outside the excavation, embankment, and slope rounding limits, cut stumps to within 

6 inches of the existing ground. 

(d) Trim tree branches that extend over the road surface and shoulders to a clear height of 20 feet. If 

required, remove other branches to present a balanced appearance. Trim according to accepted tree 

surgery practices. Treat cuts with tree wound dressing. 

201.05 Grubbing. Grub deep enough to remove stumps, roots, buried logs, moss, turf, grass, and other 

vegetation as follows: 

(a) Grub areas to be excavated, except for cut slope rounding areas. 

(b) Grub embankment areas. Undisturbed stumps less than 24 inches in diameter may be left in place 

if they protrude less than 4 inches above the original ground and will be covered with more than 

48 inches of embankment. Remove all other stumps. 

(c) Grub pits, channel changes, and ditches only to the depth necessary for the excavation. 

(d) Backfill stump and grubbing holes with common backfill to the level of the surrounding ground 

according to Subsection 209.09. Compact backfill according to Subsection 209.10. 

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Section 201 

201.06 Disposal. Merchantable timber is the Contractor’s property. Dispose of clearing and grubbing 

debris according to Subsection 203.07. 

201.07 Acceptance. Material for tree wound dressing will be evaluated under Subsections 106.02 and 

106.03. 

Clearing and grubbing will be evaluated under Subsection 106.02. 

Backfilling and compacting of stump and grubbing holes will be evaluated under Section 209. 

Measurement 

201.08 Measure the Section 201 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

Do not make deductions from the area computation unless excluded areas are shown in the plans. 

Do not measure clearing and grubbing of borrow or material sources. 

Payment 

201.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 201 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

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Section 202 

Section 202. — ADDITIONAL CLEARING AND GRUBBING 

Description 

202.01 This work consists of clearing and grubbing outside the clearing limits specified in Section 201. 

202.02 Definitions. 

(a) Selective clearing. Clearing where some trees and vegetation are designated to remain. 

(b) Selective clearing and grubbing. Clearing and grubbing where some trees and vegetation are 

designated to remain. 

(c) Special clearing and grubbing. Clearing and grubbing where all trees and vegetation are 

removed. 

(d) Removal of individual trees or stumps. Removing individual trees or stumps outside the clearing 

limits designated in Section 201 or outside areas designated in Subsections 202.02(a) through (c). 

Construction Requirements 

202.03 General. Clear and grub according to Section 201. Clear, grub, and dispose of trees, snags, brush, 

downed timber, stumps, roots, buried logs, moss, turf, grass, and other vegetation designated to be 

removed. 

Do not push, pull, or fall trees into trees designated to remain. Remove designated debris by methods that 

prevent damage to vegetation not designated to be removed. 

Cut trees to within 4 inches of the existing ground. Remove and dispose of designated trees or stumps 

according to Subsections 203.05 and 203.07. 

Dispose of clearing and grubbing debris according to Subsection 203.07. 

202.04 Acceptance. Additional clearing and grubbing will be evaluated under Subsection 106.02. 

Clearing and grubbing will be evaluated under Section 201. 

Measurement 

202.05 Measure the Section 202 pay items listed in the bid schedule according to Subsection 109.02. 

Payment 

202.06 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 202 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

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Section 203 

Section 203. — REMOVAL OF STRUCTURES AND OBSTRUCTIONS 

Description 

203.01 This work consists of removing, disposing, and salvaging of structures, obstructions, and materials 

not designated to remain. The work also includes backfilling the trenches, holes, and pits resulting from 

structure removal. 

Material 

203.02 Conform to the following Subsection: 

Soil and soil-aggregate materials 704.01 

Construction Requirements 

203.03 Submittals. At least 30 days before starting the specified work, submit the following according to 

Subsection 104.06: 

(a) Bridge removal plan. Submit a plan that includes the following: 

(1) Methods and equipment to be used; 

(2) Measures to be used for protecting the environment, public, adjacent property, and workers; 

and 

(3) Methods to keep debris out of wetlands and waters. 

(b) Hazardous material disposal plan. Submit a detailed disposal plan according to 

Subsection 203.08 that includes how material will be handled, loaded, and transported to the disposal 

facility. Submit a copy of disposal permits. Include the name and address of the facility where the 

material will be taken. Describe steps that will be taken to ensure that contaminated materials will be 

contained throughout the process. Measures may include additional steps or precautions when lifting 

and handling the material. 

203.04 Salvaging Material. Salvage designated material with reasonable care. Salvage in readily 

transportable sections or pieces. Replace or repair members, pins, nuts, plates, and related hardware 

damaged, lost, or destroyed during the salvage operation. Notify the CO in writing if parts are damaged, 

missing, or destroyed before starting the salvage operation. 

Label all members of salvaged structures with match marks. Securely attach parts to adjacent members or 

pack them in approved and marked containers with the contents clearly listed. 

Submit one set of drawings according to Subsection 104.06 identifying the members and their respective 

match marks. 

Stockpile salvaged material at a designated area. 

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203.05 Removing Material. 

(a) Full removal. Remove the structure or obstruction from the project unless otherwise specified. 

Raze and remove buildings, foundations, pavements, culverts, sidewalks, curbs, fences, structures, and 

other obstructions interfering with the work and not designated to remain. 

(b) Partial removal. Saw cut sidewalks, curbs, pavements, and structures if partial removal is 

required. 

Remove structures and obstructions in the roadbed to 36 inches below subgrade elevation. Remove 

structures and obstructions outside the roadbed to 24 inches below finished ground or to the natural stream 

bottom. 

Construct structurally adequate debris shields to contain debris within the construction limits. Do not allow 

debris to enter wetlands and waters, travel lanes open to public traffic, or areas designated not to be 

disturbed. Handle material with lead contamination according to Section 563. 

Except in excavation areas, backfill and compact resulting trenches, holes, and pits left by structure 

removal with common backfill to the lines and grades of the finished ground. Backfill according to 

Section 209. 

203.06 Abandoning Structures. Abandon structures or obstructions from the project as shown in the 

plans or as directed. Ensure that abandoned structures do not entrap water. 

If abandoning manholes, inlets, catch basins, and spring boxes, seal pipes entering the structure with a 

tight-fitting plug of concrete at least 6 inches thick or water-tight masonry at least 8 inches thick. 

If abandoning culvert pipes in place, remove the upstream and downstream portion of the culvert to within 

48 inches of the subgrade or embankment slope. Ensure the abandoned pipe is at least 48 inches from a 

new culvert or structure. Seal the abandoned culvert ends with a tight-fitting plug of concrete according 

to Section 601, at least 6 inches thick. 

203.07 Disposing of Material. Dispose of unsuitable and excess material. Recycle or dispose of material 

legally off the project according to Sections 105 and 107. Submit a statement documenting the nature and 

quantity of material processed or sold for recycling. Otherwise, submit a signed copy of the disposal 

agreement before disposal starts. 

Dispose of hazardous material according to Subsection 203.08. 

203.08 Disposing of Hazardous Material. Dispose of material according to Federal, state, and local rules 

and regulations. 

Include the SDS with the material to the disposal facility. Ensure that loads transported from the site are 

adequately contained and covered. Submit a copy of the receiving report from the disposal facility 

acknowledging that the material being delivered contains hazardous material. 

(a) Lead paint removal. Dispose of lead contaminated steel either by transporting to an approved 

scrap facility for recycling or remove and dispose of lead contamination in an appropriate waste 

facility. 

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If the Contractor chooses to salvage the steel members, the paint may be removed subject to the 

following requirements: 

(1) Remove lead contaminated paint in an appropriate containment facility. 

(2) Conform to Section 563. 

(3) Manifest and dispose of lead contaminated waste according to the requirements of 40 CFR 260 

through 268 – Resource Conservation and Recovery Act (RCRA). 

(b) Asbestos containing material. Dispose of asbestos containing material (ACM) according to 

Federal, state, and local rules and regulations. Ensure the safety of workers, visitors to the site, and the 

public according to applicable laws, rules, and regulations. 

(1) Asbestos abatement plan. Submit a detailed asbestos abatement plan that includes how ACM 

will be handled, loaded, and transported for disposal. Include the following in the plan: 

(a) Name of the National Emission Standards for Hazardous Air Pollutants (NESHAP) 

certified supervisor and training program for workers handling ACM. 

(b) Name and address of the facility where the ACM will be taken. 

(c) Proposed steps taken to remove ACM according to applicable rules and regulations. 

(d) Description of how the work will comply with OSHA protective clothing and personal 

protective equipment requirements, and employee monitoring requirements. 

(2) Certification and worker training. Provide at least one NESHAP certified person on site 

during asbestos removal. Ensure that workers are trained according to 29 CFR 1926.1101. 

(3) ACM removal and disposal. Before removal of ACM, submit required notifications to the 

appropriate regulatory agency and submit copies of approvals. Complete and sign transport and 

disposal forms. Maintain ACM in an undamaged and non-friable condition by keeping the material 

wet during demolition or by using methods approved by the regulatory agency. Keep material 

sealed during transport to the disposal facility. Dispose of containerized asbestos waste according 

to 40 CFR, Part 61.156. 

203.09 Acceptance. Removal of structures and obstructions will be evaluated under Subsection 106.02. 

Backfilling and compacting trenches, holes, and pits resulting from structure removal will be evaluated 

under Section 209. 

Lead contaminated material removal will be evaluated under Section 563. 

Minor concrete will be evaluated under Section 601. 

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Section 203 

Measurement 

203.10 Measure the Section 203 pay items listed in the bid schedule according to Subsection 109.02. 

Payment 

203.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 203 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

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Section 204 

Section 204. — EXCAVATION AND EMBANKMENT 

Description 

204.01 This work consists of excavating material and constructing embankments. This work also includes 

providing, hauling, stockpiling, placing, disposing, sloping, shaping, compacting, and finishing earthen 

and rocky material. 

204.02 Definitions. 

(a) Excavation. Excavation consists of the following: 

(1) Roadway excavation. Material excavated from within the right-of-way or easement areas, 

except subexcavation covered in Subsection 204.02(a)(2) and structure excavation covered in 

Sections 208 and 209. Roadway excavation includes all material encountered regardless of its 

nature or characteristics. 

(2) Subexcavation. Material excavated from below subgrade elevation in cut sections or from 

below the original ground-line in embankment sections. Subexcavation excludes the work required 

by Subsection 204.05 or 204.06. 

(3) Borrow excavation. Material used for embankment construction that is obtained from outside 

the roadway prism. Borrow excavation includes unclassified borrow and select borrow. 

(b) Embankment construction. Embankment construction consists of placing and compacting 

roadway or borrow excavation. This work includes: 

(1) Preparing foundations for embankments; 

(2) Constructing roadway embankments; 

(3) Benching for side-hill embankments; 

(4) Constructing dikes, ramps, mounds, and berms; and 

(5) Backfilling subexcavated areas, holes, pits, and other depressions. 

(c) Conserved topsoil. Excavated material conserved from the roadway excavation and embankment 

foundation areas that is suitable for growth of grass, cover crops, or native vegetation. 

(d) Waste. Excess or unsuitable roadway excavation and subexcavation that cannot be used. 

Material 

204.03 Conform to the following Section and Subsections: 

Crushed aggregate 

Geosynthetic material 

Select borrow 

703.06 

714 

704.02 

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Section 204 

Soil and soil-aggregate materials 704.01 

Water for construction 725.01(c) 

Construction Requirements 

204.04 Preparation for Roadway Excavation and Embankment Construction. Clear the area of 

vegetation and obstructions according to Section 201 and 203. 

Road pioneering may proceed concurrently with excavation and embankment. Maintain drainage during 

pioneering operations. 

204.05 Conserved Topsoil. Conserve topsoil from roadway excavation and embankment foundation 

areas. Stockpile conserved topsoil in low windrows less than 4 feet in height and located immediately 

beyond the rounding limits of cut and embankment slopes or in other approved locations. Separate topsoil 

from other excavated material. Do not drive or park on conserved topsoil. 

Place conserved topsoil on completed slopes according to Section 624 within 1 year of stockpiling. 

204.06 Roadway Excavation. Excavate as follows: 

(a) Rock cuts. Verify the top portion of the rock cuts during pioneer access or initial excavation. 

Construct the final soil cut before starting drilling for rock blasting or other rock excavation methods 

unless approved. 

Blast rock according to Section 205. Excavate rock cuts to 6 inches below subgrade within the roadbed 

limits. Backfill to subgrade with select borrow. Compact the material according to Subsection 204.11. 

(b) Earth cuts Scarify earth cuts to 6 inches below subgrade within the roadbed limits. Compact the 

scarified material according to Subsection 204.11. 

Conserve 6-inch minus material from the roadway excavation to use for finishing the roadbed. Dispose of 

unsuitable or excess excavation material according to Subsection 204.14. Replace shortage of suitable 

material caused by premature disposal of roadway excavation. 

At the end of each day’s operations, shape to drain and compact the work area to a uniform cross-section. 

204.07 Subexcavation. Excavate material to the required limits. Dispose of unsuitable material according 

to Subsection 204.14. Take measurements before backfilling. Backfill with select borrow in horizontal 

lifts no more than 12 inches in compacted thickness and compact according to Subsection 204.11. Place 

earthwork geosynthetics according to Section 207 as shown in the plans. Place crushed aggregate 

according to Section 302 as shown in the plans. Prevent unsuitable material from mixing with backfill. 

204.08 Borrow Excavation. Use suitable roadway excavation in embankment construction. Do not use 

borrow excavation if it results in excess roadway excavation. Deduct excess borrow excavation from the 

total borrow excavation quantity. 

Obtain borrow source approval according to Subsection 105.02. Develop and restore borrow sources 

according to Subsections 105.03 and 105.06. Do not excavate beyond the established limits. If applicable, 

shape the borrow source to allow accurate measurements when excavation is complete. 

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204.09 Preparing Foundation for Embankment Construction. Prepare foundation for embankment 

construction as follows: 

(a) Embankment over natural ground. Remove topsoil and break up the ground surface to a 

minimum depth of 6 inches by plowing or scarifying. Compact the ground surface according to 

Subsection 204.11. 

(b) Embankment over an existing asphalt, concrete, or gravel road surface. Scarify gravel roads 

to a minimum depth of 6 inches. Scarify or pulverize asphalt and concrete roads to 6 inches below the 

pavement. Reduce particles to a maximum size of 6 inches and produce a uniform material. Compact 

the surface according to Subsection 204.11. 

(c) Embankment across ground that cannot support equipment. Dump successive loads of 

embankment material in a uniformly distributed lift to construct the lower portion of the embankment. 

Limit the lift thickness to the minimum depth necessary to support the equipment. 

(d) Embankment on an existing slope steeper than 1V:3H. Cut horizontal steps in the existing slope 

to a sufficient width to accommodate placement and compaction operations and equipment. Step the 

slope as the embankment is placed and compacted in lifts. Start each step at the intersection of the 

original ground and the vertical cut of the previous step. 

204.10 Embankment Construction. Incorporate only suitable roadway excavation material into the 

embankment. When the supply of suitable roadway excavation is exhausted, provide unclassified borrow 

to complete the embankment. Construct embankments as follows: 

(a) General. At the end of each day’s operations, shape to drain away from the embankment and 

compact the embankment surface to a uniform cross-section. Eliminate ruts and low spots that could 

hold water. 

During all stages of construction, route and distribute hauling and leveling equipment over the width 

and length of each lift of material. 

Compact embankment side slopes with a tamping foot roller, by walking with a dozer, or by 

over-building the fill and then removing excess material to the final slope line. For slopes 1V:13⁄4H or 

steeper, compact the slopes as embankment construction progresses. 

(b) Embankment within the roadway prism. Place embankment material in horizontal lifts no more 

than 12 inches in compacted thickness. Construct the top 12 inches of the embankment using 6-inch 

minus material. Incorporate oversize boulders or rock fragments into the lower lifts by reducing them 

in size or placing them individually as required below. Compact each lift according to 

Subsection 204.11 before placing the next lift. 

Material composed predominately of boulders or rock fragments too large for 12-inch lifts may be 

placed in lifts up to 24 inches thick. Incorporate oversize boulders or rock fragments into the 24-inch 

lift by reducing them in size or placing individual rock fragments and boulders greater than 24 inches 

in diameter as follows: 

(1) Reduce rock to less than 48 inches in the largest dimension. 

(2) Distribute rock within the embankment to prevent voids. 

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(3) Place lifts of embankment material around each rock to a depth not greater than allowed by 

Subsection 204.10(b). Fill voids between rocks. 

(4) Compact each lift according to Subsection 204.11(a) before placing the next lift. 

(c) Embankment outside of roadway prism. If placing embankment outside the staked roadway 

prism, place material in horizontal lifts less than 24 inches in compacted thickness. Compact each lift 

according to Subsection 204.11. 

204.11 Compaction. For compaction, use AASHTO T 27 to determine the quantity of material retained 

on a No. 4 sieve. Compact each lift of material to a firm and stable condition and until there is no visible 

evidence of further consolidation or deflection. Compact as follows: 

(a) More than 80 percent retained on a No. 4 sieve. Compact as follows: 

(1) Adjust the moisture content to a level suitable for compaction. 

(2) Fill the voids around rock with earth or other fine material as practical. 

(3) Use compression-type rollers at speeds less than 6 feet per second and vibratory rollers at 

speeds less than 3 feet per second. 

(4) Compact each lift of material full width with one of the following: 

(a) 4 roller passes of a vibratory roller with a minimum centrifugal force of 40,000 pounds 

impact per vibration and a minimum frequency of 1000 vibrations per minute; 

(b) 8 roller passes of a 20-ton compression-type roller; or 

(c) 8 roller passes of a vibratory roller with a minimum centrifugal force of 30,000 pounds 

impact per vibration and a minimum frequency of 1000 vibrations per minute. 

(5) Increase the compactive effort for lifts deeper than 12 inches as follows: 

(a) For each additional 6 inches or fraction thereof, increase the number of roller passes in 

Subsection 204.11(a)(4)(a), by 4 passes; or 

(b) For each additional 6 inches or fraction thereof, increase the number of roller passes in 

Subsection 204.11(a)(4)(b) and (c), by 8 passes. 

(b) 50 to 80 percent retained on a No. 4 sieve. Classify the material according to AASHTO M 145. 

Adjust the moisture content of material classified A-1 through A-5 to a moisture content suitable for 

compaction. Adjust the moisture content of material classified A-6 and A-7 to within 2 percent of the 

optimum moisture content. Use AASHTO T 99 to determine the optimum moisture content of the 

portion of the material passing a No. 4 sieve. Multiply this number by the percentage of material 

passing a No. 4 sieve and add 2 percent to determine the optimum moisture content of the material. 

Use nonvibratory rollers at speeds less than 6 feet per second and vibratory rollers at speeds less than 

3 feet per second. Compact each lift of material full width according to Subsection 204.11(a). 

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(c) Less than 50 percent retained on a No. 4 sieve. Classify the material according to AASHTO 

M 145. For material classified A-1 or A-2-4, determine the maximum density according to AASHTO 

T 180, Method D. For other material classifications, determine the optimum moisture content and 

maximum density according to AASHTO T 99, Method C. For material with more than 30 percent 

retained on the 3⁄4-inch sieve, compact according to Subsection 204.11(a). 

Adjust the moisture content of material classified A-1 through A-5 to a moisture content suitable for 

compaction. Adjust the moisture content of material classified A-6 and A-7 to within 2 percent of the 

optimum moisture content. 

Use compression-type or vibratory rollers. Compact each lift of material full width to at least 

95 percent of the maximum density. Determine the in-place density and moisture content according to 

AASHTO T 310 or other approved test procedures. 

204.12 Ditches. Slope, grade, and shape ditches. Remove projecting roots, stumps, rock, and similar 

matter. Maintain ditches in an open condition and without debris. 

Form furrow ditches by plowing or using other approved methods to produce a continuous furrow. Place 

excavated material on the downhill side so the bottom of the ditch is approximately 18 inches below the 

crest of the loose material. Clean the ditch using a hand shovel or other suitable method. Shape to provide 

drainage without overflow. 

204.13 Sloping, Shaping, and Finishing. Complete slopes, ditches, culverts, riprap, and other 

underground minor structures before placing aggregate courses. Slope, shape, and finish as follows: 

(a) Sloping. Leave earth slopes with uniform roughened surfaces, except as described in 

Subsection 204.13(b), with no noticeable break as viewed from the road. Except in solid rock, round 

tops and bottoms of slopes including the slopes of drainage ditches. Round material overlaying solid 

rock to the extent practical. 

Remove loose or unstable rocks and dress all rock slopes as the excavation process progresses and 

slopes are still accessible to the equipment. 

Do not round slopes in wetlands or other sensitive areas. 

Do not place topsoil or mulch on slopes until approved. If a shallow landslide occurs on a cut or 

embankment slope, remove or replace the material and repair or restore damage to the work. Bench or 

key the slope to stabilize the slide. Reshape the cut or embankment slope to an acceptable condition. 

(b) Shaping. Shape the subgrade to a smooth surface and to the cross-section required. Shape slopes 

to gradually transition into slope adjustments without noticeable breaks. At the ends of cuts and at 

intersections of cuts and embankments, adjust slopes in the horizontal and vertical planes to blend into 

each other or into the natural ground. 

(c) Finishing. Remove material larger than 6 inches from the top 6 inches of the roadbed. Remove 

unsuitable material from the roadbed and replace it with suitable material. 

Finish roadbeds and ditch cross-sections to within ±0.10 foot of the design or staked line and grade. 

Maintain proper ditch drainage. 

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204.14 Disposal of Unsuitable or Excess Material. Dispose of unsuitable or excess material according 

to Subsection 203.07. 

If there is a pay item for waste, shape and compact the waste material in its final location. Do not mix 

clearing or other material not subject to payment with the waste material. 

204.15 Acceptance. See Table 204-1 for sampling, testing, and acceptance requirements. 

Material for embankment will be evaluated under Subsections 106.02 and 106.04. 

Excavation and embankment construction will be evaluated under Subsections 106.02 and 106.04. 

Subexcavation will be evaluated under Subsections 106.02 and 106.04. 

Clearing will be evaluated under Section 201. 

Crushed aggregate will be evaluated under Section 302. 

Earthwork geosynthetics will be evaluated under Section 207. 

Placing conserved topsoil will be evaluated under Section 624. 

Removal of obstructions will be evaluated under Section 203. 

Rock blasting will be evaluated under Section 205. 

Measurement 

204.16 Measure the Section 204 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

(a) Roadway excavation. Measure roadway excavation in its original position as follows: 

(1) Include the following volumes in roadway excavation: 

(a) Roadway prism excavation. Use the design volume. The design volume is defined as the 

bid schedule quantity less any allowance, as shown in the summary of quantities sheet in the 

plans. This volume is subject to adjustments resulting from changes to slope stakes according 

to Subsection 152.05(d); 

(b) Rock material excavated and removed from below subgrade in cut sections; 

(c) Unsuitable material below subgrade and unsuitable material beneath embankment areas, 

when a pay item for subexcavation is not listed in the bid schedule; 

(d) Ditches, except furrow ditches measured under a separate pay item; 

(e) Conserved topsoil stripped from cuts; 

(f) Borrow material used in the work when a pay item for borrow is not listed in the bid 

schedule; 

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(g) Loose scattered rocks removed and placed as required within the roadway; 

(h) Conserved material taken from pre-existing stockpiles and used in Section 204 work, 

except topsoil measured under Section 624; and 

(i) Shallow landslide material not attributable to the Contractor’s method of operation. 

(2) Do not include the following in roadway excavation: 

(a) Overburden and other spoil material from borrow sources; 

(b) Overbreakage from the backslope in rock excavation; 

(c) Water or other liquid material; 

(d) Material used for purposes other than required; 

(e) Roadbed material scarified in place and not removed; 

(f) Material excavated while rounding cut slopes; 

(g) Preparing foundations for embankment construction; 

(h) Conserved topsoil stripped from fill; 

(i) Material excavated while benching for embankments; 

(j) Shallow landslide material attributable to the Contractor’s method of operation; 

(k) Conserved material taken from stockpiles constructed at the option of the Contractor; 

(l) Material excavated outside the established slope limits; 

(m) Pioneering for temporary roads outside of the proposed roadway prism; and 

(n) Material removed during sloping, shaping, and finishing of rock slope excavations. 

(3) If both roadway excavation and embankment construction pay items are listed in the bid 

schedule, measure roadway excavation only for the following: 

(a) Unsuitable material below subgrade in cuts and unsuitable material beneath embankment 

areas if a pay item for subexcavation is not listed in the bid schedule; 

(b) Shallow landslide material not attributable to the Contractor’s method of operations; and 

(c) Drainage ditches, channel changes, and diversion ditches. 

(b) Unclassified borrow and select borrow. When measuring by the cubic yard, measure in its final 

position. 

Measure borrow only after suitable roadway excavation is depleted. 

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(c) Embankment construction. Measure embankment construction in its final position. Do not make 

deductions from the embankment construction quantity for the volume of minor structures. 

(1) Include the following volumes in embankment construction: 

(a) Roadway prism embankments; 

(b) Material used to backfill holes, pits, and other depressions; 

(c) Material used to restore obliterated roadbeds to original contours; and 

(d) Material used for dikes, ramps, mounds, and berms. 

(2) Do not include the following in embankment construction: 

(a) Preparing foundations for embankment construction; 

(b) Adjustments for subsidence or settlement of the embankment or of the foundation on which 

the embankment is placed; 

(c) Material used to round fill slopes; and 

(d) Material used to backfill subexcavated areas. 

(d) Rounding cut slopes. Measure rounding cut slopes horizontally along the centerline of the 

roadway. 

(e) Waste. Measure waste by the cubic yard in its final position. Take initial cross-sections of the 

ground surface after stripping overburden. Upon completion of the waste placement, retake 

cross-sections before replacing overburden. 

(f) Subexcavation. Measure subexcavation by the cubic yard in its original position. 

Payment 

204.17 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 204 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

109 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 204-1 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Source 

Unclassified 

borrow 

(704.01) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Classification(1) – AASHTO 

M 145 

1 per soil 

type & 

source of 

material 

Source of 

material Yes 

Before 

using in 

work 

– 

Select borrow 

(704.02) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Classification(1) – AASHTO 

M 145 

1 per soil 

type & 

source of 

material 

Source of 

material Yes 

Before 

using in 

work 

– 

Gradation – AASHTO 

T 27 & T 11 " " " " – 

Liquid limit – 

AASHTO 

R 58 & T 89, 

Method A 

" " " " – 

Production 

Unclassified 

borrow 

(704.01) 

Measured & 

tested for 

conformance 

(106.04) 

Moisturedensity – 

AASHTO 

T 180, 

Method D(2) 

or 

T 99, 

Method C(2) 

1 per 

soil type 

but not 

less than 1 

per each 

13,000 yd3 

Processed 

material Yes 

Before 

using in 

work 

– 

Density – 

AASHTO 

T 310 or 

other 

approved 

procedures 

1 per 

3500 yd2 

but not 

less than 1 

per lift 

In-place No 

Before 

placement 

of 

next lift 

– 
 

 

 

 

 

 

 

 

 

 

Table 204-1 (continued) 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Production (continued) 

Select 

borrow 

(704.02) 

Measured & 

tested for 

conformance 

(106.04) 

Classification – AASHTO 

M 145 

1 per 

soil type 

but not less 

than 1 per 

each day of 

production 

Processed 

material Yes 

Before 

using in 

work 

– 

Gradation – AASHTO 

T 27 & T 11 " " " " – 

Liquid limit – 

AASHTO 

R 58 & T 89, 

Method A 

" " " " – 

Moisturedensity – 

AASHTO 

T 180, 

Method D(2) 

or T 99, 

Method C(2) 

1 per 

soil type 

but not less 

than 1 per 

each 

13,000 yd3 

" " " – 

Density – 

AASHTO 

T 310 or 

other approved 

procedures 

1 per 

3500 yd2 

but not less 

than 1 per 

lift 

In-place No 

Before 

placement 

of 

next lift 

– 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 204-1 (continued) 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Production (continued) 

Earth 

embankment 

(204.11) 

Measured & 

tested for 

conformance 

(106.04) 

Classification – AASHTO 

M 145 

1 per 

soil type 

Source of 

material Yes 

Before 

using in 

work 

– 

Moisturedensity – 

AASHTO 

T 180, 

Method D(2) 

or T 99, 

Method C(2) 

1 per 

soil type 

but not less 

than 1 per 

each 

13,000 yd3 

" " " – 

Density – 

AASHTO 

T 310 or 

other 

approved 

procedures 

1 per 

3500 yd2 

but not less 

than 

1 per lift 

In-place No 

Before 

placement 

of 

next lift 

– 

Top of 

subgrade 

(204.11) 

" Density – 

AASHTO 

T 310 or 

other 

approved 

procedures 

1 per 

2500 yd2 

but not less 

than 

1 per lift 

In-place No 

Before 

placement 

of 

next lift 

– 

Finished Product 

Roadbed 

(204.13) 

Measured & 

tested for 

conformance 

(106.04) 

Final 

line & grade – Field measured As directed As directed No 

Before 

placement 

of 

next lift 

– 

(1) Not required if using Government-furnished source. 

(2) At least 5 points per proctor. 
 

 

 

 

 

 

 

Section 205 

Section 205. — ROCK BLASTING 

Description 

205.01 This work consists of rock fragmentation blasting using production and controlled blasting 

techniques to construct engineered rock cuts. 

205.02 Definitions. 

(a) Production blasting. Blasting using widely spaced blast holes that typically contain larger 

explosive charges to expedite movement and fragmentation for rock removal. 

(b) Controlled blasting. Blasting that includes presplit blasting and cushion blasting hole techniques. 

Controlled blasting uses closely-spaced and carefully aligned blast holes that typically contain lighter 

charges than production holes to produce stable, aesthetically pleasing rock faces with minimal blast 

damage. Controlled blast holes are the first row of blast holes, normally located within 24 inches of 

the top of the staked slope. 

(1) Presplit blasting. Presplit blasting detonates closely spaced backslope holes before drilling for 

production blasting or before detonating the production blasting holes to produce a highly 

controlled, smooth cut face. 

(2) Cushion blasting. Cushion blasting is similar to presplitting, except that the detonation of the 

cushion holes along the backslope is detonated immediately after the detonation of the production 

and buffer holes, generally resulting in a more natural cut face appearance. 

(c) Lift. For rock blasting, a lift is the vertical height of rock fragmented from a single blast. 

(d) Mudcapping. The blasting of boulders by placing a quantity of explosives against a rock, boulder, 

or other object without confining the explosives in a drill hole. 

(e) Blockholing. The breaking of boulders by firing a charge of explosives that has been loaded in a 

drill hole. 

Construction Requirements 

205.03 Regulations. Comply with Federal, state, and local rules and regulations for the purchase, 

transportation, storage, and use of explosive material. Federal regulations include the following: 

(a) Safety and health. OSHA, CFR Title 29, Part 1926, Subpart U. 

(b) Storage, security, and accountability. Bureau of Alcohol, Tobacco, and Firearms (ATF), CFR 

Title 27, Part 555, Commerce in Explosives. 

(c) Shipment. DOT, CFR Title 49, Parts 171-179, 390-397. 

(d) National Park Service. For projects in National Park Service lands, comply with National Park 

Service Director’s Order No. 65, Explosives Use and Blasting Safety. 

113 
 

 

 

 

 

 

Section 205 

205.04 Qualifications. At least 14 days before starting drilling and blasting work, submit the following 

for approval: 

(a) Blaster-in-charge. Provide an individual to directly supervise the drilling and blasting crew during 

drilling, loading, and detonation of charges. Include the following: 

(1) A résumé describing at least 5 years’ experience as a blaster-in-charge on 3 projects with 

similar work, and provide a brief description of each project including the owner’s name and 

contact information; and 

(2) Copy of a valid blaster license accepted by the state where the project is located for the type of 

blasting required. 

(b) Blasting crew personnel. Documentation that each blasting crew member has completed at least 

24 hours of blasting safety training within the past 5 years or has at least 2 years’ blasting experience 

along with proof of a Federal Employee Possessor Permit; 

(c) Drillers. A résumé for each drill operator describing at least 1 year’s experience as a driller; and 

(d) Vibration specialist. A résumé describing at least 5 years’ experience as a vibration specialist on 

projects with similar work. 

205.05 Blasting Plans. Submit proof of applicable permits, licenses, and a general blasting plan signed 

by the blaster-in-charge at least 14 days before drilling and blasting operations. Blasting plans are not 

required for boulder reduction blasts (mudcapping or blockholing). 

(a) General blasting plan. Submit a general blasting plan for review and approval. The CO will 

review and approve the General Blasting Plan within 7 days or return it for corrections. Include the 

following: 

(1) Procedures and safety precautions for transporting, handling, storing, loading, and detonating 

explosives, conducting pre- and post-blast surveys, monitoring blasts, managing misfires, and 

removing and disposing of excess explosives. 

(2) Explosives transportation and storage plan, including: 

(a) Name, address, and telephone number of explosives suppliers; 

(b) Description and license number of explosives transport vehicles, routes to be traveled, 

proposed hours of travel, and driver qualifications; 

(c) Magazine and day-box locations; 

(d) Explosives and accessories inventory system; and 

(e) Contact information for the person responsible for security of project blasting material and 

supplies. 

(3) Area security plan including explosives and general site security, methods of site 

communication, pre- and post-blast signage and audible signaling systems, road closure 

requirements, and pre-blast notification for affected agencies or entities. 

114 
 

 

 

 

 

 

 

Section 205 

(4) Manufacturer’s technical and safety data sheets for proposed explosives, primers, initiators, 

and related blasting devices and accessories. 

(5) Excavation plans and equipment lists for pre-blast dressing and access roads, and benches for 

drilling and blasting operations. 

(6) Typical scaled plan and section views for both production and controlled blasting. Include the 

following: 

(a) Stationing intended for each typical blast plan; 

(b) Maximum blast length and free face; 

(c) Hole spacing, hole inclination, hole depth, hole diameter, and burden; 

(d) Stemming depth, decking method and materials (if required), and subdrill depth; 

(e) Powder factor, charge weight per delay; and 

(f) Initiation method, sequence, and delay times. 

(7) Methods for limiting dust and noise. 

(8) Fire watch plan including number of post-blast observers and duration of the fire watch. 

(9) Contingency plan for blast flyrock containment, including a drawing and description of the 

proposed containment system designs. 

Do not deliver explosives to the project until the general blasting plan is accepted. Submit revisions 

and updates within 48 hours of changes in the above information. Do not blast until revisions and 

updates to the general blasting plan are approved. 

(b) Site-specific blasting plans and general plan revisions and updates. Submit site-specific 

blasting plans after approval of the general blasting plan or at times there is a change in drilling and 

blasting methods provided in the general blasting plan. Allow 3 days for approval. Do not start drilling 

until the plan is approved. Include the following: 

(1) Proposed excavation sequence; 

(2) Station limits and plan view of the proposed blast, showing how the proposed blast fits into the 

lift excavation sequence; 

(3) Elevations of the tops and bottoms of each lift; 

(4) Scaled drawings for each blast showing access, containment, plan and section views of drill 

patterns, clearing limits, free face, burden, blast hole locations, blast hole spacing, subdrill depths, 

lift height, blast hole diameters, and blast hole angles; 

(5) Loading diagram for each blast showing powder factor, charge weight per delay, type and 

quantity of explosives, primers, initiators, locations of decking, and range of stemming depths for 

substantial variations within the drill pattern; 

115 
 

 

 

 

 

Section 205 

(6) Initiation method and sequence of blast holes for each blast. Include delay times, delay system, 

and downhole firing times; 

(7) Flyrock, air-blast overpressure (noise), and ground vibration control measures; 

(8) Estimated volume of in-place rock to be blasted. Include the total length of production and 

controlled blast hole; 

(9) Location and orientation of significant joints, fractures, faulting, bedding planes or other rock 

mass structural features that affect the site-specific blasting plan; 

(10) Post-blast rockfall containment designs and procedures; and 

(11) If structures are within an area of ground vibration or air-blast overpressure concern, prepare 

an attenuation study with information for the affected structures. Develop a plot of peak particle 

velocity versus peak frequency according to the United States Department of the Interior, Bureau 

of Mines Report of Investigation 8507 (RI 8507). From this plot, determine the values of peak 

particle velocity and peak frequency that will not damage each structure in the site-specific blast 

plan. 

205.06 Pre-Blast Condition Survey and Vibration Monitoring and Control. The Contractor is 

responsible for damage resulting from blast related ground vibrations and air-blast overpressures. 

Determine the need for vibration monitoring depending on soil and rock conditions, blasting parameters 

as outlined in the blasting plan, and proximity of buildings, structures, utilities, and sensitive natural 

features that may be subject to damage from ground vibrations or air-blasts. If vibration monitoring is 

required, comply with the following requirements: 

(a) If not specified in the contract, establish referenceable blasting criteria for buildings, structures, 

utilities, and natural features that conform to Federal, state, and local rules and regulations. Present 

blasting criteria in terms of distance of the facility or feature from blasting, maximum allowable peak 

particle velocity limits versus structure type, maximum allowable peak particle velocity and peak 

frequency as determined by RI 8507, and air overpressure structure damage limits. 

(b) Conduct a pre-blast condition survey of nearby buildings, structures, utilities, and natural features 

potentially damaged by blasting-related ground vibrations or air-blast. Document the natural 

frequency of each affected structure or feature. Use a survey method acceptable to the Contractor’s 

insurance company. Submit a copy of pre-blast condition survey records with the site-specific blasting 

plans for CO review. 

(c) If ground vibration or air-blast damage is possible, monitor each blast with digital recording 

seismographs and approved air-blast monitoring equipment calibrated within the last year. Locate 

monitoring equipment according to the directions of the vibration specialist. Place at least three 

recording stations between the blast area and closest susceptible structures, utilities, and immediately 

adjacent to natural features. Place one of the three recording stations on the critical structures. For 

ground vibration monitoring, use self-triggering seismographs that can measure peak air blast 

overpressure and record particle velocity, displacement, and acceleration for three mutually 

perpendicular components of vibration in the range generally found for controlled blasting. Provide 

instruments with internal calibration and triaxial orthogonal transducers with flat frequency response 

from 2 to 250 hertz with a sampling rate of at least 1000 data points per second with sufficient memory 

116 
 

 

 

 

 

Section 205 

to store the full blasting sequence and their locations. Provide seismographs that can produce a 

permanent digital time history file for each ground motion episode. 

(d) Control ground vibrations and air-blast overpressures with adjustments to delay sequences and 

maximum allowable charge weights per delay. Verify allowable charge weights per delay by 

conducting representative trial blasts and measuring ground vibrations and air-blast overpressure 

levels. Prepare an attenuation study that will enable prediction of the peak particle velocity in any 

component (longitudinal, transverse, or vertical) on the surface of all structures. Conduct test blasts 

with blast plan modifications that limit ground vibrations and air-blast overpressures to levels that will 

not cause damage to nearby buildings, structures, utilities, and or natural features as determined by the 

vibration specialist. Submit a copy of the attenuation study results and predicted maximum allowable 

peak particle velocity and peak frequency for each structure based on a plot of peak particle velocity 

versus peak frequency according to RI 8507. 

(e) Record each blast using digital video equipment from two locations that clearly show the entire 

proposed blast site, preferably from locations on both sides or by unmanned aircraft system above the 

blast. Provide digital videos with sound, with a minimum 1080p resolution, and in a common file 

format for viewing. 

(f) Ensure blasting operations incorporate collected data and findings from vibration monitoring by 

having the vibration specialist interpret seismograph and air-blast records. 

(g) Submit a copy of the interpreted seismograph and air-blast records with a certifying signature by 

the vibration specialist. If actual peak particle velocity versus peak frequency measurements exceeds 

those predicted for a structure, adjust the site-specific blast plans for the actual structural response to 

the blasting. 

205.07 Test Blasting. Before starting full-scale drilling and blasting, demonstrate adequacy of the sitespecific blasting plan by drilling, blasting, and excavating a test blast up to 100 linear feet, as measured 

along the roadway centerline, with proposed containment measures in-place. Conduct the test blast at an 

approved location within the planned excavation area. 

Space blast holes for presplit and cushion blasting no more than 30 inches apart for the initial test blast. 

Adjust the spacing based on the results of the test blasts for each excavation in differing geology as 

approved. Use the approved spacing in the full-scale blasting or subsequent test blasts if necessary. 

A test blast is unacceptable if it results in excessive flyrock, potentially damaging ground vibrations or 

air-blasts, unplanned overbreak and backbreak, excessive damage to the final rock cut face, or results in 

unwanted overhangs. If a test blast is unacceptable, revise the site-specific blasting plan and conduct 

additional test blasts until the combination of blast hole pattern spacing, timing, controlled blast hole 

alignment, and charges produce acceptable results. 

205.08 Blasting. Use explosives and initiating devices less than 1 year old. Locate explosives magazines 

at approved sites. 

Inspect the pre-blast area and submit the proposed extent of pre-blast clearing and dressing for approval. 

Blasting with angle-drilled or fan-drilled holes is only allowed during initial pioneering operations to 

establish access to the top of cut. Controlled blasting requirements are applicable to pioneering work. 

117 
 

 

 

 

 

 

 

 

 

 

Section 205 

Before drilling, remove overburden, soil, and loose or decomposed rock along the top of the excavation 

for a distance of at least 30 feet beyond the end of the production hole drilling limits, or to the end of the 

cut. 

Record and maintain a log of each blast hole drilled identifying the depth, color, and character of the 

cuttings, penetration rate, hole collar location and hole orientation, loss of drilling air, groundwater, and 

other pertinent information. Before initiating the blast, prepare a blast plan map and submit it showing 

designated hole numbers along with individual hole logs completed, dated, and signed by the driller. 

Ensure blast holes are free of obstructions for the entire depth before placing charges. Take necessary 

precautions when placing charges so caving of material from the walls of the holes and the hole collar will 

not occur. 

Mitigate uncontrolled gas pressure loss during blasting and excessive blast noise by stemming the upper 

portion of blast holes with appropriate dry granular material passing the 1⁄2-inch sieve. Do not stem holes 

with drill cuttings or trash. 

Blast according to the approved site-specific blasting plan. Use blasting mats, rockfall containment 

systems, and other protective devices to prevent damage to surrounding features. 

(a) Production blasting. When conducting cushion blasting or presplitting, drill a lighter-loaded 

buffer row of production holes on a parallel plane adjacent to the controlled blast line to minimize 

blast damage to the final slope. 

Drill production blast holes a maximum of 4 inches in diameter to a depth such that unbroken rock 

does not extend above the finish surface. Drill production blast holes to the design depth. If more than 

5 percent of the production blast holes in a lift do not conform to the design depth requirements, redrill 

the shallow holes to the proper depth. Except when subdrilling, do not drill production blast holes 

below the base plane of the controlled blast holes. 

Drill production blast holes within two drill hole diameters of the planned collar location. If more than 

5 percent of the drill hole collars in a lift are out of tolerance, fill each hole outside of the location 

tolerance with crushed stone and redrill. 

Detonate production holes in a controlled delay sequence. 

(b) Controlled blasting. Use controlled blasting to form the final cut face on rock cuts where the 

staked slope ratio is 11⁄3V:1H or steeper and the slope height is more than 10 feet above the ditch grade. 

Use drilling equipment that accurately controls the angle of the drill as it enters the rock. Select a lift 

height and conduct drilling operations so the blast hole spacing and downhole alignment does not vary 

more than 8 inches from the proposed spacing and alignment. If more than 5 percent of the holes 

exceed the variance, reduce the lift height and modify drilling operations until the holes are within 

tolerance. 

Drill holes a maximum of 3 inches in diameter and within 3 inches of the staked collar location. Fill 

and redrill blast holes outside of the location tolerance if more than 5 percent of the hole collars in a 

lift are outside of the location tolerance. Fill the blast holes with crushed stone before redrilling. Drill 

the controlled blast hole line at least 30 feet beyond loaded production holes or to the end of the cut. 

118 
 

 

 

 

 

 

 

Section 205 

Do not exceed 30 feet for bench height or drill hole length. Limit subdrilling of holes to one-half of 

the hole spacing or 24 inches, whichever is deeper. 

Offset lifts up to 24 inches horizontally to allow for drill equipment clearance. Remove benches 

resulting from the drilling offset. 

Compensate for drift that may occur in the upper lifts. Adjust the drill inclination angle or the initial 

drill collar location to obtain the required typical section. Limit drilling to one-half of the hole spacing 

or 24 inches, whichever is deeper. 

Do not use bulk ammonium nitrate and fuel oil for controlled blasting. Only use standard explosives 

manufactured specifically for controlled blasting in controlled blast holes, unless approved. 

For explosives in controlled blast holes use a maximum diameter no greater than one-half of the 

diameter of the presplit hole. 

(c) Revising blasting plans. Stop drilling and blasting operations, and submit a revised site-specific 

blasting plan according to Subsection 205.05(b), if the following occur: 

(1) Slopes are unstable; 

(2) Slopes exceed overbreak tolerances within the limits of the excavation or as determined by the 

CO for the site geology; 

(3) Unwanted overhangs, ridges, or ledges are created; 

(4) Excessive blast damage occurs within the limits of the excavation or as determined by the CO; 

(5) Poor fragmentation results in oversize material requiring secondary blasting and rehandling; 

(6) Safety of the public is jeopardized; 

(7) Property or natural features are endangered; 

(8) Excessive or uncontrolled flyrock is generated; 

(9) Excessive ground vibration or air-blast overpressure occurs where damage to buildings, 

structures, utilities, or natural features is possible; or 

(10) Desired slope or rock face conditions are not produced. 

Dress the cut face by removing or stabilizing cut face rock that is loose, hanging, or potentially dangerous 

after each blast. Dress the cut face by approved methods. Leave minor irregularities or surface variations 

in place if they do not create a hazard. Excavate and remove material outside the neat line slopes which is 

unstable and a potential hazard. Drill the next lift only after the slope stabilization and blast cleanup work 

is complete. 

205.09 Reporting. 

(a) Post-blast. Prepare a post-blast report. Submit the report within 3 days following a blast and before 

drilling for the next blast. Include the following: 

119 
 

Section 205 

(1) Results of the blast. Include overbreak, blast damage, noise levels, flyrock, drill trace retention, 

fragmentation, material containment, material rehandling requirements, and misfires; 

(2) Proposed changes for future site-specific blasting plans that will produce acceptable results if 

blasting objectives were not met; 

(3) Proposed repairs or stabilization plans for unstable or blast damaged backslopes; 

(4) A detailed blasting plan modified to show significant changes in pattern, loading, or timing; 

(5) Drilling logs for each hole completed (dated and signed by the driller) that identify the depth, 

color, and character of the cuttings. Include the penetration rate, hole collar location, hole 

orientation, and conditions that adversely affected drilling or explosives loading operations; 

(6) Depth measurements of production and controlled blast holes; 

(7) A drawing or sketch showing the direction of blast, the face, or faces, hole numbers, and the 

physical blast layout; 

(8) Measurement of overbreak quantities following lift mucking; 

(9) Date and time of loading and detonating the blast; and 

(10) Name and signature of the blaster-in-charge. 

(b) Monitoring. Submit copies of the digital videos after each blast. Do not continue drilling and 

blasting operations until the video has been received and reviewed by the CO. Allow 24 hours for 

review. 

If vibration or air-blast monitoring is required, submit a vibration and air-blast report within 3 days 

following a blast and before drilling for further blasting. Do not drill until directed. Include the 

following: 

(1) Type of vibration or air-blast recording station used and instrument identification numbers; 

(2) Name of vibration specialist observing the blast and interpreting vibration and air-blast data; 

(3) Blast identification number and location of blast; 

(4) Distance and direction of ground vibration and air-blast overpressure recording stations from 

the blast area; 

(5) Type of material the ground vibration recording stations were sitting on at the time of the blast; 

(6) Maximum applicable charge weight per delay; 

(7) Peak displacement, particle velocity, and frequency recorded at each ground vibration sensor 

location; 

(8) Peak overpressure recorded at each air-blast sensor location; 

120 
 

 

 

Section 205 

(9) Dated and signed copy of instrument records; 

(10) Post-blast condition survey noting changes from the pre-blast survey; and 

(11) Comments on success of the blast in terms of adherence to established ground vibration or 

air-blast criteria and management practices. 

If failing to meet ground vibration and air-blast criteria and management objectives, submit proposed 

changes to future site-specific blasting plans that will produce acceptable results. 

(c) Close-out. Before demobilizing from the project site, submit a written statement signed by the 

blaster-in-charge certifying: 

(1) Blast holes loaded with explosive material have been either detonated or unloaded and disposed 

of properly; and 

(2) Blasting is complete and explosive material has been removed from the project site. 

205.10 Acceptance. Material for rock blasting will be evaluated under Subsections 106.02 and 106.03. 

Rock blasting will be evaluated under Subsections 106.02 and 106.04. 

Measurement 

205.11 Measure the Section 205 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring controlled blasting by the square foot, measure the face blast as shown in the blasting 

plan. 

When measuring controlled blast holes by the linear foot, measure the actual length of drilling recorded 

in the post-blast reports. Controlled blast holes include the row of holes lying closest to the trim line. 

Do not measure presplit blast holes with more than 8-inch misalignment. 

Do not measure production blast holes. 

Do not measure dressing of the cut face rock. 

Payment 

205.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 205 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

121 
Section 206 

Section 206. — RESERVED 

122 
 

 

 

 

 

Section 207 

Section 207. — EARTHWORK GEOSYNTHETICS 

Description 

207.01 This work consists of providing and installing geotextile in separation, stabilization, filter, and 

reinforcement applications, geogrid in stabilization and reinforcement applications, and geomembranes in 

moisture barrier applications. 

Material 

207.02 Conform to the following Subsections: 

Geomembranes 714.05 

Geotextile 714.01 

Reinforcement geotextile and geogrid 714.04 

Stabilization geogrid 714.03 

Construction Requirements 

207.03 General. Identify, store, and handle geosynthetics according to ASTM D4873 and the 

manufacturer’s recommendations. Elevate and protect geosynthetic rolls with a waterproof cover if stored 

outdoors. Maintain product identification labels in a visible location on the inside of the core. Limit 

geosynthetics exposure to less than 10 days of ultraviolet radiation. 

Unless otherwise specified, overlap geosynthetics in the direction, sequence, and distance according to 

the manufacturer’s recommendations. 

For seams sewn on site, comply with the manufacturer’s recommendations. Obtain approval of the seam 

before installation. Use thread consisting of high strength polypropylene or polyester. Do not use nylon 

thread. Use thread that is resistant to ultraviolet radiation and a contrasting color to the geotextile. 

If geosynthetic joints are field constructed, submit an installation plan according to Subsection 104.06 at 

least 14 days before installation that includes proposed equipment, the QCP, and the following: 

(a) Assembly description. Include the seam type, seam allowance, stitch type, sewing thread tex 

ticket numbers and types, stitch density, and stitch gauge; 

(b) Proposed panel layout drawing. Show seam and overlap locations; and 

(c) Sewn seam samples. Sew seam samples using the same equipment and procedures used to sew 

production seams. Submit samples that have at least 6 feet of sewn seam and are at least 5 feet wide. 

If production seams are sewn in both the machine and cross-machine directions, provide sewn seam 

samples that are oriented in both the machine and cross-machine directions. 

Replace or repair geosynthetic that is torn or punctured according to the manufacturer’s recommendations. 

123 
 

 

 

 

Section 207 

207.04 Geotextile and Geogrid in Separation and Stabilization Applications. 

(a) Surface preparation. Before placing the geotextile remove sharp objects and large rocks. Fill 

depressions or holes with suitable material to provide a smooth surface. Prepare the surface as follows: 

(1) Existing ground. Cut trees and shrubs flush with the ground surface. Clear the area of 

vegetation and obstructions according to Sections 201 and 203. 

(2) Subgrade. Prepare the subgrade according to Subsections 204.13(b) and (c). 

(3) Subexcavation. Perform subexcavation according to Subsection 204.07. 

(b) Geotextile or geogrid placement. Place geogrid on top of geotextile if both are shown at the same 

elevation in the plans. Place the geosynthetic smooth, taut, and wrinkle free on the underlying surface. 

Conform to curves. Overlap in the direction of construction. Overlap at least 24 inches at the ends and 

sides of adjoining sheets or sew the joints according to the approved installation plan. Do not place 

longitudinal overlaps below anticipated wheel paths. Hold the geosynthetic in place with pins, staples, 

or piles of cover material. 

(c) Backfilling. 

(1) First lift placement and compaction. Place the specified backfill onto the geotextile or 

geogrid from the edge of the geosynthetic or from previously placed cover material. Do not operate 

equipment directly on the geosynthetic. Spread the pile of cover material maintaining a minimum 

6-inch lift over the geosynthetic. Avoid sudden stops, starts, or turns of the construction equipment. 

Fill ruts from construction equipment with additional cover material. Do not blade material down 

to remove ruts. If rutting exceeds 3 inches during placement, decrease the construction equipment 

size, decrease the equipment weight, or increase the first lift thickness as directed. 

Compact according to Subsection 204.11. Do not use sheepsfoot or studded compaction 

equipment. Compact the cover material with pneumatic-tire or nonvibratory smooth drum rollers. 

(2) Subsequent lift placement and compaction. Place subsequent lifts according to 

Subsection 204.10. 

Compact according to Subsection 204.11. Vibratory rollers may be used unless pumping or 

foundation failures occur. Repair damaged areas and then use only nonvibratory rollers. 

207.05 Geotextile Filter Applications. 

(a) Surface preparation. Before placing the geotextile remove sharp objects and large rocks. Fill 

depressions or holes with suitable material to provide a smooth surface. Prepare the surface as follows: 

(1) Existing ground. Cut trees and shrubs flush with the ground surface. Clear the area of 

vegetation and obstructions according to Sections 201 and 203. 

(2) Subgrade. Prepare the subgrade according to Subsections 204.13(b) and (c). 

(3) Subexcavation. Perform subexcavation according to Subsection 204.07. 

124 
 

 

 

 

 

 

 

 

 

 

Section 207 

(b) Geotextile placement. For slope or wave protection, place the long dimension of the geotextile 

down the slope. For stream bank protection, place the long dimension of the geotextile parallel to the 

centerline of the channel. 

Overlap or sew seams at the ends and sides of adjoining sheets. 

(1) Overlapping. Overlap the uphill or upstream sheet over the downhill or downstream sheet. 

For above water applications, overlap the geotextile at least 12 inches. For underwater 

applications, overlap the geotextile at least 36 inches. 

(2) Sewing. Sew the geotextile seam according to the approved installation plan. 

Offset end joints of adjacent sheets at least 5 feet. Use key trenches or aprons at the crest and toe of 

slopes to hold the geotextile in place. As an alternative use anchor pins, at least 18 inches long and 

spaced at 36 inches on centers to hold the geotextile sheets in place. 

(c) Backfilling. Place aggregate, slope protection, or riprap on the geotextile starting at the toe of the 

slope and proceeding upward. Place riprap onto the geotextile from a height of less than 12 inches. 

Place slope protection rock or aggregate backfill onto the geotextile from a height less than 36 inches. 

Do not allow stones weighing more than 100 pounds to roll down the slope. In underwater 

applications, place the geotextile and cover material in the same day. 

207.06 Geotextile and Geogrid Reinforcement Applications. For MSE retaining walls and reinforced 

soil slopes, place reinforcement geosynthetics according to Section 255 or 261, as applicable. For deep 

patch and other reinforcement geosynthetic applications, perform the work as follows: 

(a) Surface preparation. Perform subexcavation according to Section 204. Provide a smooth, flat, 

and firm foundation for the geosynthetic. 

(b) Geosynthetic placement. Place the reinforcement geosynthetic with the higher strength direction 

oriented perpendicular to the road centerline or slope face, as shown in the plans. Place the 

geosynthetic smooth, taut, and wrinkle free on the underlying surface. Conform to curves. Overlap 

24 inches for biaxial geosynthetics in the direction of construction. For uniaxial geogrids, do not splice 

in the high strength direction, and abut adjacent sheets of geogrid. Hold the geosynthetic in place with 

pins, staples, or piles of cover material. 

(c) Backfilling. Place the specified material onto the geosynthetic from the edge of the geosynthetic 

or from previously placed cover material. Do not operate equipment directly on the geosynthetic. 

Spread the material maintaining a minimum 6-inch lift over the geosynthetic before operating 

equipment over the geosynthetic. Avoid sudden stops, starts, or turns of the construction equipment. 

Fill ruts from construction equipment with additional cover material. Do not blade material down to 

remove ruts. If rutting exceeds 3 inches during placement, decrease the construction equipment size, 

decrease the equipment weight, or increase the first lift thickness as directed. 

Compact according to Subsection 204.11. Do not use sheepsfoot or studded compaction equipment. 

Compact from the face of slope or wall towards the back of the reinforcement. 

207.07 Geomembrane Applications. Conduct a preparatory phase meeting at least 7 days before start of 

geomembrane installation according to Subsection 153.06(a). Discuss details of the approved submittal 

according to Subsection 207.03 and observe performance of seam test strips. 

125 
 

 

 

 

 

Section 207 

(a) Surface preparation. Provide a smooth, flat, firm, unyielding foundation for the geomembrane 

with no sudden, sharp, or abrupt changes or break in grade. Remove rocks, stones, sticks, sharp objects, 

and debris protruding more than 1⁄2 inch above the prepared surface. 

(b) Geomembrane placement. Orient seams parallel to the line of maximum slope. Use sandbags or 

piles of cover material to hold the geomembrane in place. Do not drive equipment directly on the 

geomembrane. 

(c) Backfilling. Place the specified backfill within the same work shift that the geomembrane is 

installed or place enough cover material to keep the geomembrane in place to resist thermal shrinking, 

expansion, and other deformations. Place backfill onto the edge of previously placed cover material 

and roll it into place. Do not push material along the geomembrane which can result in damage, 

stretching, or wrinkling. 

207.08 Acceptance. Geosynthetics will be evaluated under Subsections 106.02 and 106.03. Submit a 

production certification with each shipment of geosynthetics. 

Geosynthetic installation will be evaluated under Subsections 106.02 and 106.04. 

Sewn joints will be evaluated under Subsection 106.02. 

Clearing will be evaluated under Section 201. 

Removal of obstructions will be evaluated under Section 203. 

Subgrade preparation and subexcavation will be evaluated under Section 204. 

Measurement 

207.09 Measure the Section 207 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring geosynthetics by the square yard, measure each individual layer on a plane parallel to 

the slope face. Do not measure return wraps at edges of the reinforced areas. 

Payment 

207.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 207 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

126 
 

 

 

Section 208 

Section 208. — STRUCTURE EXCAVATION AND BACKFILL 

FOR SELECTED MAJOR STRUCTURES 

Description 

208.01 This work consists of excavating material for the construction of selected structures. This work 

also includes preserving channels, shoring and bracing, constructing cofferdams, sealing foundations, 

dewatering, preparing foundations, backfilling, and removal of safety features and cofferdams. 

Material 

208.02 Conform to the following Subsections: 

Neat hydraulic cement grout 

Soil and soil-aggregate materials 

701.04(a)(2) 

704.01 

Construction Requirements 

208.03 General. Slope the sides of excavations, use shoring and bracing, and use other safety features 

according to OSHA safety standards 29 CFR, Part 1926, Subpart P, Excavations. If sides of excavations 

are sloped for safety considerations, submit one copy of the design that demonstrates compliance with 

OSHA standards. If support systems, shield systems, or other protective systems are used, design the 

shoring according to Section 562. Submit drawings and construction details according to 

Subsection 104.06. 

Clear the area of vegetation and obstructions according to Sections 201 and 203. 

Saw cut existing pavements or concrete structures adjacent to the area to be excavated that are designated 

to remain. 

Where necessary, blast rock according to Section 205. 

Conserve suitable material for structural backfill from excavated material. Do not deposit excavated 

material in or near a waterway. From the edge of the excavation, do not stockpile excavated material or 

allow equipment closer than specified in OSHA safety standards 29 CFR, Part 1926, Subpart P, 

Excavations. Use suitable material in embankment construction if approved. Dispose of unsuitable or 

excess material according to Subsection 204.14. 

Remove safety features when no longer necessary. Remove shoring and bracing to at least 48 inches below 

the surface of the finished ground. 

208.04 Channel Preservation. Perform work in or next to waters as follows: 

(a) Excavate and conserve material inside cofferdams, sheeting, or other separations (such as dikes or 

sandbags). 

(b) Do not disturb the natural bed of the waters adjacent to the work. 

(c) Backfill the excavation to original ground-line with conserved material. 

127 
 

 

Section 208 

208.05 Cofferdams. Use cofferdams when excavating under water or when the excavation is affected by 

groundwater. 

Submit drawings showing proposed methods and construction details of cofferdams according to 

Subsection 104.06 and Section 562. Design and construct cofferdams that conform to the following: 

(a) Extend below the bottom of the footing; 

(b) Brace to withstand pressure without buckling and secured in place to prevent tipping or movement; 

(c) Construct as watertight as practical; 

(d) Provide sufficient clearance for the placement of forms and the inspection of their exteriors; 

(e) Provide for dewatering; 

(f) Protect fresh concrete from damage; and 

(g) Prevent damage to the foundation by erosion. 

Remove cofferdam material down to the natural bed of the waterway or to the top of seal, whichever is 

lower. Remove cofferdam material outside the waterway to at least 48 inches below the surface of the 

finished ground. 

208.06 Foundation Seal. Seal the foundation area from water by placing Class S (Seal) concrete if the 

area cannot be pumped reasonably free of water. 

Provide and place Class S (Seal) concrete according to Section 552. Maintain the water level inside the 

cofferdam at the same level as the water outside the cofferdam while placing a foundation seal. Vent or 

port the cofferdam at low water level when a foundation seal is placed in tidal water. 

Do not dewater a concrete-sealed cofferdam until the Class S (Seal) concrete strength is sufficient to 

withstand the hydrostatic pressure. 

208.07 Dewatering. Remove and dispose of water according to Federal, state, and local rules and 

regulations. 

208.08 Foundation Preparation and Approval. Provide a firm foundation of uniform density throughout 

its length and width. Obtain CO approval of the foundation when the excavation is complete. 

Prepare foundations as follows: 

(a) Footings placed on bedrock. Excavate to the specified elevation. Clean the foundation surface of 

deleterious material. Clean and grout seams and crevices greater than 1⁄2 inch wide. Where needed to 

backfill over-excavations or over-break areas, place flowable backfill or structural concrete (Class A) 

to provide a level bearing pad for footing as directed. Do not place soil or aggregate backfill under the 

footing unless approved for the design bearing resistance. 

(b) Footings placed on an excavated surface other than bedrock. Excavate material to foundation 

grade and compact the foundation before footing is placed. 

128 
 

 

 

 

 

Section 208 

(c) Footings keyed into undisturbed material. Excavate the foundation to the limits of the footing 

and compact the foundation. Where material does not stand vertically, fill the space between the limits 

of the bottom of footing and the undisturbed material with structural concrete (Class A). Fill only to 

the top of the excavation if the excavation is below the top of the footing. Concrete placed against 

steel sheet piles in cofferdams is considered as being against undisturbed material. 

(d) Unstable material below footing elevation. Excavate unstable material below foundation grade 

as directed and backfill with foundation fill. Place foundation fill in horizontal lifts that do not exceed 

6 inches in compacted thickness. Compact each lift according to Subsection 208.10. 

(e) Foundations using piles. If foundation seals are required, drive the piles before placing Class S 

(Seal) concrete unless otherwise specified. Remove loose and displaced material and reshape the 

bottom of the excavation to the foundation elevation. Grade and compact the bed to receive the footing. 

208.09 Backfill. Place structural backfill in horizontal lifts that do not exceed 6 inches in compacted 

thickness. Compact each lift according to Subsection 208.10. 

Place structural backfill lifts evenly on all sides of the structure as appropriate. Extend each lift to the 

limits of the excavation or to natural ground. 

Do not place structural backfill against concrete until 80 percent of the design strength is attained. 

Backfill in or next to a running waterway according to Subsection 208.04. 

208.10 Compacting. Determine optimum moisture content and maximum dry density according to 

AASHTO T 99, Method C. Adjust the moisture content of the backfill to a moisture content suitable for 

compaction. 

Compact material placed in each lift to at least 95 percent of the maximum density. Determine the in-place 

density and moisture content according to AASHTO T 310 or other approved test procedures. 

Do not apply density requirements as measured by AASHTO T 310 to material that cannot be tested or 

compacted to maximum values determined by AASHTO T 99. For this material, fill the voids around the 

rocky material in each lift with structural backfill or foundation fill as appropriate. Compact each lift until 

there is no visible evidence of further consolidation. 

208.11 Acceptance. See Table 208-1 for sampling, testing, and acceptance requirements. 

Material for grout will be evaluated under Subsections 106.02 and 106.03. 

Material for structural backfill and foundation fill will be evaluated under Subsections 106.02 and 106.04. 

Grout will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill work will be evaluated under Subsections 106.02 and 106.04. 

Clearing will be evaluated under Section 201. 

Concrete will be evaluated under Section 552. 

Flowable backfill will be evaluated under Section 614. 

129 
 

 

 

 

 

 

Section 208 

Removal of obstructions will be evaluated under Section 203. 

Rock blasting will be evaluated under Section 205. 

Temporary works will be evaluated under Section 562. 

Measurement 

208.12 Measure the Section 208 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring structural excavation by the cubic yard in its original position, do not include the 

following volumes: 

(a) Material excavated outside the vertical planes located 18 inches outside and parallel to the limits 

of the footings or foundations; 

(b) Material included within the staked limits of the excavation (such as contiguous channel changes 

and ditches) for which measurement is covered under other Sections; 

(c) Water or other liquid material; 

(d) Material excavated before measurement of the original ground; 

(e) Material re-handled, except when the contract specifically requires excavation after embankment 

placement; or 

(f) Excavation for cofferdam seals. 

When measuring foundation fill and structural backfill by the cubic yard in place, measure the volume 

placed inside the vertical planes located 18 inches outside and parallel to the limits of the footings or 

foundations. 

Payment 

208.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 208 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Payment for structure excavation, shoring and bracing, and cofferdams will be full compensation for 

excavation to a depth of 6 feet below the lowest elevation shown in the plans for each foundation structure. 

When the excavation exceeds 6 feet, either the Contractor or the CO may request an equitable price 

adjustment for the depth in excess of 6 feet. 

(a) Progress payments for dewatering by the lump sum will be paid as follows: 

(1) 25 percent of the pay item amount, no more than 0.5 percent of the original contract amount, 

will be paid at the start of dewatering operations. 

(2) The remaining portion of the pay item amount will be prorated based on the structural 

excavation work completed. 

130 
 

 

Section 208 

(b) Progress payments for shoring and bracing by the lump sum will be paid as follows: 

(1) 25 percent of the pay item amount will be paid after the design submittal is approved. 

(2) An additional 25 percent of the pay item will be paid after 50 percent of the shoring and bracing 

work is completed. 

(3) The remaining portion of the pay item amount will be paid after structural excavation work is 

completed and shoring and bracing material is removed. 

(c) Progress payments for cofferdam by the lump sum will be paid as follows: 

(1) 25 percent of the pay item amount will be paid after the design submittal is approved. 

(2) An additional 25 percent of the pay item will be paid after 50 percent of the cofferdam work is 

completed. 

(3) The remaining portion of the pay item amount will be paid after structural excavation work is 

completed and cofferdam material is removed. 

131 
 

 

 

 

 

 

 

Table 208-1 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Source 

Foundation 

fill(1) 

(704.01) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Classification − AASHTO 

M 145 

1 per 

soil type 

Source of 

material Yes 

Before 

using 

in work 

−

Gradation − AASHTO 

T 27 & T 11 " " " " −

Structural 

backfill(1) 

(704.01) 

" 

Plasticity index − AASHTO 

R 58, T 89, & T 90 " " " " −

Gradation − AASHTO 

T 27 & T 11 " " " " −

Production 

Foundation 

fill 

(704.01) 

Measured & 

tested for 

conformance 

(106.04) 

Moisturedensity −

AASHTO 

T 99, 

Method C(2) 

1 per 

soil type 

Source of 

material Yes 

Before 

using 

in work 

−

Density −

AASHTO 

T 310 or other 

approved 

procedures 

1 per 

300 yd3 In place No 

Before 

placing 

next lift 

−

Structural 

backfill 

(704.01) 

" 

Moisturedensity −

AASHTO 

T 99, 

Method C(2) 

1 per 

soil type 

Source of 

material Yes 

Before 

using 

in work 

−

Density −

AASHTO 

T 310 

or other 

approved 

procedures 

2 per 

lift In place No 

Before 

placing 

next lift 

−

(1) Not required when using Government-furnished source. 

(2) At least 5 points per proctor. 
 

 

 

 

Section 209 

Section 209. — STRUCTURE EXCAVATION AND BACKFILL 

Description 

209.01 This work consists of excavating material for the construction of structures, except those 

specifically designated under Section 208. This work also includes preserving channels, shoring, and 

bracing, sealing foundations, dewatering, preparing foundations, bedding, and backfilling. 

Material 

209.02 Conform to the following Subsection: 

Soil and soil-aggregate materials 704.01 

Construction Requirements 

209.03 General. Clear the area of vegetation and obstructions according to Sections 201 and 203. 

Excavate trenches or foundation pits according to Subsection 208.03. Excavate to foundation grade 

without disturbing the trench or foundation surface. Foundation grade is the elevation at the bottom of the 

bedding for installing the structure. 

209.04 Channel Preservation. Preserve channels according to Subsection 208.04. 

209.05 Foundation Seal. If foundation seals are necessary, construct a foundation seal according to 

Subsection 208.06. 

209.06 Dewatering. If dewatering is necessary, dewater according to Subsection 208.07. 

209.07 Foundation Preparation. Excavate unsuitable material if encountered at foundation grade as 

directed. 

If a footing is required to be keyed into undisturbed material, prepare foundation and construct footing 

according to Subsection 208.08(c). 

Backfill and compact with foundation fill according to Subsection 208.08(d). 

209.08 Bedding for Pipe Culverts. Level the foundation. Place uncompacted bedding material over the 

foundation in a layer of uniform thickness. Lay 4 inches of bedding for pipes with diameters of 12 to 

54 inches. Lay 6 inches of bedding for pipe with diameters larger than 54 inches. Recess the bedding to 

receive the joints for pipes with belled joints. Place the culvert on the uncompacted bedding layer and 

backfill according to Subsection 209.09(b). 

209.09 Backfill. Backfill as follows: 

(a) General. Place backfill lifts evenly on all sides of the structure. Extend each lift to the limits of 

the excavation or natural ground. 

Place backfill in compacted lifts no more than 6 inches in thickness. When using flowable backfill, 

backfill according to Section 614. 

133 
 

 

Section 209 

Do not place backfill against concrete until 80 percent of the design strength is attained. 

Compact each lift according to Subsection 208.10. 

(b) Pipe culverts. Backfill according to one of the following: 

(1) Pipe culverts. Place and compact common backfill or plastic pipe backfill in evenly balanced 

lifts on each side of the pipe to a height of 12 inches above the top of the pipe culvert. 

Complete backfilling to the top of the trench. Place and compact common backfill or plastic pipe 

backfill in the trench in lifts no more than 6 inches in thickness according to Subsection 209.10. 

(2) Pipe culverts with flowable backfill. Place and anchor pipe to prevent floating and movement. 

Backfill using flowable backfill according to Section 614. 

(c) Box culverts and structures other than pipe culverts. Place and grade common backfill in 

compacted lifts no more than 6 inches in thickness. Compact each lift according to Subsection 208.10. 

(d) Structural plate structures. Place and compact common backfill to a height of 12 inches above 

the top of the structural plate structure. If applicable, complete backfilling and compacting according 

to Subsection 204.10. 

(e) Repair existing pavement areas. Conform to Subsection 418.04. 

209.10 Compacting. Determine optimum moisture content and maximum dry density according to 

AASHTO T 99, Method C. Adjust the moisture content of the backfill to a moisture content suitable for 

compaction. 

Compact material placed in each lift to at least 95 percent of the maximum density. Determine the in-place 

density and moisture content according to AASHTO T 310 or other approved test procedures. 

Do not apply density requirements as measured by AASHTO T 310 to material that cannot be tested or 

compacted to maximum values determined by AASHTO T 99. For this material, fill the voids around the 

rocky material in each lift with structural backfill or foundation fill as appropriate. Compact each lift until 

there is no visible evidence of further consolidation. 

209.11 Acceptance. See Table 209-1 for sampling, testing, and acceptance requirements. 

Material for common backfill, bedding material, plastic pipe backfill, and foundation fill will be evaluated 

under Subsections 106.02 and 106.04, except flowable backfill for bedding or backfill will be evaluated 

under Section 614. 

Shoring and bracing will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill work will be evaluated under Subsections 106.02 and 106.04. 

Clearing will be evaluated under Section 201. 

Removal of obstructions will be evaluated under Section 203. 

134 
 

Section 209 

Measurement and Payment 

209.12 Do not measure structure excavation and backfill for payment. See Subsection 109.05. 

135 
 

 

 

 

 

 

 

 

 

Table 209-1 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Source 

Foundation 

fill, bedding 

material, 

common 

backfill, 

plastic pipe 

backfill(1) 

(704.01) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Classification − AASHTO 

M 145 

1 per 

soil type 

Source of 

material Yes 

Before 

using 

in work 

−

Gradation − AASHTO 

T 27 & T 11 " " " " −

Production 

Foundation 

fill, bedding 

material, 

common 

backfill, 

plastic pipe 

backfill 

(704.01) 

Measured & 

tested for 

conformance 

(106.04) 

Moisturedensity −

AASHTO T 

99, 

Method C(2) 

1 per 

soil type 

Source of 

material Yes 

Before 

using 

in work 

−

Density −

AASHTO 

T 310 or other 

approved 

procedures 

2 per 

lift(3) In-place No 

Before 

placing 

next lift 

−

(1) Not required if using Government-furnished source. 

(2) At least 5 points per proctor. 

(3) When installing culvert pipe the backfill placed on both sides of the pipe is considered to be contained in the same lift when the 

material is placed to the same elevation on both sides of the culvert, the compactive effort applied to one side of the culvert is the same 

as that applied to the other, and the compactive effort is applied to both sides of the pipe during a single work operation. 
Section 210 

Section 210. — RESERVED 

137 
 

 

Section 211 

Section 211. — ROADWAY OBLITERATION 

Description 

211.01 This work consists of obliterating or closing roadways and areas outside the roadway prism. 

Construction Requirements 

211.02 Roadway Obliteration Methods. 

(a) Method 1. Obliterate the roadway by restoring to approximate original ground contours. Keep 

excavated material within the original construction limits. Finish slopes to provide gradual transitions 

in slope adjustments without noticeable breaks. 

(b) Method 2. Close roads by filling ditches and outsloping the roadbed to drain. Remove and slope 

embankment material at localized drainages to restore the natural drainage patterns. Eliminate ruts and 

low spots that could hold water. 

211.03 Material Handling. 

(a) Rigid material. Remove rigid material according to Section 203. Dispose of material according 

to Federal, state, and local rules and regulations. 

(b) Nonrigid material. 

(1) Nonasphalt material. Scarify or rip the gravel, crushed stone, or other nonrigid surface, base, 

and subbase material. Mix the scarified or ripped material with the underlying soil. Bury the 

mixture under at least 12 inches of onsite soil. 

(2) Asphalt contaminated material. Dispose of asphalt contaminated material according to 

Subsection 203.07. 

211.04 Waterbars and Barriers. Construct waterbars as shown in the plans. Construct barriers to prevent 

vehicle access as shown in the plans. 

211.05 Acceptance. Roadway obliteration will be evaluated under Subsection 106.02. 

Removal of obstructions will be evaluated under Section 203. 

Measurement 

211.06 Measure the Section 211 pay items listed in the bid schedule according to Subsection 109.02. 

Payment 

211.07 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 211 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

138 
 

 

Section 212 

Section 212. — LINEAR AND SITE GRADING 

Description 

212.01 This work consists of performing linear and site grading at designated locations within specified 

tolerances. 

212.02 Definitions. 

(a) Linear grading. Consists of constructing and grading roadways on a designated alignment. 

(b) Site grading. Consists of constructing and grading designated areas outside the roadway prism. 

Construction Requirements 

212.03 Roadway and Site Preparation. Clear the area of vegetation and obstructions according to 

Sections 201 and 203. 

212.04 Excavation and Embankment. Construct the roadbeds and sites according to the applicable 

requirements of Section 204, except as modified in this Section. 

Adjust the moisture content of embankment material to a moisture content suitable for compaction. Place 

embankment material in 12-inch lifts and compact each lift according to Subsection 204.11(a). If 

compacting with rollers is not practical, use approved mechanical or vibratory compaction equipment. 

Construct approach connections to existing roads, parking areas, and trails as directed. 

Do not make alignment or profile grade adjustments that adversely affect drainage. 

212.05 Grading Tolerance. Construct roadbeds and sites within the following grading tolerances: 

(a) Linear grading. 

(1) Alignment (centerline). Alignment may be shifted a maximum of 10 feet left or right of the 

planned centerline. Curve radii may be reduced by up to 50 percent. Do not construct curves with 

radii less than 100 feet. Compound curves are allowed. 

(2) Profile grade. Profile grade may be shifted a maximum of 5 feet from the plan elevation 

provided the new grade tangent does not vary more than 2 percent from the plan grade tangent. 

Connect revised forward and back grade tangents with a uniform vertical curve consistent with the 

design. 

(b) Site grading. The footprint may be shifted a maximum of 10 feet in any direction. The profile of 

the site may be adjusted a maximum of 2 feet from the plan elevation. 

212.06 Acceptance. Linear and site grading work will be evaluated under Subsections 106.02 and 106.04. 

Clearing will be evaluated under Section 201. 

Removal of obstructions will be evaluated under Section 203. 

139 
Section 212 

Measurement 

212.07 Measure the Section 212 pay items listed in the bid schedule according to Subsection 109.02. 

Payment 

212.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 212 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

140 
 

 

 

 

Section 213 

Section 213. — SUBGRADE STABILIZATION 

Description 

213.01 This work consists of processing and incorporating stabilizing additives into the upper layer of 

subgrade. 

Material 

213.02 Conform to the following Subsections: 

Chemical admixtures 711.03 

Fly ash 701.03(a) 

Hydraulic cement 701.01 

Lime for soil stabilization 725.03(b) 

Water for construction 725.01(c) 

Construction Requirements 

213.03 Proportioning. Submit a subgrade stabilization mix design at least 30 days before production. 

Include compressive strength values for at least three application rates with at least one application rate 

above and one below the strength shown in Table 213-1. 

Table 213-1 

Subgrade Stabilization Compressive Strength Requirements 

Stabilization Mixture Test Procedure Average Unconfined Compressive 

Strength (3 specimens minimum) 

Lime-Soil ASTM D5102, Procedure B 100 psi minimum(1) 

Lime-Fly ash-Soil ASTM D5102, Procedure B 150 psi minimum(1) 

Cement-Soil, 

Cement-Fly ash-Soil, 

or Fly ash-Soil 

ASTM D1633, Method A 200 psi minimum(2) 

(1) At 7-day cure at 105 °F. 

(2) At 7-day cure. 

Include the following with the mix design as applicable: 

(a) Source of each component material; 

(b) Results of the applicable tests including optimum moisture content (after treatment), hydration 

moisture rate, maximum dry density (after treatment), Atterberg limits (before and after treatment), 

and recommended application rates of stabilizing material; and 

(c) If requested: 

(1) 200-pound sample of the subgrade soil; 

(2) 25-pound sample of the fly ash; 

141 
 

 

 

 

 

 

 

 

 

 

 

 

Section 213 

(3) 25-pound sample of the lime; 

(4) 25-pound sample of the cement; and 

(5) 2-pound sample of each chemical admixture. 

Start production after the mix design is approved. Provide a new mix design if there is a material source 

change. 

213.04 Production Start-Up Procedures. Conduct a pre-stabilization preparatory phase meeting at least 

7 days before the start of stabilizing operations according to Subsection 153.06(a). 

Notify the CO at least 7 days before starting operations. 

213.05 General. Store stabilizing additives and chemical admixtures in closed, weatherproof containers. 

Recondition the subgrade according to Subsection 303.06. Scarify or pulverize the subgrade to the 

required depth. Use a rotary mixer with direct water injection capabilities to adequately blend the material 

and to produce a homogeneous mixture within 2 percent of the optimum moisture content. 

At the end of each production day, shape the subgrade surface to provide positive drainage. Provide a 

construction joint according to Subsection 305.11 for tying into existing stabilized subgrade. 

213.06 Application. Do not apply stabilizing additives when weather conditions cause excessive material 

loss or when the air temperature may fall below 32 °F within 48 hours. Apply stabilizing additives when 

the prepared subgrade surface temperature is at least 40 °F. 

Adjust the subgrade material moisture content to 2 to 3 percent above optimum. 

Apply fly ash by the dry method. Apply lime and cement by either the dry or slurry method. 

(a) Dry method. Uniformly apply the stabilizers using an approved metered spreader. Apply water 

using approved methods to obtain the proper moisture content for mixing and compaction. If quicklime 

and fly ash are pre-blended, limit the maximum particle size of the quicklime to 1⁄8 inch to avoid

segregation. 

(b) Slurry method. Mix material with water. Report the percent solids in the slurry to the CO for each 

production day. Apply the slurry using either trucks with approved distributors or rotary mixers. Equip 

the distributor truck or rotary mixer tank with an agitator to keep the stabilizers suspended in water. 

Make successive passes over the material to obtain the proper moisture and additive content. 

213.07 Mixing. Keep traffic, except mixing equipment, off the spread material. Use a rotary mixer. 

(a) Lime mixtures. 

(1) Preliminary mixing. Adjust the moisture content of the mixture to optimum plus necessary 

hydration moisture. Use the mix design hydration moisture rate. Thoroughly mix the lime, soil, 

and water to obtain a homogeneous friable mixture. Complete the mixing on the same day lime is 

applied. Check to ensure lime is fully hydrated and add additional water if necessary. 

142 
 

 

 

 

 

 

Section 213 

Mellow the mixture for 1 to 4 days at a moisture content of 2 to 3 percent above optimum as 

directed. 

(2) Final mixing. Remix until 95 percent of the mixture, except hard and durable particles, passes 

a 11⁄2-inch sieve and at least 50 percent of the soil portion of the mixture passes a No. 4 sieve when 

tested according to AASHTO T 27 in the non-dried condition. 

(b) Lime/fly ash mixtures. Mix according to Subsection 213.07(a)(1). Use either a pre-blended 

lime/fly ash mixture or mix the lime and fly ash in separate operations. 

If the lime and fly ash are mixed separately, mix the lime first and mix the fly ash within 2 days of 

lime mixing. Adjust the moisture content of the lime/fly ash mixture to 2 to 3 percent above optimum. 

Mix the material to prevent formation of fly ash balls. Complete the mixing within 2 hours after adding 

the fly ash. 

(c) Cement, fly ash, or cement/fly ash mixtures. Add water to adjust the moisture content of the 

mixture to 2 to 3 percent above optimum. Mix the material until 95 percent of the mixture, except hard 

and durable particles, passes a 11⁄2-inch sieve and at least 50 percent of the soil portion of the mixture 

passes a No. 4 sieve when tested according to AASHTO T 27 in the non-dried condition. Complete 

the mixing within 2 hours after the cement, fly ash, or both are added. 

213.08 Compacting and Finishing. Immediately after final mixing, spread and compact the mixture. Use 

a vibratory sheepsfoot roller to achieve compaction. Use pneumatic-tire and steel drum rollers for finish 

rolling. 

Compact the mixture to at least 95 percent of maximum dry density from the approved mix design. 

Complete compaction operations within 2 hours of completion of mixing. 

Finish the compacted subgrade to within ±0.10 foot of the staked line, grade, and cross-section. Check the 

surface with a 10-foot metal straightedge. 

Add or remove material to correct surface deviations more than 3⁄4 inch in 10 feet between two contacts of 

the straightedge with the surface. When adding material, scarify the subgrade to at least 6 inches. Remix 

according to Subsection 213.07 and recompact the area to restore the required density and strength. 

213.09 Curing. Keep the subgrade continuously moist and within 3 percent of optimum moisture content 

until the next course is placed. Apply water under pressure through a spray bar equipped with nozzles, 

which produce a fine, uniform spray. Place the next course within 14 days after compacting and finishing. 

If the subgrade deforms, loses density, or ravels before placement of the next course; correct the damaged 

subgrade. 

Traffic may be allowed on the stabilized subgrade 24 hours after compaction and finishing if approved. 

213.10 Acceptance. See Table 213-2 for sampling, testing, and acceptance requirements. 

Material for subgrade stabilization stabilizing additives will be evaluated under Subsections 106.02 and 

106.03. 

Subgrade stabilization work will be evaluated under Subsections 106.02 and 106.04. 

143 
 

 

Section 213 

Construction joints will be evaluated under Section 305. 

Reconditioning of subgrade will be evaluated under Section 303. 

Measurement 

213.11 Measure the Section 213 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring subgrade stabilization by the square yard, measure the length horizontally along the 

centerline of the roadway and the width horizontally to include the top of the subgrade stabilization width, 

including widenings. 

Payment 

213.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 213 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

144 
 

 

 

 

 

 

 

 

 

Table 213-2 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Mix Design 

Subgrade 

stabilization 

Measured & 

tested for 

conformance 

(106.04) 

Proportioning − Subsection 

213.03 

1 per 

submitted 

mix design 

Existing 

roadbed or 

subgrade 

If requested 

30 days 

before 

production 

−

Production 

Stabilized 

material 

Measured & 

tested for 

conformance 

(106.04) 

Moisturedensity −

AASHTO 

T 99, 

Method C(1) 

1 per 

soil type but 

not less than 

1 for each 

day of 

production 

Processed 

material 

behind 

mixer 

If 

requested 

Before 

using 

in work 

−

Gradation − AASHTO 

T 27 & T 11 

1 per 

3500 yd2 

but not less 

than 1 per 

layer 

" " " −

Density −

AASHTO 

T 310 or other 

approved 

procedures 

" In-place No 

Before 

placing 

next layer 

−

Compressive 

strength 

(7-day cure) 

−

ASTM 

D5102,

(2) 

D1633(3) 

as applicable 

" 

Processed 

material 

behind 

mixer 

" " −

(1) At least 5 points per proctor. 

(2) At 7-day cure at 105°F. Compact sampled material immediately according to Procedure B. Do not complete the proportioning and mixing of 

Sections 10.2 and 10.3. Report average unconfined compressive strength from at least three specimens. 

(3) At 7-day cure. Report average unconfined compressive strength from at least three specimens. 
 

DIVISION 250 EARTH RETAINING 

SYSTEMS AND SLOPES 

146 
 

 

 

 

 

 

Section 251 

Section 251. — RIPRAP 

Description 

251.01 This work consists of providing and placing riprap. 

Riprap gradation is designated according to Subsection 251.07. 

Material 

251.02 Conform to the following Subsections: 

Geotextile 

Neat hydraulic cement grout 

Rock for riprap 

714.01 

701.04(a)(2) 

705.02 

Construction Requirements 

251.03 General. Excavate and backfill according to Section 209. Dress the slope to produce a smooth 

surface. Place geotextile according to Section 207, as required. 

251.04 Placed Riprap. Place riprap on a prepared surface. 

Place riprap to its full thickness in one operation. Do not place riprap material by methods that cause 

segregation or damage to the prepared surface. Place or rearrange individual rocks by mechanical or hand 

methods to obtain a dense uniform blanket with a reasonably smooth surface. 

251.05 Keyed Riprap. Key riprap on a prepared surface and set into place by impact pressure. 

Place rock for keyed riprap according to Subsection 251.04. Set the riprap into place by exerting impact 

pressure with a hydraulic-powered bucket or an approximate 5000-pound flat-faced mass. Repeat impacts 

until the rock is firmly seated and forms a reasonably uniform surface without reducing the effective sizes 

of the rocks. Do not use impact pressure on riprap below the water surface. 

251.06 Grouted Riprap. Place or key riprap on a prepared surface with the voids filled with grout. 

Place rock for grouted riprap according to Subsection 251.04. Place rock for keyed grouted riprap 

according to Subsection 251.05. Thoroughly moisten the rocks and wash excess fines from the riprap or 

to the underside of the riprap. Do not place grout unless the air temperature is at or above 35 °F within the 

near-surface voids of the riprap. Prevent segregation during grout placement. Start placing grout at the 

lowest elevation of the riprap. Fill voids without unseating the rocks. Do not exceed 5-foot thickness for 

each layer of grouted riprap. Allow 3 days curing time before adding the next layer of riprap and grout. 

Provide weep holes through the grouted riprap as required. Keep the grouted riprap moist for 3 days after 

the work is completed and protect it from freezing for at least 7 days after grouting. 

251.07 Riprap Gradation. 

(a) Wolman count. For source approval, test individual riprap size by Wolman Count according to 

FLH T 521. 

147 
 

Section 251 

(b) Size method. During production, test individual riprap using the size method, by confirming that 

the largest rock has an intermediate dimension greater than the upper limit of the D85 size range shown 

in Table 705-1. 

251.08 Acceptance. See Table 251-1 for sampling, testing, and acceptance requirements. 

Material for grout will be evaluated under Subsections 106.02 and 106.03. 

Rock for riprap will be evaluated under Subsections 106.02 and 106.04. 

Placing grout will be evaluated under Subsection 106.02. 

Riprap construction will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Geotextile will be evaluated under Section 207. 

Measurement 

251.09 Measure the Section 251 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring riprap by the cubic yard, measure in place. 

Payment 

251.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 251 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

148 
 

 

 

 

 

 

 

Table 251-1 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Source 

Rock for 

riprap 

(705.02) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Apparent 

specific gravity 

& absorption 

– AASHTO 

T 85 

1 per 

material 

type 

Source 

of 

material 

Yes 

Before 

using in 

work 

– 

Soundness 

using 

sodium sulfate 

– AASHTO 

T 104 " " " " – 

LA abrasion – AASHTO 

T 96 " " " " – 

Gradation(1) – FLH T 521 " " No " – 

Production 

Rock for 

riprap 

(705.02) 

Process 

control 

(153.03) Gradation – FLH T 521 

1 per 

100 yd3 

per Class 

Stockpile 

or source(2) No 

Before 

using in 

work 

– 

Measured & 

tested for 

conformance 

(106.02 & 

106.04) 

Size method(1) – Subsection 

251.07(b) 

1 per 

100 yd3 

per Class 

On site 

stockpile 

or 

in-place(3) 

No 24 

hours – 

(1) Notify CO at least 7 days before performing test. 

(2) To be measured before delivery to project. 

(3) Point of sampling to be approved. 
 

 

 

Section 252 

Section 252. — ROCKERY, SPECIAL ROCK EMBANKMENT, 

AND ROCK BUTTRESS 

Description 

252.01 This work consists of constructing rockeries, special rock embankments, and rock buttresses. 

252.02 Definitions. 

(a) Rockeries. Consists of providing and placing interlocking, dry-stacked rocks without reinforcing 

steel, mortar, or concrete. 

(b) Special rock embankments. Consists of providing and placing rock in fill-side sections. 

(c) Rock buttresses. Consists of providing and placing rock in cut-side sections. 

Material 

252.03 Conform to the following Subsections: 

Corrugated polyethylene drainage tubing 708.04 

Geotextile 714.01 

Granular rock backdrain 703.17 

Rock for buttresses 705.05 

Rock for rockeries 705.06 

Rock for special rock embankments 705.04 

Construction Requirements 

252.04 Qualifications. At least 14 days before starting rockery work, submit a résumé for the on-site 

supervisor describing experience on at least three projects of similar construction and complexity within 

the past 5 years. Include project names, a brief description of each project, construction dates and 

quantities, locations, and contact information for project owners. 

252.05 Submittals. At least 14 days before starting rockery, special rock embankment, and rock buttress 

work, submit the following according to Subsection 104.06: 

(a) Start date and schedule; 

(b) Description of construction methods and proposed equipment; and 

(c) Photos of completed rockeries with narrative descriptions of the rockeries, equipment used, and 

special or unusual conditions encountered during the construction and how construction methods were 

adapted. 

252.06 General. Survey according to Section 152 and verify the limits of installation. Notify the CO if 

planned lengths, heights, or both are inadequate to intersect with the adjacent slopes. Submit cross-sections 

verifying intersections for approval. 

150 
 

 

 

 

Section 252 

Construct as follows: 

(a) Excavation. Perform the work according to Sections 204 and 209. Do not excavate more areas 

than can be replaced with construction in one shift, except as otherwise noted. The CO may allow 

excavation beyond the limits that can be completed in one shift provided the Contractor demonstrates 

that the excavation will remain stable until the rock work is completed or provides shoring. Protect 

backslopes from damage by surface water. 

(b) Erection. Place geotextile filter according to Section 207 as shown in the plans. Remove sharp 

objects from the backslope before installing geotextile filter. 

252.07 Rockery. Provide and install underdrain systems according to Section 605 as shown in the plans. 

Seat base rocks firmly on stable foundation subgrades or leveling pad as shown in the plans. Do not place 

rocks with shapes that create voids with a linear dimension greater than 12 inches. 

Place rocks to avoid continuous joints in any direction. Locate at least one bearing point a distance no 

greater than 6 inches from the face of the rockery. Place each rock to ensure it bears on at least two rocks 

below. Place incrementally smaller rocks as construction proceeds in successive rows. Slope the top 

surface of each rock towards the back of the rockery at an inclination of at least 5 percent. 

Choke voids in each successive row. Choke voids greater than 6 inches with a rock large enough to fill 

the void. 

Backfill with granular rock backdrain concurrent with rock placement until level with the top of rock. 

Place granular rock backdrain in horizontal lifts no more than 12 inches compacted depth. Compact each 

lift according to Subsection 204.11. Compact areas not accessible to rollers with other approved methods. 

252.08 Special Rock Embankment and Rock Buttress. Place rocks in a stable orientation with minimal 

voids to produce a random pattern. Construct the exposed face of the rock mass reasonably uniform with 

projections beyond the line of the slope that are no greater than 12 inches for mechanically-placed rock or 

6 inches for hand-placed rock. 

Use rock smaller than the minimum rock size to choke the larger rock solidly in position and to fill voids 

between the large rocks. 

252.09 Acceptance. See Table 252-1 for sampling, testing, and acceptance requirements. 

Material for rockeries, special rock embankments, and rock buttresses will be evaluated under 

Subsections 106.02, 106.03, and 106.04. 

Construction of rockeries, special rock embankments, and rock buttresses will be evaluated under 

Subsections 106.02 and 106.04. 

Geotextile filters will be evaluated under Section 207. 

Roadway excavation will be evaluated under Section 204. 

Structure excavation and backfill will be evaluated under Section 209. 

Survey will be evaluated under Section 152. 

151 
 

Section 252 

Underdrain systems will be evaluated under Section 605. 

Measurement 

252.10 Measure the Section 252 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring rockeries by the square foot, measure the rockery from the bottom of the base rock 

elevation to the top of the cap rock elevation. Measure the front face on a plane parallel to the rockery 

face. 

When measuring special rock embankments and rock buttresses by the cubic yard, measure in place. 

Payment 

252.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 252 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

152 
 

 

 

 

 

Table 252-1 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Source 

Rock for 

buttresses 

(705.05) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Rock breadth 

and thickness − Subsection 705.05(a)(1) 

1 per 

rock type 

Source of 

material No 

Before 

using 

in work 

−

Apparent 

specific 

gravity 

− AASHTO 

T 85 " " Yes " 

Not required 

if using 

Government 

-furnished 

source 

Absorption − " " " " " " 

Durability 

index 

(coarse) 

− AASHTO 

T 210 " " " " " 

Rock for 

rockeries 

(705.06) 

" 

Apparent 

specific gravity − " 1 per 

rock type 

Source of 

material Yes 

Before 

using 

in work 

Not required 

if using 

Government 

-furnished 

source 

Absorption − " " " " " " 

LA abrasion − AASHTO 

T 96 " " " " " 

Durability 

index 

(coarse) 

− AASHTO 

T 210 " " " " " 

Soundness 

using 

sodium sulfate 

− AASHTO 

T 104 " " " " " 
 

 

 

 

 

 

 

Table 252-1 (continued) 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Production 

Rock for 

special rock 

embankment 

(705.04) 

Process 

control 

(153.03) 

Size − (1) 1 per 

100 yd3 In-place No 24 

hours −

Rock for 

buttresses 

(705.05) 

" " − " 1 per 

100 yd3 " " " −

Rock for 

rockeries 

(705.06) 

" " − (2) 

2 per 

row of rock 

per rockery 

" " " −

(1) For mechanically-placed embankments, verify rock size by confirming that the largest accessible rock has an intermediate dimension greater 

than the D50 size shown in Table 705-2. Also confirm that the smallest accessible rock has an intermediate dimension within the lower D50 size 

range shown in Table 705-2. 

For hand placed embankments, verify rock size by confirming that the largest accessible rock has an intermediate dimension greater than the D75 

size shown in Table 705-3. Also confirm that the smallest accessible rock has an intermediate dimension within the D25 size range shown in 

Table 705-3. 

(2) Verify rock size by confirming that the largest accessible rock has a width greater than the minimum width shown in the plans. 
 

 

 

Section 253 

Section 253. — GABIONS AND REVET MATTRESSES 

Description 

253.01 This work consists of constructing rock filled gabion structures and revet mattresses. 

Material 

253.02 Conform to the following Subsections: 

Crushed aggregate 703.06 

Gabion and revet mattress material 720.02 

Gabion and revet mattress rock 705.01 

Geotextile 714.01 

Soil and soil-aggregate materials 704.01 

Construction Requirements 

253.03 General. Survey according to Section 152 and verify the limits of installation. Submit installation 

drawings according to Subsection 104.06. Conform to Section 257 for Contractor-designed gabion walls. 

Excavate and backfill according to Section 209. Grade the foundation for a width equal to the base width 

of the gabions or revet, plus any additional width shown in the plans. 

If required, as determined by the Contractor, design and construct temporary shoring according to 

Section 562. 

Excavate wall foundations to within 4 inches horizontally and vertically from the staked location. 

If shown in the plans, install underdrain system according to Section 605. 

253.04 Basket Assembly. Provide twisted wire or welded wire mesh baskets. Do not damage wire 

coatings during basket assembly, structure erection, cell filling, or backfilling. Rotate the basket panels 

into position and join the vertical edges with fasteners according to Subsection 253.05. Temporary 

fasteners may be used for basket assembly if they are supplemented during structure erection with 

permanent fasteners according to Subsection 253.05. 

Rotate the diaphragms into position and join the vertical edges according to Subsection 253.05. 

253.05 Structure Erection. Construct gabion walls to the following tolerances: 

(a) Vertical and horizontal. ±1 inch at top of wall for every 10 feet of wall height. 

(b) Horizontal straight edge. ±2 inches deviation at a point in the wall from a 10-foot metal 

straightedge placed horizontally or vertically on the theoretical plane of the design face. 

Place the empty gabion baskets on the foundation and interconnect the adjacent baskets along the top and 

vertical edges using permanent fasteners. Where shown in the plans, place 6 inches of compacted crushed 

aggregate or other specified leveling course material under the baskets. 

155 
 

 

 

 

 

 

Section 253 

Where lacing wire is used, wrap the wire with alternating single and double loops every other mesh 

opening as shown in the plans or as recommended by the manufacturer and no more than 6 inches apart. 

Where spiral binders are used, crimp the ends to secure the binders in place. Where alternate fasteners are 

used, space the fasteners in every mesh opening and no more than 6 inches apart. 

Interconnect the base of each basket to the lids of the underlying baskets along the ends and sides of the 

upper basket. 

253.06 Cell Filling. Remove kinks and folds in the wire mesh, and properly align the baskets. Place rock 

carefully in the basket cells to prevent bulging of the baskets and to minimize voids in the rock fill. 

Maintain the basket alignment. 

Place stiffeners and cross-tie wires as recommended by the manufacturer in each unrestrained exterior 

basket cell greater than 12 inches in height. This includes interior basket cells left temporarily 

unrestrained. Place stiffeners and cross-tie wires concurrently with rock placement. 

Fill the cells in a row to ensure no cell is filled more than 12 inches above an adjacent cell. Repeat this 

process until the basket is full and the lid bears on the final rock layer. Secure the lid so that no more than 

a 1-inch gap remains at any connection. 

Secure the lid to the sides, ends, and diaphragms according to Subsection 253.05. Make exposed basket 

surfaces smooth and neat with no sharp rock edges projecting through the wire mesh. 

253.07 Backfilling. Place a geotextile filter over the back face of the gabion structure according to 

Section 207. Concurrently with the cell filling operation, backfill the area behind the gabion structure with 

structural backfill according to Subsection 209.09. Compact each lift according to Subsection 209.10, 

except use an acceptable lightweight mechanical or vibratory compactor within 36 inches of the gabion 

structure. 

If using gabion basket as a free-standing roadside rockfall barrier according to Section 265, do not place 

a geotextile over the back face or backfill the area behind the gabion structure unless otherwise shown in 

the plans. 

253.08 Revet Mattresses. Place a geotextile filter according to Section 207. Construct revet mattresses 

according to Subsections 253.04 through 253.06. Anchor the mattresses in place according to the 

manufacturer’s recommendations. Place a geotextile filter against the vertical edges of the mattress and 

backfill against the geotextile filter using common backfill or the specified backfill. Overfill revet 

mattresses by 1 to 2 inches. 

253.09 Acceptance. Material for gabion structures and revet mattresses will be evaluated under 

Subsections 106.02 and 106.03. 

Construction of gabion structures and revet mattresses will be evaluated under Subsections 106.02 and 

106.04. 

Geotextile filters will be evaluated under Section 207. 

Structure excavation, structural backfill, crushed aggregate, and common backfill will be evaluated under 

Section 209. 

156 
 

 

Section 253 

Survey will be evaluated under Section 152. 

Temporary works will be evaluated under Section 562. 

Underdrains will be evaluated under Section 605. 

Measurement 

253.10 Measure the Section 253 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring gabions by the cubic yard, measure in the structure. 

When measuring revet mattresses by the square yard, measure the exposed face on a plane parallel to the 

revet mattress face. 

Payment 

253.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 253 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

157 
 

 

 

 

 

 

Section 254 

Section 254. — SOLDIER PILE RETAINING WALLS 

Description 

254.01 This work consists of constructing permanent soldier pile retaining walls. 

254.02 Definition. For soldier pile retaining walls, a lift is defined as a stable height of unsupported 

excavation before installation of lagging. 

Material 

254.03 Conform to the following Section and Subsections: 

Geocomposite drain 

Piling 

Reinforcing steel 

Welded stud shear connectors 

714.02 

715 

709.01 

717.05 

Construction Requirements 

254.04 Qualifications. Provide an engineer or geologist, a supervisor, and foreperson with experience 

installing soldier pile retaining walls. At least 30 days before starting soldier pile retaining wall work, 

submit the following for approval: 

(a) Professional engineer or geologist. A résumé for a professional engineer or professional geologist 

with at least 2 years’ experience logging subsurface profiles of soldier pile retaining wall or drilled 

shafts, and documenting construction and testing results; 

(b) Engineer or geologist. If applicable, a résumé for a geotechnical engineer or engineering geologist 

working under the direct supervision of the professional engineer or professional geologist described 

in Subsection 254.04(a); and 

(c) Supervisor and foreperson. A résumé for each individual describing their experience on at least 

five soldier pile retaining wall projects of similar size and complexity within the past 10 years. Include 

project names, locations, and contact information for project owners. 

254.05 Submittals. At least 30 days before starting the soldier pile wall installation work, submit the 

following according to Subsection 104.06: 

(a) Start date; 

(b) Description of equipment and methods of excavation, hole stability, cleanout, spoils containment, 

and pile installation; 

(c) Retaining wall construction sequence; 

(d) Structural steel types, sizes, and details. Include lifting bracket, support bracing or anchor 

locations, and centralization methods; 

(e) Descriptions of concrete and backfill materials and placement methods; 

158 
 

 

 

 

 

 

 

 

Section 254 

(f) Drilling method and details for ground anchors according to Subsection 256.04; 

(g) Temporary lagging design details, backfill materials, drainage materials, and method of 

installation; 

(h) Reinforcing steel bar order lists and bending diagrams according to Subsections 104.06 and 

554.03; and 

(i) Production certificates with each shipment of piles and lagging. 

254.06 General. Survey according to Section 152 and verify limits of wall installation. Provide an 

engineer or geologist to log subsurface material condition descriptions from the ground surface to the 

bottom of the shafts. Conform to Section 257 for Contractor-designed soldier pile walls. 

254.07 Soldier Pile Installation. If driven piles are specified, install according to Section 551. Drive or 

drill pile to the elevation shown in the plans or approved drawings. When drilling, perform the following: 

(a) Drill through material to bottom of shaft elevation shown in the plans or approved drawings. If 

caving conditions are encountered, do not excavate further until implementing the method to prevent 

ground caving as described in the approved drawings. Do not leave more than 2 inches of loose or 

disturbed material in the bottom of the hole for soldier piles with permanent ground anchors, or more 

than 12 inches of loose material for soldier piles without permanent ground anchors. 

(b) Install steel soldier pile in the drilled hole. Position and center the steel soldier pile to maintain the 

specified minimum concrete cover. 

(c) Construct structural concrete according to Section 552, and flowable backfill according to 

Section 614. If multiple types of concrete or backfill are specified, place the specified material in the 

lower section to specified elevation. Allow the concrete to initially set to sufficient strength before 

placing the next type of concrete or backfill. Do not drill adjacent holes for 12 hours after backfilling. 

(d) Place the specified upper concrete or backfill to the specified upper elevation. Pump out water or 

place concrete or backfill using a tremie pipe if more than 6 inches of water is present at the time of 

concrete or backfill placement. 

(e) Use the on-site engineer or geologist to log the drilling and ground conditions with depth. Note 

advancement rates, seepage zones and rates, drilling fluid, casing type and depth, drilling methods and 

equipment used, installation notes, concrete or backfill placement methods, and remarks. 

(f) Place the centerline of the steel soldier piles so that the top is within 1 inch of the plan location and 

plumb to within 0.5 percent of the length based on the total length of the pile. 

254.08 Excavation and Lagging Installation. 

(a) Excavation. Excavate for the wall in staged lifts concurrent with lagging installation. Do not allow 

the exposed unsupported final excavation face cut height to exceed 6 feet or the short-term stand-up 

height of the ground, whichever is less. Provide a soil face during excavation with a smooth contact 

surface for the lagging. Backfill caving areas with approved material. 

159 
 

 

 

 

 

 

 

 

 

Section 254 

(b) Lagging. Provide timber lagging according to Section 557 and as shown in the plans or approved 

drawings. Place lagging boards behind the front flange of the soldier pile overlapping the end of the 

lagging by at least 3 inches on both ends of the lagging boards. Secure the lagging board to prevent 

slippage as indicated in the plans or approved drawings. Provide a gap between boards as shown in 

the plans or approved drawings. Install the lagging tight up against the excavated soil. If the excavation 

caves or is not even enough to install the lagging tight up against the soil, backfill using the method 

and materials in the approved drawings to accommodate subsurface drainage. 

Do not install lagging more than 3 feet below the level of the ground anchors before installation of the 

anchors. 

254.09 Backfill Installation. Backfill behind the lagging according to the approved drawings before 

continuing excavation. Repeat this process until excavation reaches the elevation as shown in the plans or 

approved drawings. Do not excavate more than 3 feet below ground anchor elevations and the bottom of 

lagging elevation. 

254.10 Geocomposite Sheet Drain Installation. Install geocomposite sheet drain system according to 

Section 605. 

254.11 Permanent Ground Anchors. Where permanent ground anchors are required, provide permanent 

ground anchors and bearing assemblies conforming to Section 256 as shown in the plans or approved 

drawings. Install all anchors at similar levels before excavation to the next level anchors. Do not excavate 

to next level anchors until all anchors at prior level are locked off. Perform proof test and performance 

test of anchors according to Section 256. 

254.12 Concrete Fascia Wall. If a cast-in-place concrete facing is specified: 

(a) Install falsework according to Section 562. 

(b) Install headed studs along the soldier pile beam as shown in the plans and according to 

Subsection 555.13. 

(c) Install reinforcing steel according to Section 554. 

(d) Install structural concrete according to Section 552. 

254.13 Final Backfill. Backfill to final grade behind and in front of the wall with the specified material 

shown in the plans or approved drawings. 

254.14 Acceptance. Material for soldier piles will be evaluated under Subsections 106.02 and 106.03. 

Construction of soldier piles will be evaluated under Subsections 106.02 and 106.04. 

Concrete will be evaluated under Section 552. 

Driven piles will be evaluated under Section 551. 

Temporary works will be evaluated under Section 562. 

Flowable backfill will be evaluated under Section 614. 

160 
 

Section 254 

Geocomposite sheet drain systems will be evaluated under Section 605. 

Permanent ground anchors will be evaluated under Section 256. 

Steel structures will be evaluated under Section 555. 

Survey will be evaluated under Section 152. 

Timber structures will be evaluated under Section 557. 

Measurement 

254.15 Measure the Section 254 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring soldier piles by the linear foot, measure from the top of steel soldier pile elevation to the 

pile tip or bottom of shaft elevation, whichever is greater. 

Payment 

254.16 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 254 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

161 
 

 

Section 255 

Section 255. — MECHANICALLY-STABILIZED EARTH WALLS 

Description 

255.01 This work consists of constructing MSE walls. 

Material 

255.02 Conform to the following Subsections: 

Geotextile 714.01 

Mechanically-stabilized earth wall material 720.01 

Reinforcement geotextile and geogrid 714.04 

Select granular backfill 704.03 

Wall facing fill 705.09 

Construction Requirements 

255.03 General. Survey according to Section 152 and verify the limits of wall installation. Submit 

installation drawings according to Subsection 104.06. Conform to Section 257 for Contractor-designed 

MSE walls. Do not disturb existing ground until limits of the wall installation have been verified and the 

CO has approved the installation drawings. 

Excavate and backfill according to Section 209. Grade the foundation for a width equal to the length of 

reinforcing elements plus the additional width shown in the plans. 

If required, as determined by the Contractor, design and construct temporary shoring according to 

Section 562. 

For concrete panel and SRWU faced walls, provide a precast reinforced or a non-reinforced cast-in-place 

concrete leveling pad. Cure cast-in-place leveling pads at least 12 hours before placing wall panels. For 

all other walls, construct a leveling pad from crushed aggregate or the specified material, if shown in the 

plans. 

Construct minor concrete according to Section 601. 

Excavate wall foundations to within 4 inches horizontally and vertically from the staked location. Install 

reinforcement elements to within 2 inches vertically from the staked location. Bench the excavation as 

necessary to accommodate variable lengths of reinforcement according to the plans and approved 

drawings. 

Install underdrain systems and geocomposite sheet drain systems according to Section 605. 

Repair damage to galvanized coatings before installation according to Subsection 563.12(b). 

255.04 Wall Erection. Erect the wall according to the plans and approved drawings. Have a field 

representative from the wall system manufacturer on site during the startup of wall erection. Construct 

MSE walls to the tolerance shown in Table 255-1. 

162 
 

 

 

 

 

 

 

Section 255 

Connect reinforcement to facing, pull taut, and anchor far end before placing additional backfill. Do not 

place reinforcing elements below the corresponding connection elevations, unless approved as part of a 

utility installation detail. 

Table 255-1 

Construction Tolerance 

Facing Type Vertical, 

inch(1) (±) 

Horizontal, 

inch(2) (±) 

Horizontal 

Straight Edge 

Point Check, 

inch(3) (±) 

Precast concrete panel, 

segmental retaining wall units 0.5 0.5 0.75 

Welded wire, gabions 1 1 2 

(1) Wall vertical tolerance at top of wall for every 10 feet of wall height. For example, 5 feet wall height 

multiply 6.5×value. 

(2) Wall horizontal tolerance at top of wall for every 10 feet of wall height. 

(3) Maximum horizontal deviation at a point in the wall from a 10-foot metal straightedge placed 

horizontally or vertically on the theoretical plane of the design face. 

(a) Precast concrete panel-faced. Construct panels by the following: 

(1) Construct according to Section 578. Use concrete class A(AE). 

(2) Finish the front face of the panel with a Class 1 finish according to Subsection 552.14. Screed 

the rear face of the panel to eliminate open pockets of aggregate and surface distortions of more 

than 1⁄4 inch. Cast the panels on a flat area. Do not attach galvanized connecting devices or fasteners 

to the face panel reinforcement steel. 

(3) Clearly write on an unexposed face of each panel the date of manufacture, the production lot 

number, and the piece mark. 

(4) Handle, store, and ship units according to Subsection 578.08. 

(5) Manufacture units within the following tolerances: 

(a) Panel dimensions. Position of panel connection devices within 1 inch. All other dimensions 

within 3

⁄16 inch. 

(b) Panel squareness. Do not exceed 1⁄2 inch as determined by the difference between the two 

diagonals. 

(c) Panel surface finish. Do not exceed 1⁄8 inch for surface defects on smooth formed surfaces 

of 5 feet or more in length. Do not exceed 5

⁄16 inch for surface defects on textured-finished 

surfaces of 5 feet or more in length. 

(6) Concrete face panels having the following defects will be rejected: 

(a) Defects that indicate imperfect molding; 

(b) Defects indicating honeycombed or open texture concrete; 

163 
 

 

 

 

 

 

 

 

 

 

Section 255 

(c) Cracked or severely chipped panels; or 

(d) Color variation on front face of panel. 

Erect panels by lifting devices connected to the upper edge of the panel. 

Size the joint openings to prevent damage to facing panels during post-construction structure 

movement and to prevent loss of wall backfill materials. Construct the joint opening and install joint 

material according to the approved drawings. Cover joints on the backside of the panels with a 

12-inch-wide strip of geotextile filter. Overlap geotextile filter splices at least 4 inches. 

Hold the panels in position with temporary wedges or bracing during backfilling operations. 

(b) Wire-faced. Place facing and backing mats in successive horizontal rows as backfill placement 

proceeds. Do not use hardware cloth or geosynthetic material to retain backfill at the face of the wall 

unless the product is specifically approved for facing applications and part of the approved drawings. 

(c) Gabion-faced. Construct gabion structures according to Section 253. Lay reinforcement mesh 

horizontally on compacted fill and normal to the face of the wall. Connect the gabion facing unit to 

reinforcement mesh with spiral binders or tie wire at 4-inch nominal spacing with alternating single 

and double locked loops, or as detailed in the approved drawings. 

(d) SRWU. Place the first course of wall units on top of and in full contact with the leveling pad. Place 

the units side by side for the full length of the wall such that adjoining units are located with minimal 

gaps. Place units to ensure only the front face of the unit is visible. Check for proper elevation and 

alignment every two courses. Install connection devices and alignment devices as required by the 

approved drawings. Fill voids in and around units with unit fill as recommended by the manufacturer’s 

installation guidelines to meet the required connection strength. If the unit fill is required to meet 

connection strength specifications, completely fill each course of block before proceeding to the next 

course. Place reinforcement at a vertical spacing no more than two times the block depth or 24 inches, 

whichever is less. Remove excess material from the top of the units before installing each succeeding 

course. 

255.05 Backfilling. Backfill the reinforced zone with the specified material according to 

Subsection 209.09. Place facing fill or unit fill as shown in the approved drawings. Place select granular 

backfill from the back of the wall face, facing fill, or unit fill to the end of the reinforcement plus the 

additional width shown in the plans. Ensure that no voids exist below the reinforcement. Compact each 

lift according to Subsection 209.10, except use an approved lightweight mechanical or vibratory 

compactor within 36 inches of the wall face. Consolidate facing fill or unit fill by rodding or other 

approved means to produce a uniform, tight fill. Where the reinforced zone supports spread footings for 

bridges or other structural loads, compact the top 5 feet to at least 100 percent of the maximum density. 

Do not damage or disturb the facing or reinforcing elements. Do not operate equipment directly on top of 

the reinforcements. Place at least 6-inch loose lift of fill before operating rubber-tired equipment over the 

reinforcements. Limit equipment speeds to 5 miles per hour and limit turning maneuvers to a minimum. 

Install and maintain reinforcement taut, unwrinkled, and in full contact with the underlying surface. 

Correct damaged, misaligned, or distorted wall elements as directed before constructing subsequent layers. 

Backfill and compact behind the reinforced zone with the specified material according to 

Subsections 209.09 and 209.10. At the end of the day’s operation, slope the last lift of backfill away from 

164 
 

 

Section 255 

the wall face to direct surface runoff away from the wall. Do not allow surface runoff from adjacent areas 

to enter the wall construction area. 

255.06 Acceptance. See Table 255-2 for sampling, testing, and acceptance requirements. 

Material for MSE walls will be evaluated under Subsections 106.02 and 106.03. Submit a production 

certification with each shipment of facing units. 

Construction of MSE walls will be evaluated under Subsections 106.02 and 106.04. 

Concrete leveling pads will be evaluated under Section 601. 

Excavation and backfill will be evaluated under Section 209. 

Gabions will be evaluated under Section 253. 

Precast concrete elements will be evaluated under Section 578. 

Survey will be evaluated under Section 152. 

Temporary works will be evaluated under Section 562. 

Underdrain systems and geocomposite sheet drain systems will be evaluated under Section 605. 

Measurement 

255.07 Measure the Section 255 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

When measuring MSE walls by the square foot, measure the front face of wall excluding footings and 

leveling courses. 

When measuring select granular backfill within the reinforced zone by the cubic yard, measure in place. 

Payment 

255.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 255 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

165 
 

 

 

 

 

 

 

 

 

 

 

Table 255-2 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Source 

Select 

granular 

backfill 

(704.03) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Gradation − AASHTO 

T 27 & T 11 

1 per 

soil type 

Source of 

material Yes 

Before 

using 

in work 

Not required 

if using 

Governmentfurnished 

source 

Angle of 

internal 

friction 

−

AASHTO 

T 236 and 

Subsection 

704.03(a)(2) 

" " " " " 

Soundness 

using 

sodium sulfate 

− AASHTO 

T 104 " " " " " 

Plasticity 

index −

AASHTO 

R 58, T 89, 

& T 90 

" " " " " 

Resistivity(1) − AASHTO 

T 288 " " " " " 

pH(1),(2) − AASHTO 

T 289 " " " " " 

Sulfate 

content(1),(3) − AASHTO 

T 290 " " " " " 

Chloride 

content(1),(3) − AASHTO 

T 291 " " " " " 
 

 

 

 

 

 

 

 

 

Table 255-2 (continued) 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Production 

Select 

granular 

backfill 

(704.03) 

Measured & 

tested for 

conformance 

(106.04) 

Moisturedensity −

AASHTO 

T 99, 

Method C(4) 

1 per 

soil type 

Source of 

material Yes 

Before 

using 

in work 

−

Density −

AASHTO 

T 310 or 

other 

approved 

procedures 

1 per lift per 

75 linear 

feet of wall 

but not less 

than 2 per 

lift 

In-place No 

Before 

placing 

next lift 

−

(1) Required for MSE walls with metallic reinforcements. 

(2) Required for MSE walls with geosynthetic reinforcements. 

(3) Tests for sulfate and chloride content are not required if resistivity is greater than 5000 ohm centimeters. 

(4) At least 5 points per proctor. 
 

 

 

 

 

Section 256 

Section 256. — PERMANENT GROUND ANCHORS 

Description 

256.01 This work consists of providing and installing permanent drilled and grouted ground anchors. 

Material 

256.02 Conform to the following Subsections: 

Anchor tendons 

Galvanized coatings 

High-strength low-alloy structu

Neat hydraulic cement grout 

Steel pipe 

722.02 

717.07 

ral steel (bearing plates) 717.01(b)(3) 

701.04(a) 

717.06 

Construction Requirements 

256.03 Qualifications. Provide an engineer or geologist, drill foreperson, and drill operators with 

experience installing permanent ground anchors. At least 30 days before starting permanent ground anchor 

work, submit the following for approval: 

(a) Drill foreperson. A résumé for each drill foreperson describing at least 2 years’ experience 

supervising construction of ground anchors of similar lengths and scope to those shown in the plans 

and in similar geotechnical conditions described in the geotechnical report. Include experience as the 

direct supervisor responsible for on-site construction operations; 

(b) Drill operator. A résumé for each drill operator describing at least 1 year’s experience in the 

construction of ground anchors; 

(c) Professional engineer or geologist. A résumé for a professional engineer or professional geologist 

with at least 5 years’ experience in the design and construction of ground anchors to log ground anchor 

installation; and 

(d) Geotechnical engineer or geologist. If applicable, a résumé for a geotechnical engineer or 

engineering geologist working under the direct supervision of the professional engineer or professional 

geologist described in Subsection 256.03(c), to log ground anchor installation. Include at least 2 years’ 

experience in the design and construction of ground anchors. 

256.04 Submittals. At least 30 days before starting ground anchor work, submit the following according 

to Subsection 104.06: 

(a) Start date and schedule; 

(b) Method of excavation and ground anchor construction sequence to ensure site safety and maintain 

slope stability; 

(c) Plan and profile drawings showing contractor-located buried utilities according to 

Subsection 107.02(d) and locations of ground anchors relative to those utilities; 

168 
 

 

 

 

 

 

 

Section 256 

(d) Ground anchor types, sizes, horizontal and vertical spacings, total length and depths, installation 

angles from horizontal, ultimate tendon strengths for the range of material to be encountered, proposed 

drill hole diameter and the minimum bond zone length for factored design loads shown in the plans. 

Include calculations for minimum bond zone lengths; 

(e) Tendons, couplers, bearing plates, facing items, and additional hardware with the manufacturer’s 

SDS, product data sheets, specifications; 

(f) Manufacturer’s recommendations for tendon and hardware handling, storing, assembly, and 

working temperature ranges; 

(g) Grout type, mix design, mixing equipment, placement procedures, and 7-day grout compressive 

strength test results; 

(h) Procedures and material for repairing corrosion protection coatings in the field; 

(i) Drilling methods and equipment; 

(j) Drill hole diameters to achieve the specified pullout resistance; 

(k) Alternative drilling and grouting methods (such as grout additives or pressure grouting); 

(l) Additional material needed to achieve required bond capacities (such as grout socks and post-grout 

tubes); 

(m) Methods to ensure borehole stability during excavation and grout placement; 

(n) Ground anchor testing methods and equipment including type and capacity of reaction load 

system, drawings, supporting calculations for structural components of the ground anchor load test 

apparatus, and calculations for soil bearing and settlement below the reaction frame; and 

(o) Identification number and calibration test certification for each jack, pressure gauge, and electronic 

load cell. Clearly indicate the serial number of each component of the testing assembly on calibration 

graphs. Submit results from calibration tests conducted by an independent testing laboratory within 

the previous 60 days. 

256.05 Tendon Fabrication. 

(a) General. Size tendons to ensure: 

(1) The design load is no more than 60 percent of the minimum ultimate tensile strength of the 

tendon; and 

(2) The maximum test load is no more than 80 percent of the minimum ultimate tensile strength 

of the tendon. 

Use the anchor tendon type shown in the plans. Protect anchors and the anchor head assembly against 

corrosion using Class I Corrosion Protection as recommended in PTI, Guide Specification for PostTensioning Materials. 

169 
 

 

 

 

 

 

 

 

Section 256 

(b) Bond length. Determine the bond length necessary to develop the design load shown in the plans. 

Do not use a bond length less than the minimum bond length shown in the plans. Provide corrosion 

protection of the tendon bond length with a cement grout cover. 

Where encapsulation of the tendon is required, protect the tendon bond length from corrosion by 

encapsulating it in a grout-filled corrugated plastic or deformed steel tube or with a corrosion 

protection coating according to ASTM A775, A934, A153 or A143. Place the grout inside the tube 

either before or after the tendon is placed in the drill hole. Centralize the tendon within the tube with 

at least 1⁄8 inch grout cover.

(c) Centralizers. Use spacers along the tendon bond length of a multi-element tendon to separate each 

of the individual elements of the tendon. Use centralizers to ensure at least 1⁄2 inch of grout cover over 

the tendon bond length or tendon bond length encapsulation as appropriate. Use centralizers that do 

not impede the free flow of grout up the bore hole. Position centralizers no more than 5 feet from the 

top of the tendon bond length, no more than 12 inches from the bottom of the tendon bond length, and 

with center-to-center spacing of no more than 10 feet. 

Centralizers are not required on hollow-stem-augured tendons if the ground anchor is grouted through 

the auger and the hole is maintained full of a grout with a slump less than 9 inches during extraction 

of the auger. 

(d) Unbonded length. Provide the unbonded length as shown in the plans. 

(1) If the drill hole is grouted in one operation, provide corrosion protection of the unbonded length 

with a PVC sheath filled with corrosion-inhibiting grease, corrosion-inhibiting grout, or a 

heat-shrinkable tube internally coated with an elastic adhesive. 

If grease is used under the sheath, coat the unbonded tendon length, fill spaces between individual 

elements of multi-element tendon with grease, and provide measures to prevent grease from 

escaping at the ends of the sheath. 

If the sheath is grout filled, provide a separate bond-breaker along the unbonded length of the 

tendon. 

(2) If a grease-filled sheath corrosion protection is provided and the drill hole above the bond 

length is grouted after the ground anchor is locked off, grout the tendon inside a second sheath. 

Where restressable ground anchors are used, provide restressable anchorage compatible with the 

post-tensioning system provided. 

If multi-element tendons are used, properly seat the wedges according to the manufacturer’s 

recommendations for the post-tensioning system provided. 

(e) Bearing plates. Size the bearing plates according to the manufacturer’s specifications and ensure: 

(1) The bending stresses in the plate do not exceed the yield strength of the steel when a load equal 

to 95 percent of the minimum specified ultimate tensile strength of the tendon is applied; and 

(2) The average bearing stress of the bearing plate is no more than recommended in the PTI, Guide 

Specification for Post-Tensioning Materials. 

170 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Section 256 

Weld trumpet to bearing plate. Make the inside diameter of the trumpet at least the size of the hole 

in the bearing plate. Make the trumpet long enough to accommodate movements during stressing 

and testing. For multiple or single element tendons with encapsulation over the unbounded length, 

make the trumpet at least 24 inches beyond the structural fascia and soil backslope interface. Fill 

the trumpet of restressable ground anchors with corrosion-inhibiting grease. Provide a permanent 

Buna-N synthetic rubber seal between the trumpet and the unbonded length corrosion protection. 

Fill the trumpets of non-restressable ground anchors with grout after anchor load lock-off is 

accepted. Provide a 12-inch minimum tightly-fitting temporary seal between the trumpet and the 

unbonded length corrosion protection. 

256.06 Handling and Storing Material. Protect ground anchors and tendons from corrosion during the 

storage, fabrication, and handling before insertion in the borehole. Provide proper care to avoid prolonged 

exposure to the elements and to avoid mechanical or physical damage which would reduce or impair the 

future ability of the components to resist corrosive conditions encountered during the service life. Replace 

tendons exhibiting abrasions, cuts, welds, weld splatter, corrosion, or pitting. Repair or replace tendons 

exhibiting damage to encapsulation or sheathing. Degrease the bond length of tendons and remove solvent 

residue before installation. 

256.07 Installation. 

(a) Drilling. Drill ground anchor holes within 12 inches of the required location. Drill the longitudinal 

axis of the drill hole parallel to the longitudinal axis of the tendon. Install the ground anchor within 

3 degrees of the required inclination from horizontal. Install the ground anchor with a horizontal angle 

within 3 degrees of a line drawn perpendicular to the plane of the structure. Do not extend ground 

anchors beyond the right-of-way or easement limits as shown in the plans. Do not damage existing 

utilities in the project site. 

Insert the tendon in the drill hole to the required total length without driving or forcing. If the tendon 

cannot be completely inserted, remove the tendon and clean or redrill the hole to allow insertion. 

Provide a professional engineer or professional geologist to observe advancement of ground anchors. 

Record material types, drilling depth of condition and material changes, drilling down-force pressure, 

production rates, and estimated water flows encountered during drilling. Submit drill logs to the CO 

at the end of each shift. 

(b) Grouting. 

(1) Equipment. Use a positive displacement grout pump equipped with a pressure gauge able to 

measure pressures of at least 150 pounds per square inch or twice the required grout pressure, 

whichever is greater. Provide a secondary pressure capability of at least 1000 pounds per square 

inch to clean out grout or dirt blockages in hoses, tremie tubes, or casings. Use a high speed, high 

shear grout mixer with a minimum operating speed of 1500 revolutions per minute to produce a 

well-mixed grout that is free of lumps or other indications of prior cement hydration. Provide 

holding tanks with a variable speed high-efficiency paddle that maintains a thoroughly mixed grout 

for pumping. 

(2) Procedures. Grout tendons into drill holes using a neat hydraulic cement grout placed in one 

continuous operation. Inject the grout from the lowest point of the drill hole. The grout may be 

placed either before or after insertion of the tendon. Record the quantity of the grout and the grout 

171 
 

 

 

 

 

 

 

 

 

 

 

Section 256 

pressure for each ground anchor. Control the grout pressures to avoid excessive heaving or 

fracturing. Inject grout within 45 minutes of adding the cement to the water or within 15 minutes 

after mixing when the ambient temperature is 90 °F or higher. Do not allow the grout temperature 

to exceed 90 °F. 

Except as indicated below, the grout above the top of the bond length may be placed at the same 

time as the bond length grout, but do not place it under pressure. Do not place grout at the top of 

the drill hole in contact with the back of the structure or the bottom of the trumpet. 

Use pressure grouting for grout protected tendons anchored in rock. After sealing the drill hole, 

pressure inject grout until a 50-pound per square inch grout pressure at the top of the drill hole is 

maintained for 5 minutes. 

(c) Finishing. After grouting of tendon is complete, fill the grout tube with grout if it will remain in 

the hole. Wait at least 3 days before loading the tendon. 

Extend the corrosion protection surrounding the unbonded length up beyond the bottom seal of the 

trumpet or 12 inches into the trumpet if no trumpet seal is provided. 

Trim the corrosion protection surrounding the tendon so it does not contact the bearing plate of the 

anchor head during testing and stressing. 

Place the bearing plate and anchorhead so the axis of the tendon is within three degrees of 

perpendicular to the bearing plate and the axis of the tendon passes through the center of the bearing 

plate without bending the tendon. 

If grout protected tendons or corrosion protection coated encapsulations are used, electronically isolate 

the bearing plate, anchorhead, and trumpet from the surrounding concrete, soldier pile, or metallic 

element embedded in the structure. 

Place trumpet grease during construction. Place trumpet grout after the ground anchor has been tested 

and stressed. 

Completely cover anchorages permanently exposed to the atmosphere with a corrosion-inhibiting 

grease or grout. 

Inspect the trumpet and anchorage grout levels 24 hours after initial grout placement. If needed, refill 

the trumpet or anchorage with grout. 

256.08 Testing and Stressing. 

(a) Testing equipment. Conform to the following: 

(1) Dial gauges. Use two dial gauges that can measure to 0.001 inch and has sufficient travel to 

measure the theoretical elastic elongation of the total length at the maximum test load without 

resetting, accounting for elongation in both the bonded and unbonded zones. Align the gauges 

parallel to the axis of the anchor or pile and support the gauges independently from the hydraulic 

jack, ground anchor, or reaction frame. 

172 
 

 

 

 

 

 

 

 

 

 

Section 256 

(2) Hydraulic jack, pressure gauge, and load cell. Apply test loads with a hydraulic jack and 

measure with a calibrated pressure gauge and electronic load cell. Use a hydraulic jack and 

pressure gauge with a pressure range no more than twice the anticipated maximum test pressure 

and calibrated as a unit by an independent firm within 90 days of the start of work. Use a pressure 

gauge graduated in 100-pound per square inch increments or less. Use a jack with ram travel 

sufficient to allow testing without resetting. 

(3) Reference gauge. Calibrate the reference gauge with the test jack and pressure gauge. Keep 

the reference gauge at the project site. 

(4) Reaction frame. Provide a reaction frame designed by a professional engineer to meet the 

requirements of the site, resist the maximum test loads, and prevent excessive deformation of the 

bearing surface. 

(b) Stressing. Place testing equipment over the ground anchor tendon to ensure the jack, bearing 

plates, load cells, and stressing assembly are axially aligned with the tendon and the tendon is centered 

within the equipment. Do not apply loads greater than 80 percent of the minimum ultimate tensile 

strength of the tendon. 

Place the reference pressure gauge in series with the pressure gauge, jack, and load cell so they need 

not be unloaded and repositioned during a test. Raise the load from one increment to another. Hold 

the load just long enough to measure and record the ground anchor movement to the nearest 0.001 inch 

with respect to an independent fixed reference point. Repump the jack as necessary to maintain a 

constant load. Monitor the load with a pressure gauge. If the load measured by the pressure gauge and 

the load measured by the reference pressure gauge differ by more than 10 percent, recalibrate the jack, 

pressure gauge, and reference pressure gauge. 

Monitor the pile during stressing of ground anchor tendons. Immediately stop the test if the pile 

deflects more than 1 inch inward. 

Provide certified calibrations for torque wrenches, hydraulic jacks, and related equipment dated no 

more than 90 days before use on the project. Verify the calibration of torquing or jacking equipment 

upon request. 

(1) Performance tests. Performance tests include the installation of the sacrificial ground anchor. 

The CO will designate locations for sacrificial ground anchors for performance tests. Test 

according to Tables 256-1 and 256-2. 

173 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Section 256 

Table 256-1 

Performance Test Load Sequence 

Test 

Sequence 

Test Load Increment 

AL(1) 0.25FDL(2) 0.50FDL(2) 0.75FDL(2) 1.00FDL(2) 

(Load-Hold Test) 

Adjust to 

Lock-Off 

Load 

1 Yes Yes – – – – 

2 Yes Yes Yes – – – 

3 Yes Yes Yes Yes – – 

4 Yes Yes Yes Yes 10 minutes(3) – 

5 Yes – – – – Yes 

(1) AL = Alignment load (no greater than 5 percent of FDL (0.05FDL) applied to the ground anchor before setting the 

movement recording devices. Zero dial gauges after the first setting of AL). 

(2) FDL = Factored design load.

(3) Hold the load to within 2 percent and measure and record the ground anchor movement during the load-hold test 

at 1, 2, 3, 4, 5, 6, and 10 minutes. When the ground anchor movement between 1 minute and 10 minutes exceeds 

0.04 inch, maintain the maximum test load an additional 50 minutes and record the movement at 20, 30, 40, 50, and 

60 minutes. 

(2) Proof tests. Test according to Tables 256-2 and 256-3. 

Table 256-2 

Proof Test Load Sequence 

Test 

Sequence 

Test Load Increment 

AL(1) 0.25FDL(2) 0.50FDL(2) 0.75FDL(2) 1.00FDL(2) 

(Load-Hold Test) 

Adjust to 

Lock-Off 

Load 

1 Yes Yes Yes Yes 10 minutes(3) – 

2 Yes – – – – Yes 

(1) AL = Alignment load. See alignment load note in Table 256-1. 

(2) FDL = Factored design load.

(3) Hold the load to within 2 percent and measure and record the ground anchor movement during the load-hold test at 

1, 2, 3, 4, 5, 6, and 10 minutes. When the ground anchor movement between 1 minute and 10 minutes exceeds 0.04 inch, 

maintain the maximum test load an additional 50 minutes, recording movement at 20, 30, 40, 50, and 60 minutes. 

(c) Lock-off. Adjust the load to the specified lock-off load shown in the plans and transfer the load to 

the anchorage device. After transferring the load and before removing the jack, measure the lift-off 

load. If the load is not within 10 percent of the specified lock-off load, reset the anchorage and 

remeasure the lift-off load. Repeat as necessary. 

256.09 Test Results and Reporting. Identify each ground anchor with a letter and a number based on the 

row and level respectively. Submit a plan sheet of the wall elevation with the proposed ground anchor 

identification methodology showing the row letter and level number. Plot the ground anchor movement 

versus the maximum load for each test sequence as shown in Tables 256-1 and 256-2 and plot the residual 

movement of the tendon at each alignment load versus the highest previously applied load. 

Provide preliminary results to the CO for each ground anchor tested before testing personnel leave the site 

at the end of each testing day. Submit detailed verification and proof test load and deflection data in a 

tabular format within 5 days. Submit a graph that plots total ground anchor head movement versus load, 

the A-line, and the B-line. The A-line is defined as 0.8 multiplied by the theoretical free test length elastic 

elongation. The B-line is defined as the theoretical free test length elastic elongation plus 0.50 multiplied 

by the theoretical bonded length elastic elongation. Allow 5 days for the CO to conduct a review of the 

data and approve ground anchor installation. 

174 
 

 

 

Section 256 

Replace ground anchors with unacceptable performance or proof test results. Do not retest failed ground 

anchors unless post-grouting has been performed. 

256.10 Acceptance. See Table 256-3 for sampling, testing, and acceptance requirements. 

Material for ground anchors will be evaluated under Subsections 106.02 and 106.03. Submit a production 

certification for the ground anchor material. 

Construction of ground anchors will be evaluated under Subsections 106.02 and 106.04. 

Installed ground anchors will be evaluated based on one of the following performance or proof test results: 

(a) After a 10-minute hold, the ground anchor carries the maximum test load with less than 0.04 inch 

of movement between 1 and 10 minutes and the total movement at the maximum test load exceeds 

80 percent of the theoretical elastic elongation of the unbonded length. 

(b) After a 60-minute hold, which is only conducted after 10-minute hold test fails, the ground anchor 

carries the maximum test load with a movement rate that does not exceed 0.08 inch per log cycle of 

time and the total movement at the maximum test load exceeds 80 percent of the theoretical elastic 

elongation of the unbonded length. 

Measurement 

256.11 Measure the Section 256 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable: 

Do not measure linear footage or quantity of sacrificial ground anchors. 

Do not measure failed performance tests. 

Do not measure anchors that failed proof testing. 

Payment 

256.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 256 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

175 
 

 

 

 

Table 256-3 

Sampling, Testing, and Acceptance Requirements 

Material or 

Product 

(Subsection) 

Type of 

Acceptance 

(Subsection) 

Characteristic Category Test Methods 

Specifications 

Sampling 

Frequency 

Point of 

Sampling 

Split 

Sample 

Reporting 

Time Remarks 

Source 

Aggregate 

quality 

(fine) 

(703.01) 

Measured & 

tested for 

conformance 

(106.04 & 

105) 

Quality – AASHTO 

M 6 

1 per 

material 

type 

Source of 

material Yes Before producing – 

Mix Design 

Neat 

hydraulic 

cement 

grout(1) 

(701.04(a)) 

Measured & 

tested for 

conformance 

(106.04) 

Flow – ASTM 

C939 

1 per 

mix design " Yes, if requested " – 

Compressive 

strength 

(7-day) 

– 

AASHTO 

T 106 

ASTM C109 

" " " " – 

Production 

Performance 

test ground 

anchor 

Measured & 

tested for 

conformance 

(106.04) 

Deformation – Subsection 

256.08(b)(1) 

5% 

or 3 

minimum 

Installation No 5 days – 

Proof test 

ground anchor " " – Subsection 256.08(b)(2) 

Each 

anchor " " " – 

(1) Make grout cubes for testing from random batches of grout as directed. Normally, strength testing for permanent ground anchors will not be 

required as system performance will be measured by load holding each anchor. Grout cube testing will be required if admixtures are used or 

irregularities occur in anchor testing. 
 

 

 

 

Section 257 

Section 257. — CONTRACTOR-DESIGNED RETAINING STRUCTURES 

Description 

257.01 This work consists of designing various types of retaining structures, including walls, reinforced 

soil slopes, and rockeries. 

Material 

257.02 Conform to the following Sections: 

Driven piles 

Gabions and revet mattresses 

Mechanically stabilized earth w

Micropiles 

Permanent ground anchors 

Reinforced concrete retaining w

Reinforced soil slopes 

Rockery, special rock embankm

Soldier pile retaining walls 

Soil nail retaining walls 

alls 

alls 

ent, and rock buttress 

551 

253 

255 

567 

256 

258 

261 

252 

254 

259 

Construction Requirements 

257.03 Qualifications. Provide a wall designer who is a professional engineer proficient in the applicable 

design field and licensed in the state where the project will be constructed. At least 30 days before starting 

the design of retaining structures, submit examples of at least three similar retaining structures designed 

by the wall designer. Submit photos of each retaining structure with narrative descriptions of design 

method used, materials used, proprietary systems used (if any), constructability issues, and other pertinent 

information. Include the name, address, and telephone number for project owners. 

257.04 Submittals. At least 30 days before starting Contractor-designed retaining structure construction, 

submit the following according to Subsection 104.06: 

(a) Plan and elevation drawings for each structure containing the following: 

(1) A plan view of the structure showing: 

(a) Horizontal offset from the construction centerline to the face of the structure at defining 

points along the base. Include begin and end stations; 

(b) Location, length, coverage ratio, and type of reinforcement or anchorage as applicable 

(such as strip, mesh, grid, geosynthetic fabric, and anchor); 

(c) Centerline and size of drainage structures, drainage pipe, and other utilities behind, passing 

through, or passing under the structure; and 

(d) Location, length, and offset from the face of wall to guardrail, guardwall, or parapet 

structures. 

177 
 

 

 

Section 257 

(2) An elevation view of the structure showing: 

(a) Elevation and station at horizontal and vertical break points and at least every 50 feet along 

the top of the structure at the face; 

(b) Elevation and station at the top of leveling pads and footings, at the top and tip of piling, 

and at least every 50 feet along the structure base; 

(c) Length and type of reinforcement, anchorage, structure module, and lagging; 

(d) Distance and elevation along the structure face to all steps in the base, footings, leveling 

pads, or lagging; 

(e) Distance along the structure face to where changes in reinforcement or anchor lengths 

occur; 

(f) Construction joints; 

(g) Original and final ground-line; 

(h) 1H:1V scale; and 

(i) Location, length, minimum slope for drainage, and type of structure underdrain system. 

(3) A typical cross-section view showing: 

(a) Type and depth of facing elements and structural connections to reinforcing and anchorage 

elements; 

(b) Structure batter or face slope; 

(c) Length, spacing, and type of reinforcement, anchorage, structure module and 

corresponding limits of excavation, and reinforced fill placement zones; 

(d) Location of guardrail or guardwall features or parapet structures. Include embedment 

depths, offset from structure facing, connection details with structure reinforcement or 

anchorage, and blockouts or other provisions to prevent damage to wall elements during 

guardrail construction; 

(e) Original and final ground-line, including right-of-way limits; and 

(f) Estimated or known location of subsurface soil and rock units. 

(4) General construction notes; 

(5) Horizontal and vertical curve data affecting the structure, including match lines or other details 

to relate structure stationing to centerline stationing; and 

(6) Material list and summary of pay item quantities. 

178 
 

 

Section 257 

(b) Dimensions and schedules of reinforcing steel. Include reinforcing bar bending details, dowels, 

studs, or both for attaching the facing; 

(c) Details and dimensions for foundations and leveling pads. Include steps in the footings or leveling 

pads; 

(d) Details and dimensions for: 

(1) Panels, modules, soldier piles, and lagging necessary to construct the structure; 

(2) Reinforcing steel in structural elements; 

(3) Details of proposed splices in reinforcements; 

(4) Location of mesh, strip attachment, or anchor devices embedded in facing panels; 

(5) Anchor no-load lengths, anchor bond lengths, anchor spacing, anchor angles and skews, 

centralizers, and anchor sheathing and corrosion protection; and, 

(6) Piles, pile spacing, pile embedment depth, pile installation method, and pile corrosion 

protection. 

(e) Details for the installation of structure drainage and underdrain systems; 

(f) Details for constructing structures around drainage features, utilities, lighting foundations, traffic 

barriers, and other obstructions; 

(g) Details for terminating structures and adjacent slope construction; 

(h) Architectural treatment details; 

(i) Design notes, a description of symbols, terminology, and computer programs used in the design of 

the structure; specify the bearing pressure beneath the structure footing, reinforced soil zone, or piles; 

(j) Design criteria, loads, load and resistance factors, and soil, rock, and reinforcement parameters for 

each structure.; and 

(k) Design calculations, assessment of temporary excavation stability, internal and external stability 

of earth retaining structures and reinforced soil slopes, joint, splice, and facing connection capacities, 

and relevant references for data used in the design. 

Submit a checklist showing that each item specified in these requirements has been addressed in the 

design. 

Update drawings when plan dimensions are revised due to field conditions or for other reasons. 

257.05 General. Ensure that the wall designer and wall material suppliers take full responsibility for the 

success of the components provided by each party, and do not qualify the responsibility for the design 

information or calculations provided by the wall designer. Indemnify the Government from claims for 

infringement of proprietary rights by others without the consent of the patent holders or licensees. 

179 
 

Section 257 

Survey according to Section 152 and verify the limits of structure installation. 

Arrange and conduct a pre-design conference following selection of the structure designer or supplier and 

before design work starts to discuss structure selection, constructability, design parameters, methods, and 

limitations. Include the CO, subcontractors, supplier, and the supplier’s design engineer. 

257.06 Design and Construction. Unless otherwise stated, design retaining structures according to 

AASHTO, LRFD Bridge Design Specifications. Design and construct retaining structures according to 

the approved drawings, and the following as applicable: 

(a) Rockeries. Conform to Section 252. Design according to FHWA-CFL/TD-06-006, Rockery 

Design and Construction Guidelines, November 2006. 

(b) Gabions. Conform to Section 253. 

(c) Soldier pile retaining walls. Conform to Section 254. 

(d) MSE walls. Conform to Section 255. 

(e) Permanent ground anchors. Conform to Sections 256 and 552. 

(f) Reinforced concrete retaining walls. Conform to Section 258. 

(g) Soil nail retaining walls. Conform to Section 259. 

(h) Reinforced soil slopes. Conform to Section 261. Design according to FHWA-NHI-10-025, 

Design and Construction of Mechanically Stabilized Earth Walls and Reinforced Soil Slopes – Volume 

II. 

(i) Micropiles. Conform to Section 567. 

257.07 Acceptance. Design of the retaining structures will be evaluated under Subsection 106.02 and the 

applicable Sections listed in Subsection 257.06. 

Survey will be evaluated under Section 152. 

Measurement 

257.08 Measure the Section 257 pay items listed in the bid schedule according to Subsection 109.02. 

Payment 

257.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 257 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for Contractor-designed retaining walls by the lump sum will be paid as follows: 

(a) 50 percent of the pay item amount will be paid after the design submittal is approved. 

180 
 

Section 257 

(b) An additional 25 percent of the pay item amount will be paid after 50 percent of the retaining wall 

construction is completed. 

(c) The remaining portion of the pay item amount will be paid after retaining wall construction is 

completed. 

181 
 

 

 

Section 258 

Section 258. — REINFORCED CONCRETE RETAINING WALLS 

Description 

258.01 This work consists of constructing reinforced concrete retaining walls. 

Material 

258.02 Conform to the following Subsections: 

Geocomposite drain 

Reinforcing steel 

Sealants, fillers, and seals 

Soil and soil-aggregate materials 

714.02 

709.01 

712.01 

704.01 

Construction Requirements 

258.03 General. Survey according to Section 152 and verify the limits of wall installation. Design and 

construct temporary works according to Section 562. Conform to Section 257 for Contractor-designed 

reinforced concrete retaining walls. 

Excavate and backfill according to Section 208. 

258.04 Reinforcing Steel. Submit order lists and bending diagrams according to Subsection 104.06. 

Provide and place reinforcing steel according to Section 554. 

258.05 Structural Concrete. Provide, place, finish, and cure structural concrete according to Section 552. 

258.06 Backfilling. Install geocomposite sheet drain system according to Subsection 605.05. Backfill the 

area behind the wall with structural backfill according to Subsection 208.09. Compact each lift according 

to Subsection 208.10, except use an approved lightweight mechanical or vibratory compactor within 

36 inches of the wall. 

Do not place structural backfill against concrete until 80 percent of the design strength is attained. 

258.07 Acceptance. Material for reinforced concrete retaining walls will be evaluated under 

Subsections 106.02, 106.03, and 106.04. 

Construction of reinforced concrete retaining walls will be evaluated under Subsections 106.02 and 

106.04. 

Concrete will be evaluated under Section 552. 

Reinforcing steel will be evaluated under Section 554. 

Excavation and backfill will be evaluated under Section 208. 

Survey will be evaluated under Section 152. 

Temporary works will be evaluated under Section 562. 

182 
Section 258

183

Measurement

258.08 Measure the Section 258 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring retaining walls by the square foot, measure by the front face of wall excluding footings.

Payment

258.09 The accepted quantities will be paid at the contract price per unit of measurement adjusted 

according to Subsection 106.05 for the Section 258 pay items listed in the bid schedule. Payment will be 

full compensation for the work prescribed in this Section. See Subsection 109.05. 

Payment for reinforced concrete retaining wall will be made at a price determined by multiplying the 

contract price by the material pay factor. The material pay factor is calculated as follows:

PFmaterial = 1 - 0.5 (1-PF) 

where:

PFmaterial = Material pay factor

PF = Pay factor for concrete as determined under Section 552. 
Section 259

184

Section 259. — SOIL NAIL RETAINING WALLS

Description

259.01 This work consists of constructing soil nail retaining walls. 

259.02 Definition. For soil nail retaining walls, a lift is defined as a stable height of unsupported 

excavation before application of shotcrete, typically midpoint between rows of soil nails. 

Material 

259.03 Conform to the following Subsections: 

Bolts and nuts 717.01(d)

Centralizers and spacers 722.02(e)

Geocomposite drain 714.02

Neat hydraulic cement grout 701.04(a)

Soil nails 722.04

Soil and soil-aggregate materials 704.01

Structural carbon steel (bearing plates) 717.01(a)(4)

Welded stud shear connectors 717.05

Construction Requirements

259.04 Qualifications. Provide a professional engineer, an on-site supervisor, and installation personnel 

with experience installing and testing soil nails. At least 30 days before starting soil nail retaining wall 

work, submit a résumé and copies of applicable certifications for each individual describing their 

experience on at least five soil nail retaining wall projects of similar complexity within the past 5 years

for approval. Include project names, locations, and contact information for project owners.

259.05 Submittals. At least 30 days before starting soil nail retaining wall work, submit the following 

according to Subsection 104.06:

(a) Start date;

(b) Method of excavation to ensure wall and slope stability; 

(c) Retaining wall construction sequence;

(d) Soil nail types, sizes, spacings, depths, and installation angles, bond zone lengths, and ultimate 

tendon strengths for the range of material to be encountered; 

(e) Tendons, couplers, bearing plates, facing items, and additional hardware with the manufacturer’s 

product technical data sheets, specifications, catalog cuts, and mill certificates;

(f) Manufacturer’s recommendations for tendon and hardware handling, storing, assembly, and 

working temperature ranges;
Section 259

185

(g) Grout type, mix design, mixing equipment, placement procedures, and 3-day and 28-day grout 

compressive strength test results;

(h) Procedures and material for repairing corrosion protection coatings in the field and for applying 

epoxy finish coatings on end hardware;

(i) Drilling methods and equipment; 

(j) Drill hole diameter to achieve the specified pullout resistance;

(k) Alternative drilling and grouting methods (such as grout additives);

(l) Additional material needed to achieve required bond capacities (such as grout socks); 

(m) Methods to ensure borehole stability during excavation and grout placement; 

(n) Soil nail testing methods and equipment. Include type and capacity of reaction load system, load 

test increments, drawings, and supporting calculations for structural components of the soil nail load 

test apparatus; and

(o) Identification number and calibration test certification for each jack, pressure gauge, and electronic 

load cell. Clearly indicate the serial number of each component of the testing assembly on calibration 

graphs. Submit results from calibration tests conducted by an independent testing laboratory within 

the previous 60 days. 

259.06 General. Conform to Section 257 for Contractor-designed soil nail retaining walls. Survey 

according to Section 152 and verify the limits of wall installation.

Clear the work area of vegetation and obstructions according to Sections 201 and 203. Excavate according 

to Section 209 for the wall in staged lifts concurrent with soil nail installation and shotcrete placement. 

Do not allow the exposed unsupported final excavation face cut height to exceed the vertical soil nail 

spacing plus the required reinforcing lap or the short-term stand-up height of the ground, whichever is 

less. Do not excavate to the next lower lift until soil nail installation, reinforced shotcrete placement, 

attachment of bearing plates and nuts, and soil nail testing have been completed and approved for the 

current lift. Cure grout and shotcrete at least 72 hours or attain the specified 3-day compressive strength 

before excavating the next underlying lift. Application of the shotcrete may be delayed up to 24 hours if 

it can be demonstrated the delay will not adversely affect the excavation face stability.

Handle and store material according to Subsection 256.06. 

259.07 Tendon Fabrication. Provide tendons designed to carry loads consistent with the approved 

drawings. Provide threaded tendon ends so they can withstand the approved test loads in addition to 

accommodating the attachment of the bearing plate, beveled washer, nut, or other appurtenances. Limit 

coupling of tendons to two per installation. Use couplers manufactured with a center stop to ensure equal 

length of thread connects each section. Do not use couplers that interfere with the flow of grout. Protect 

couplings from corrosion using the same corrosion protection used on the soil nail tendon assembly. Use 

centralizers to position the tendon within 1 inch of the center of the drill hole. Use centralizers that do not 

impede the free flow of grout into the drill hole. Position centralizers within 24 inches from the top and 
Section 259

186

bottom of the tendon and with center-to-center spacing of 10 feet or less. Secure centralizers to the tendon 

to prevent shift during handling or inserting into the drill hole.

259.08 Installation. 

(a) Drilling. Drill soil nail holes at the required locations and orientations. Use drilling equipment and 

methods suitable for the ground conditions. Do not use water, drilling slurry, or other fluids for drilling 

or removing cuttings. 

Insert the soil nail tendon into the hole. Clean or redrill holes if the tendon with centralizers cannot be 

completely inserted without forcing or driving.

(b) Grouting. Use a positive displacement grout pump according to Subsection 256.07(b)(1).

Grout tendons into holes using a neat hydraulic cement grout. Mix grout as recommended by the 

cement supplier at the specified water-to-cementitious material ratio. Inject grout within 45 minutes 

of adding the cement to the water or within 15 minutes after mixing when the ambient temperature is 

90 °F or higher. Do not allow the grout temperature to exceed 90 °F.

Grout the hole within 2 hours of completing drilling. 

Inject the grout at the lowest point of each hole. Place primary and secondary grout stages in one 

continuous operation. Keep the outlet end of the grout tube below the surface of the grout as the tube 

is withdrawn to prevent voids. Control grout pressures to avoid ground heaving or fracturing. Record 

the quantity of injected grout and the grout pressure for each soil nail installation. After grouting is 

complete, fill the grout tube with grout if it will remain in the hole.

Maintain the temporary unbonded length of proof test soil nails open for later grouting. If the unbonded 

test length of production proof test soil nails cannot be satisfactorily grouted after testing, install a new 

soil nail in its place.

259.09 Testing and Stressing. 

(a) Testing equipment. Provide equipment conforming to Subsection 256.08(a).

(b) Stressing. Place stressing equipment over the soil nail so that the jack, bearing plates, load cells, 

and stressing assembly are axially aligned with the tendon and the tendon is centered within the 

equipment. Do not apply loads greater than 80 percent of the minimum guaranteed ultimate tensile 

strength of the tendon for Grade 150 bars, or 90 percent of the minimum guaranteed ultimate tensile 

strength of the tendon for Grade 60 or 75 bars. Do not test soil nails until the soil nail grout and 

shotcrete facing have cured for at least 72 hours and attained the specified 3-day compressive strength.

Place the reference pressure gauge in series with the pressure gauge and jack so they need not be 

unloaded and repositioned during a test. Raise the load from one increment to another. Hold the load 

for the required time starting immediately after the load is applied and record the soil nail head 

movement to the nearest 0.001 inch with respect to an independent fixed reference point. Repump the 

jack as necessary to maintain a constant load. Monitor the load with a pressure gauge. If the load 

measured by the pressure gauge and the load measured by the reference pressure gauge differ by more 

than 10 percent, recalibrate the jack, pressure gauge, and reference pressure gauge.
Section 259

187

(1) Verification test. Perform sacrificial verification tests at locations shown in the plans or as 

directed.

Provide verification test soil nails with a minimum unbonded length of 3 feet and a minimum 

bonded length of 10 feet. Grout with the same methods, equipment, and materials as will be used 

for the production nails. 

Use the following formula to determine the maximum bonded length for Grades 60 or 75 steel: 

 

Use the following formula to determine the maximum bonded length for Grade 150 steel: 

 

where:

LB VTmax = Maximum verification test soil nail bonded length (ft) 

CRTY = Reduction coefficient for mild grade steel = 0.9 for grades 60 or 75 bars 

CRTU = Reduction coefficient for high strength steel = 0.8 for grade 150 bars

fy = Yield strength of test tendon for mild steel (psi) 

fu = Ultimate tensile strength of test tendon for high-strength steel (psi)

At = Cross-sectional area of the test tendon (in2) 

RPO = Nominal pullout resistance (per unit length) of soil nail = π × qu × Ddh

Determine the design test load by the following equation: 

VTL = LB VT × RPO

where:

VTL = Verification test load (lb) 

LB VT = Bonded test length (ft) as determined from test residual elongation

Provide a larger bar size if necessary for safety. Test according to Table 259-1 and see Table 259-5

for acceptance criteria.
Section 259

188

Table 259-1 

Verification Test Load Schedule

Test Load Increment Hold Time

(minutes)(2) 

AL(1) 1 (Record at 0, 1)

0.10VTL 10 (Record at 0, 1, 2, 4, 5, 10)

0.20VTL 10 (Record at 0, 1, 2, 4, 5, 10)

0.30VTL 10 (Record at 0, 1, 2, 4, 5, 10)

0.40VTL 10 (Record at 0, 1, 2, 4, 5, 10)

0.50VTL 10 (Record at 0, 1, 2, 4, 5, 10)

0.60VTL 10 (Record at 0, 1, 2, 4, 5, 10)

0.70VTL 10 (Record at 0, 1, 2, 4, 5, 10)

0.80VTL (Creep Test) 60 (Record at 0, 1, 2, 4, 5, 10, 20, 30, 50, 60)

0.90VTL or failure 10 (Record at 0, 1, 2, 4, 5, 10)

1.00 VTL or failure (Maximum acceptance load) 10 (Record at 0, 1, 2, 4, 5, 10)

AL(1) 1 (Record at 0, 1)

(1) No greater than 2.5 percent of VTL (0.025VTL) applied to the soil nail before setting the movement 

recording devices. Zero dial gauges after the first setting of AL.

(2) Hold the load to within 2 percent of the test load increment and measure.

Provide a written report confirming soil nail geometry, construction, testing details, and 

verification test results for approval before installing production soil nails.

(2) Proof tests. The CO will designate production soil nails for proof testing, including 5 percent 

of the nails in a row and at least one per each day of production. 

Provide production proof test soil nails with a minimum temporary unbonded length of 3 feet and 

a minimum bonded length of 10 feet.

Use the following formula to determine the maximum bonded length for Grades 60 or 75 steel: 

 

Use the following formula to determine the maximum bonded length for Grade 150 steel: 

 

where:

LB PTmax = Maximum verification test soil nail bonded length (ft) 

CRTY = Reduction coefficient for mild grade steel = 0.9 for grades 60 or 75 bars 

CRTU = Reduction coefficient for high strength steel = 0.8 for grade 150 bars

fy = Yield strength of test tendon for mild steel (psi) 

fu = Ultimate tensile strength of test tendon for high-strength steel (psi)

At = Cross-sectional area of the test tendon (in2) 
Section 259

189

RPO = Nominal pullout resistance (per unit length) of soil nail = π × qu × DDH 

qu = Bond strength 

DDH = Drill hole diameter

Determine the design test load by the following equation: 

PTL = LB PT × RPO × 0.75 

where:

PTL = Proof test load (lb) 

LB PT = Bonded test length (ft) as determined from test residual elongation

Test according to Table 259-2 and see Table 259-6 for acceptance criteria.

Table 259-2 

Proof Test Load Schedule

Test Load Increment Hold Time

(minutes)

AL(1) 1 (Record at 0, 1)

0.10PTL(2) Until movement stabilizes(3)

0.30PTL(2) " 

0.50PTL(2) " 

0.70PTL(2) " 

0.80PTL(2) " 

1.00PTL (Creep Test) 60(4)

AL(1) 1 (Record at 0, 1)

(1) No greater than 2.5 percent of PTL (0.025PTL) applied to the soil nail before setting the movement 

recording devices. Zero dial gauges after the first setting of AL 

(2) Times are measured at the and after the target load value has been achieved in each increment.

(3) Hold each load increment for 10 minutes and to record the soil nail movement at 1, 2, 5, and 10 

minutes if the movement does not stabilize after 1 minute.

(4) Hold the load to within 2 percent and measure and record soil nail movement at 1, 2, 3, 5, 6, and 

10 minutes. When the soil nail movement between 1 and 10 minutes exceeds 0.04 inch, continue 

measuring and recording soil nail movement at 20, 30, 50, and 60 minutes. 

(c) Test results and reporting. Provide preliminary results to the CO for each soil nail tested before 

testing personnel leave the site. Submit detailed verification and proof test load and deflection data in 

a tabular format. Submit a graph that plots total soil nail movement versus load, the A-line, and the 

B-line. The A-line is defined as 0.8 multiplied by the theoretical free test length elastic elongation. 

The B-line is defined as the theoretical free test length elastic elongation plus 0.50 multiplied by the 

theoretical bond length elastic elongation. Allow 5 days for the CO to conduct a review of the data 

and approve ground anchor installation. 

259.10 Wall Drainage Network. Install required elements of the wall drainage network before applying 

shotcrete to each lift.

Install geocomposite sheet drain system according to Subsection 605.05. Center geocomposite sheet 

drains between soil nail columns with the geotextile filter side against the ground. Install additional sheet 

drains at wet locations and as requested. Secure sheet drains to the excavated face to prevent shotcrete 
Section 259

190

from contaminating the ground side of the geotextile. Construct sheet drain splices according to the 

manufacturer’s recommendations. 

Install underdrains at the bottom of the wall according to Section 605. 

259.11 Wall Construction. Place welded wire steel mesh and reinforcing steel according to Section 554. 

Construct a shotcrete construction facing according to Section 566. Completely fill ungrouted zones of 

soil nail drill holes or other voids with shotcrete.

Attach a bearing plate and nut to each soil nail head. Uniformly seat the plate by tightening the nut with a 

hand wrench while the shotcrete is still plastic. Where uniform contact between the plate and the shotcrete 

cannot be provided, set the plate in a bed of grout and tighten the nut with a hand wrench after the grout 

has set for 24 hours. 

Construct wall elements to the tolerances shown in Table 259-3. 

Table 259-3 

Wall Element Construction Tolerances

Wall Element Tolerance 

Horizontal location of headed studs, from plan location 3⁄8 inch

Location of headed studs on bearing plate, from plan location 1⁄4 inch

Soil nail head bearing plate, deviation from parallel to wall face 10 degrees

259.12 Permanent Wall Facing. Construct the permanent wall facing according to the applicable Section 

below. 

(a) Shotcrete-faced walls. Construct according to Section 566 and to the construction tolerances 

shown in Table 259-4.

(b) Concrete-faced walls. Construct according to Section 258. 

(c) Simulated stone masonry. Construct according to Section 613. 

(d) Stone masonry. Construct according to Section 620. 

(e) Precast concrete panels. Construct according to Section 578. Use concrete class A(AE). Erect 

panels by lifting devices connected to the upper edge of the panel. Construct joints between panels 

according to the manufacturer’s recommendations.

Table 259-4 

Permanent Shotcrete Facing Construction Tolerances

Facing Finish Tolerance, inch

Complete thickness of shotcrete, from plan dimension:

 Troweled or screeded finish ±5⁄8

 Shot finish ±11⁄8

Planeness of finish face, surface gap under a 10-foot straightedge:

 Troweled or screeded finish 5⁄8

 Shot finish 11⁄8

259.13 Backfilling Behind Wall Facing Upper Cantilever Section. Backfill behind the wall with 

structural backfill according to Subsection 209.09. Use light mechanical tamper to compact within 
Section 259

191

36 inches behind the wall facing section. Do not compact behind cantilever until permanent facing 

concrete or shotcrete has cured at least 7 days. 

259.14 Acceptance. See Table 259-7 for sampling, testing, and acceptance requirements.

Material for the soil nails will be evaluated under Subsections 106.03 and 106.04. Submit a production 

certification with each shipment of soil nails.

Construction of soil nail retaining walls will be evaluated under Subsections 106.02 and 106.04. 

Clearing of vegetation will be evaluated under Section 201. 

Reinforcing steel will be evaluated under Section 554. 

Removal of obstructions will be evaluated under Section 203. 

Excavation and backfill will be evaluated under Section 209. 

Survey will be evaluated under Section 152. 

Underdrains will be evaluated under Section 605. 

Installed soil nails will be evaluated based on the criteria in Table 259-6.

Verification test soil nails will be evaluated based on the criteria in Table 259-5. 

Table 259-5 

Verification Test Soil Nail Criteria

Total Load-Test

Hold Movement

at 0.80 VTL

Total Movement at

Maximum Load

Pullout

Failure(2)

< 0.080 inch

between

6 and 60 minutes(1) 

A-line criteria: Greater than 80% of the apparent elastic 

elongation of the test soil nail unbonded length. No pull-out

at

B-line criteria: Less than the apparent elastic elongation of the 1.00 VTL

test soil nail unbonded length and half of the bond length.

(1) And the rate of movement is linear or decreasing throughout the load-hold period.

(2) Pullout failure is the inability to further increase the test load while there is continued pullout movement of 

the test soil nail. Record the pullout failure load as part of the test data.

If the soil nail verification is unacceptable, establish the cause and make design or construction 

modifications. Submit modifications requiring changes to the structure and retest the new system as 

directed.
Section 259

192

Table 259-6 

Proof Soil Nail Acceptance Criteria

Total Load-Hold

Movement

at PTL

Total Movement at

Maximum Load

Pullout

Failure(2)

< 0.040 inch

between

1 & 10 minutes 

or

< 0.080 inch between

6 & 60 minutes(1)

A-line criteria: Greater than 80% of the apparent elastic 

elongation of the test soil nail unbonded length. No pull-out at 

1.00 PTL

B-line criteria: Less than the apparent elastic elongation of the 

test soil nail unbonded length & half of the bond length.

(1) And the rate of movement is linear or decreasing throughout the load-hold period.

(2) Pullout failure is the inability to further increase the test load while there is continued pullout movement of 

the test soil nail. Record the pullout failure load as part of the test data.

If a proof-tested soil nail is unacceptable, replace some or all the installed production soil nails between 

the unacceptable proof test soil nail and the next proof test soil nail in the row as directed. Alternatively, 

install additional proof test soil nails within this area to ensure that the acceptance criteria are met within 

this area. Propose alternative installation and testing methods before installing additional soil nails. If 

ground conditions, soil nail installation methods, or testing procedures change, conduct additional 

verification testing before proceeding with production soil nail installation.

Measurement

259.15 Measure the Section 259 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring soil nail retaining walls by the square foot, measure the front wall face.

When measuring verification test soil nails by the each, do not measure failed verification test soil nails 

or additional verification test soil nails installed to verify alternative soil nail installation methods 

proposed by the Contractor. 

When measuring production soil nails by the linear foot, measure along bar centerline from the line of the 

wall excavation face to the tip of the soil nail.

Payment

259.16 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 259 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 259-7 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

Neat

hydraulic

cement

grout

(701.04(a))

Measured & 

tested for

conformance

(106.04)

Compressive

Strength(1) − AASHTO

T 106

1 per

mix design

Source of

material Yes

30

days

before

production

−

Production

Neat

hydraulic

cement

grout

(701.04(a))

Measured & 

tested for

conformance

(106.04)

Compressive

Strength(1) − AASHTO

T 106

1 per

row or day(2)

Source of

material Yes 28days −

Verification

test soil nail

Measured & 

tested for

conformance

(106.04)

Performance − Subsection

259.09(b)(1)

Each

soil nail Installed No 7 days −

Proof test

soil nail " " − Subsection

259.09(b)(2) " " " 5 

days −

(1) At 3-day and 28-day.

(2) If three successive samples are tested and compliance to the specifications is indicated, screening tests may be reduced to an approved 

frequency.
Section 260

194

Section 260. — ROCK BOLTS AND DOWELS

Description

260.01 This work consists of providing and installing rock bolts and dowels.

260.02 Definitions. 

(a) Rock bolt. Fully grouted, deformed steel bars that are post-tensioned, installed entirely in rock, 

and actively reinforce a rock mass.

(b) Rock dowels. Fully grouted, deformed steel bars that are untensioned, installed entirely in rock, 

and passively reinforce a rock mass.

Material 

260.03 Conform to the following Subsections: 

Non-shrink grout 701.04(b)(2)

Rock bolts and rock dowels 722.03

Water for cementitious materials 725.01(a)

Construction Requirements

260.04 Qualifications. Provide an on-site drill foreperson and drill operators with experience installing 

and testing rock bolts and dowels. At least 21 days before starting rock bolt and dowel work, submit the 

following for approval:

(a) Drill foreperson. A résumé for the drill foreperson describing five projects within the past 5 years 

that the drill foreperson has completed with at least 3000 linear feet of rock bolts and dowels installed 

according to similar contract requirements; 

(b) Drill operators. A résumé for each drill operator describing three projects within the past 5 years 

that each drill operator has completed safely and satisfactorily with at least 1000 linear feet of rock 

bolts and dowels installed according to similar contract requirements; and 

(c) Rope supported laborers. A résumé for rope supported laborers conforming to

Subsection 262.02. 

260.05 Submittals. At least 21 days before starting rock bolt and dowel work, submit the following 

according to Subsection 104.06:

(a) Proposed construction sequence and schedule; 

(b) Proposed drilling methods and equipment; 

(c) Proposed drill hole diameter and the minimum bond zone length for design loads shown in the 

plans. Design minimum bond zone lengths according to PTI, Recommendations for Prestressed Rock 

and Soil Anchors; 
Section 260

195

(d) Proposed rock bolt and dowel type, couplers, bearing plate, washers (flat and beveled), nut, 

stressing anchorages, centralizers, and bond breakers (if applicable) with specifications including 

manufacturer’s data sheets, and brochures. Include manufacturer’s verification for the bearing plate 

thickness for the specified rock bolt and dowel capacities; 

(e) Manufacturer’s recommendations for bar and hardware handling, storing, and working temperature 

ranges;

(f) Non-shrink cement grout type, mix design, 3-day and 7-day compressive strength test results, 

placement procedures, manufacturer’s SDS and brochures, and mixing equipment for each of the 

following stages of non-shrink cement grouting: 

(1) Two-stage grouting. Means for determining the level of primary (first-stage) grout in the hole;

(2) Single-stage grouting. Fabrication details for proposed bond-breaker in the free stressing zone 

including corrosion inhibiting compounds, if applicable; 

(g) Manufacturer certification for corrosion-resistant bar coating and procedures and material for 

repairing corrosion protection coatings in the field; 

(h) If open joints, seams, or loose material is encountered, the methods, equipment, and materials used 

to control excessive grout injection volumes; 

(i) Details for placing, stressing, and testing rock bolts and dowels. Schedule of a test installation to 

demonstrate rock bolt and dowel installation, testing equipment, and procedures. The proposed rock 

bolt stressing equipment, setup, and procedures that will be used for the performance and proof testing;

(j) If required, a detailed procedure for placing the anchor head assembly (bearing plate and nut) below 

the exposed rock surface or for removing the anchor head assembly following final lock-off without 

impacting the bar design load. Include details for a countersink or flush-cut with a colored grout patch, 

if applicable;

(k) Special installation methods (such as upwardly inclined rock bolts and dowels, techniques for 

constructing bearing pads, grouting across open joints and debris-filled discontinuities) if applicable;

(l) Identification number and calibration test certification for each jack, pressure gauge, and electronic 

load cell to be used for testing. Clearly indicate the serial number of each component of the testing 

assembly on calibration graphs. Submit results from calibration tests conducted by an independent 

testing laboratory within the previous 90 days; and

(m) Report documentation examples including installation and testing report formats. 

260.06 Rock Bolt and Dowel Fabrication.

(a) General. Fabricate rock bolts and dowels according to PTI, Recommendations for Prestressed 

Rock and Soil Anchors. Deliver rock bolts and dowels to the job site in bulk lengths and field cut to 

the appropriate lengths after drilling for each rock bolt and dowel. Do not precut rock bolts and dowel 

steel bars at the factory. Size bars to ensure:
Section 260

196

(1) The design load does not exceed 60 percent of minimum ultimate tensile strength of the bar; 

and 

(2) The maximum test load does not exceed 80 percent of the minimum ultimate tensile strength 

of the bar. 

(b) Couplers. Couple only fully-grouted anchors. Couple sections together only if the design length 

exceeds the standard commercially available bar lengths. Use couplers with a center stop to ensure 

equal length of thread connects each section. Do not use couplings that interfere with the flow of grout.

(c) Anchorage. For the stressing anchorage, use a steel bearing plate, washers (flat hardened, beveled 

or, spherical, as required), and a nut that can develop 95 percent of the minimum ultimate tensile 

strength of the bar. 

(d) Centralizers. For cement grouted rock bolts and dowels, place centralizers along the bar at 10-

foot centers, with at least one centralizer per rock bolt or dowel. Locate the lowermost centralizer

within 12 inches of the end. Use centralizers of sufficient strength to support the bar in the drilled hole 

and provide at least 0.5 inch of grout cover around it. Do not place centralizers on the bond breaker. 

260.07 Handling and Storing Material. Handle and store bars according to ASTM A767 and D3963 

guidelines and the manufacturer’s recommendations. Repair or replace bars with damage to corrosion 

protection coatings as required by ASTM A767 and D3963. 

Handle, transport, and store hardware material according to the manufacturer’s recommendations. Protect 

finishes from abrasions that remove the darkened color.

Repair minor damages to epoxy coated, galvanized, and weathered surfaces. Repair galvanized finishes 

according to Section 563. 

260.08 Installation. Before installing rock bolts and dowels, complete on-slope rock stabilization work 

as applicable.

Perform safety scaling that the Contractor deems necessary according to Section 262. 

If applicable, treat exposed galvanized steel surfaces according to Section 563. 

Provide and install rock bolts and dowels with a minimum design capacity as shown in the plans. 

(a) Drilling. Provide equipment able to drill straight, uniform-diameter holes no larger than 4 inches 

in diameter. Do not use water or drilling slurry. Drill rock bolt and dowel holes to the minimum depths 

shown in the plans, and within 6 inches of the required location. Adjust total bolt and dowel lengths 

to address existing subsurface conditions encountered. Unless otherwise shown in the plans, drill rock 

bolts and dowels perpendicular to rock faces or inclined slightly downward (0 to 5 degrees) from the 

axis perpendicular to the rock face. Size drill hole diameters to provide at least 0.5 inch of grout cover 

around bars. Clean drill holes of cuttings, sludge, and debris. If rock bolts and dowels cannot be 

installed in a drilled hole, re-drill the hole. Do not use hand drills to advance holes unless approved. 

(b) Grouting. Install rock bolts or dowels no more than 24 hours after completing drill holes. Orient 

reinforcement no more than 5 degrees outside of the specified angle. Complete first-stage grouting no 

more than one week after rock bolt and dowel installations. Tension each rock bolt and dowel no more 
Section 260

197

than one week after completing first stage grouting. Complete second stage grouting no more than 3 

days after successful post tensioning, wherever two-stage grouted rock bolts are installed.

Use positive displacement grout pumps according to Subsection 256.07(b)(1).

Install steel bars and grout according to the manufacturer’s recommendations. Incorporate an 

acceptable bond breaker where rock bolts are grouted in a single stage. Where grouting rock bolts in 

two stages, completely fill the minimum bond zone length under stage one, and after successful post 

tensioning of the bolt fill the free-stressing (unbonded) length with grout under stage two. Control 

grout pressures to avoid ground heaving or fracturing, and fill grout tube with grout when it will remain 

in the hole. 

Flush surplus water and diluted grout from lines before injection and replace leaky fittings before 

continuing grouting operations. Clean excess grout off rock surfaces, rock bolts and dowels, and 

bearing plates. Perform QC of the grout by performing minimum compressive strength tests, and 

submit test results to the CO.

Record the quantity of injected grout and the grout pressure for each installation. Notify the CO of 

grout quantity overruns including the reason for the overrun and proposed actions to minimize future 

overruns. Obtain approval for alternative grouting methods. 

(c) Bearing plate installation. Install bearing plates so at least three-quarters of the plate’s surface is 

in contact with a rock face. If rock faces are irregular or unsound, chip out surrounding rock or 

construct an approved bearing pad. Ensure that the rock bolt or dowel axis is within 20 degrees of 

being perpendicular to the bearing plate and that the bar passes through bearing plate center without 

bending. Use beveled washers where the bar axis is more than 5 degrees from the bearing plate 

perpendicular. Allow at least 6 inches of bolt and dowel length beyond the nut and washers. Use oversized bearing plates as approved where rock surfaces are weak or highly weathered.

After load-testing and acceptance, tension and lock-off the rock bolts, place the second stage of nonshrink grout in the entire free stressing length, and remove excess grout from rock faces and anchorage 

assembly hardware.

Ensure the bar is fully encapsulated in grout to the collar of the hole. Check grout levels through 

key-holes the day after grout filling and fill the annulus space with grout as needed using a tremie 

tube. Repeat grout level checks and grout filling procedures until a fully grouted annulus space is 

achieved.

260.09 Rock Bolt Testing, Stressing, and Finishing. Conduct testing of tensioned and untensioned rock 

bolts according to PTI, Recommendations for Prestressed Rock and Soil Anchors. 

If applicable, trim the corrosion protection surrounding the free stressing length of the bar so it does not 

contact the bearing plate during testing and stressing. For single stage cement grouted rock bolts, tension 

the bar after the bond zone grout is set and attains sufficient pull-out strength. For two-stage cement 

grouted rock bolts, tension the bar after the bond zone grout is set and attains sufficient pull-out strength 

and before the free stressing length is grouted. 

(a) Performance tests. Before starting production bolting, design rock bolts and construct test bolts 

for each rock type according to the approved submittal drawings. Do not start production bolting for 

a rock type until the CO approves the constructed test bolt, rock bolt design, and construction methods 
Section 260

198

for that rock type. Perform at least two successful performance tests for each different rock unit, anchor 

type, and proposed drilling-installation-grouting method before starting production rock bolt 

installation. Performance tests may be required on bolts shown in the plans, or in sacrificial locations, 

if reasonable access for inspection is not provided according to FAR Clause 52.246-12 Inspection of 

Construction. 

Use a calibrated hollow-ram hydraulic jack and gauge with graduations of 200 pounds per square inch 

or less to tension rock bolts. Tension rock bolts to 133 percent of the design load, and maintain the 

tension at least 10 minutes, and no more than 60 minutes if needed, with a maximum load tolerance 

of 200 pounds per square inch. Apply loads and record extensions under loads with a tool that can 

measure to 1 mil. Conduct loading according to Table 260-1. The Design Load (DL) during the testing 

is as shown in the plans. The alignment load (AL) is the minimum load required to align the testing 

apparatus and should not exceed 10 percent of the DL.

Table 260-1 

Performance Test Loading Schedule

Load Hold Time

AL Obtain reading

0.25DL Obtain reading

0.50DL Obtain reading

0.75DL Obtain reading

1.00DL Obtain reading

1.20DL Obtain reading

1.33DL Obtain reading

" 1 minimum

" 2 minimum

" 3 minimum

" 4 minimum

" 5 minimum

" 6 minimum

" 10 minimum

" 60 minimum (if needed)

AL Obtain reading

DL Lockoff

Submit rock bolt test results to the CO for further analysis. Rock bolts are acceptable when the 

following conditions are met:

(1) The total elastic movement obtained at the maximum test load exceeds 80 percent of the 

theoretical elastic elongation of the free stressing length;

(2) The total elastic movement obtained at the maximum test load does not exceed the theoretical 

elastic elongation of 100 percent the free stressing length plus 50 percent of the bond length plus 

the jack length; 

(3) The rock bolt carries the maximum test load with a creep rate less than 0.04 inch from the 

1-minute reading to the 10-minute reading, or 0.08 inch per log cycle of time from the 6-minute 

reading to the 60-minute reading; and

(4) The CO approves submitted test results in writing.

Perform additional performance tests if installations fail to meet the test criteria.
Section 260

199

(b) Proof testing. Proof test each rock bolt by tensioning bolts applying and maintaining 133 percent 

of the design load for 10 minutes. Rock bolts are acceptable when no loss of load occurs during the 

proof test. Replace failed rock bolts at no additional cost to the Government and document the 

expected reasons for failure to address and rectify deficiencies in the rock bolt installation methods 

used for given site conditions. Adjust rock bolt installation methods as approved before installing 

additional rock bolts.

After rock bolts are acceptable, lower the tension and lock off the load at 100 percent of the design 

load with a nut and a flat or beveled washer as needed to ensure that the nut is flush against the bearing 

plate. Grout the remaining portion of the rock bolt no more than 72 hours after re-tensioning and lock 

off.

(c) Finishing. Trim completed rock bolt ends to within 6 inches of the rock face. Treat field cuts, 

repair damages to galvanization, and repair and finish exposed steel surfaces according to Section 563. 

260.10 Rock Dowel Lift-Off Testing and Finishing. Test rock dowels according to PTI, 

Recommendations for Prestressed Rock and Soil Anchors. 

Test only fully grouted dowels. Conduct at least two successful lift-off tests for each different rock unit, 

anchor type, and proposed method of drilling, installation, and grouting. Gradually load lift-off test 

reinforcements to 60 percent of the minimum ultimate tensile strength of the dowel bar and monitor the 

pressure gauge to verify the anchor is holding the design load for at least 10 minutes. Test 5 percent of the 

remaining dowels if the anchors do not pull out. Replace the dowel and conduct lift-off tests on remaining 

rock dowels when pressure gauge drops are due to anchorage movements. Apply 100 foot-pounds of 

torque to ensure proper seating against the rock face. Trim completed rock dowel ends to within 6 inches 

of the rock face.

260.11 Drilling Logs, Test Results, and Reporting. Submit drilling logs and test results to the CO for 

review. Maintain daily records of rock bolt and dowel work including the following: 

(a) Drawings depicting the location of each anchor on post-scaled photographs, noting anchor 

designation, date drilled, general drilling logs that note the drilling conditions and materials 

encountered, the location of significant drilling changes (geologic contacts, voids, or open fractures), 

dates of grouting operations, total anchor length, bonded length, free stressing length, grout mix, grout 

volume, average grout pressure, hole diameter, size of bar, bar inclination, and installation comments. 

Submit as-built drawings according to Subsection 104.06(c).

(b) Performance and proof test data forms, including the anchor designation, bonded length, free 

stressing length, stressing length, date of stressing operation, signature of stressing operator or 

inspector, required elongation and associated gauge pressure, actual elongation and associated gauge 

pressure, identification numbers of jacking equipment, comments, and a table including incremental 

jack pressure, jack load, and movement. 

260.12 Acceptance. See Table 260-2 for sampling, testing, and acceptance requirements.

Material for rock bolts and dowels will be evaluated under Subsections 106.02, 106.03, and 106.04. 

Construction of rock bolts and dowels will be evaluated under Subsections 106.02 and 106.04. 

Grouting will be evaluated under Subsections 106.02 and 106.04. 
Section 260

200

Safety scaling will be evaluated under Section 262. 

Treating exposed surfaces and repairing galvanized surfaces will be evaluated under Section 563. 

Measurement

260.13 Measure the Section 260 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring rock bolts and dowels by the linear foot, measure from the trimmed steel end to 6 inches 

from the slope face. Do not measure rock bolts and dowels that failed testing. 

Payment

260.14 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 260 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 260-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate 

quality (fine) 

(703.01)

Measured &

tested for

conformance

(106.04 & 

105)

Quality – AASHTO M 6

1 per

Material 

type

Source of

material Yes Beforeproducing – 

Mix Design

Non-shrink 

grout 

(701.04(b)(2) 

Measured & 

tested for 

conformance 

(106.04)

Flow – AASHTO C939 1 per mix 

design

Source of

material

Yes, if 

requested

Before

producing – 

Compressive 

Strength (3-day 

& 7-day)

– ASTM C109 1 per mix 

design

Source of

material

Yes, if 

requested

Before

producing – 

Production

Non-shrink 

grout 

(701.04(b)(2))

Measured & 

tested for 

conformance

(106.04) 

Compressive 

Strength (3-day 

& 7-day)

– ASTM C109

1 set from 

each batch 

of grout

Source of

material

Yes, if 

requested

Within 24 

hours after 

completion of 

test

– 

Performance 

test for rock 

bolts

Measured & 

tested for 

conformance 

(106.04)

Deformation – Subsection 

260.09(a)

Subsection 

260.09(a) Installation No

Within 

24 hours after 

completion of 

test

– 

Proof test for 

rock bolts

Measured & 

tested for 

conformance 

(106.04)

Deformation – Subsection 

260.09(b) Each bolt Installation No

Within 

24 hours after 

completion of 

test

– 

Lift-off test 

for rock dowel

Measured & 

tested for 

conformance 

(106.04)

Deformation – Subsection 

260.10

Subsection 

260.10 Installation No

Within 

24 hours after 

completion of 

test

– 
Section 261

202

Section 261. — REINFORCED SOIL SLOPES

Description

261.01 This work consists of constructing reinforced soil slopes. 

Material 

261.02 Conform to the following Subsections: 

Crushed aggregate 703.06

Reinforcement geotextile and geogrid 714.04

Soil and soil-aggregate materials 704.01

Wall facing fill 705.09

Wire facing and backing mat 720.01(b)

Construction Requirements

261.03 Submittals. At least 30 days before starting reinforced soil slope work, submit the following 

according to Subsection 104.06:

(a) Manufacturer’s certification. Certification and test results indicating the proposed reinforcement 

material and facing material meets requirements; and

(b) Facing details. Provide installation methods and connection details for facing system. 

261.04 General. Conform to Section 257 for Contractor-designed reinforced soil slope systems.

Survey according to Section 152 and verify the limits of the reinforced soil slope installation.

Excavate and prepare foundation soils for the reinforced soil slope according to Section 204. Conserve 

topsoil according to Subsection 204.05. 

Grade the foundation soils supporting the reinforced soil slope for a width equal to the length of the lowest 

soil reinforcement level. Step the reinforced soil slope into existing slopes according to 

Subsection 204.09(d).

Construct a leveling pad from crushed aggregate or the specified material if shown in the plans. 

Install underdrain system according to Section 605 if shown in the plans. 

261.05 Soil Reinforcement and Facing. Lay each layer of soil reinforcement flat, pull tight, and hold in 

place with pins, soil piles, or other approved methods. Construct the reinforced soil slope to achieve the 

slopes specified and roadbed tolerances according to Subsection 204.13(c). 

Grade and compact RSS backfill according to Subsections 204.09 and 204.11 before placing the next soil 

reinforcement layer. Maintain a minimum cover of 6 inches over the reinforcement during spreading and 

compacting of fill material. Avoid sudden stops, starts, and turns of the equipment. Do not use sheepsfoot
Section 261

203

rollers. Use lightweight mechanical tampers, rollers, vibratory systems, or other methods for compaction 

within 36 inches of the slope face.

Tension the reinforcement during RSS backfill placement. Work from the slope face to the back of 

reinforcement.

Do not leave reinforcement exposed at end of shift. At the end of each shift, shape to drain and compact 

the work area to a uniform cross-section. At the end of the day’s operation, slope the last lift of backfill 

away from the slope face to direct surface runoff away from the slope.

261.06 Acceptance. Material for reinforced soil slopes will be evaluated under Subsections 106.02, 

106.03, and 106.04. 

Construction of reinforced soil slopes will be evaluated under Subsections 106.02 and 106.04. 

Excavation will be evaluated under Section 204. 

Survey will be evaluated under Section 152. 

Underdrains will be evaluated under Section 605.

Measurement

261.07 Measure the Section 261 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring RSS backfill within the stabilized volume by the cubic yard, measure in place.

Payment

261.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 261 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 262

204

Section 262. — SLOPE SCALING

Description

262.01 This work consists of removing and disposing of loose or detached blocks of rock from existing 

rock slopes and natural rock outcrops by slope scaling. 

Construction Requirements

262.02 Qualifications. Provide an on-site supervisor and personnel with slope scaling project experience 

of similar scope and complexity to those shown in the plans and in similar conditions described in the 

geotechnical or geological reports. At least 30 days before starting slope scaling work, submit the 

following for rope supported laborers: 

(a) Scaling foreperson. A résumé for scaling foreperson describing at least 2000 hours' scaling 

experience and 3 years’ experience as a slope scaling foreperson on similar projects. Include required 

certifications;

(b) Journeyman scaler. A résumé for journeyman scalers describing at least 1500 hours’ scaling 

experience and at least 1 year’s experience on similar projects. Include required certifications; and

(c) Apprentice scaler. If apprentice scalers are proposed, provide certification of training.

262.03 Submittals. At least 30 days before starting slope scaling work, submit the following according 

to Subsection 104.06: 

(a) Proposed construction sequence and schedule; 

(b) Describe the method of rope work used and training for rope supported laborers and scaling 

foreperson (such as Professional Climbing Instructors Association (PCIA), Society of Professional 

Rope Access Technicians (SPRAT), or equivalent internal training certification program);

(c) Identify and provide contact information for the municipal emergency responders that will perform 

rescue. Include mapped travel routes for rescue team, rendezvous sites and estimated response time;

(d) Examples of worksheets for evaluating slope safety before rope entry (such as a Slope Access 

Safety Evaluation or Slope Scaling Assessment);

(e) The types of equipment and tools to be used; 

(f) The number of slope scalers for the project;

(g) Removal and disposal plan for existing ditch debris (if present) and rock and debris generated from 

the slope scaling and vegetation removal work, and; 

(h) Rockfall protection plan including provisions to protect the roadway and traffic according to 

Section 156, and facilities and existing utilities according to Subsection 107.02(d).

262.04 General. Before starting scaling work, provide temporary roadway protection and public safety 

measures according to the approved Rockfall Protection Plan. 
Section 262

205

Conduct a pre-slope scaling preparatory phase meeting at least 7 days before the start of slope scaling 

operations according to Subsection 153.06(a) to evaluate approaches to the slope and site geology 

conditions and constraints. 

The CO will require that the Contractor remove any slope scaler working or directing others to work in 

an incompetent, careless, or unsafe manner in according to FAR Clause 52.236-5 Materials and 

Workmanship. 

Perform general scaling within the limits shown in the plans and as directed. 

If applicable, specific unstable blocks to be removed and areas requiring greater scaling efforts are 

identified in the plans as intensive scaling areas. Intensive scaling areas are portions of the slope that may 

need additional time or specific equipment to address.

Perform vegetation removal from slope brows and rock slope faces, including the removal of trees, shrubs, 

and other vegetation. 

Perform slope scaling and tree and vegetation removal before other slope stabilization work or permanent 

rockfall mitigation work.

Dispose of scaled debris and vegetation according to Subsection 203.07. 

262.05 Equipment. Perform slope scaling using rope supported laborers with hand tools. 

Include scaling bars, portable hydraulic wedges, and air bag jacks. Provide air bag jacks or hydraulic 

wedges with a lift capacity of at least 15 tons. Provide rope supported laborers in compliance with 

Subsection 262.02. 

262.06 Safety Scaling. Provide safety scaling beyond scaling and tree removal limits as needed to safely 

perform the prescribed work.

262.07 Slope Scaling Operations. Comply with the following: 

(a) Perform slope scaling only when the scaling foreperson is present. Perform slope scaling only 

when the scaling foreperson has continuous visual contact with all scalers on the slope. Additional 

scaling forepersons may be required. The scaling foreperson may not be actively scaling with the onslope scalers but can access the site as necessary to supervise scaling operations.

(b) Assign two journeyman scalers for each individual apprentice scaler. Allow apprentice scalers to 

work only when under the direct supervision of two journeyman scalers.

(c) Adjust operations to allow emergency traffic through the work site according to Section 156. 

(d) Cut the identified trees and other vegetation as shown in the plans. Cut trees and large woody 

shrubs as close as possible to the ground surface while leaving the root wad intact. Remove vegetation 

before starting slope scaling operations. 

(e) Establish anchors for rope access within the construction limits unless otherwise approved.

(f) Perform slope scaling working in a top to bottom sequence. As the work progresses remove loose 

rocks, detached rocks, and rocks. 
Section 262

206

(g) Remove scaling debris from the slope. The CO will review the scaled area to determine when the 

rock slope scaling and vegetation removal has been completed based on the site geology. If additional 

vegetation or loose or unstable rocks are identified for removal, continue to scale the slope until the 

scaling has been completed to the satisfaction of the CO.

(h) If the roadway will be open to traffic, do not leave accumulated scaling debris on the roadway, in 

the roadside ditch, or in pullouts adjacent to the roadway overnight or at the end of a work shift. 

262.08 Acceptance. Slope scaling will be evaluated under Subsection 106.02. 

Measurement

262.09 Measure the Section 262 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Slope scaling will be measured by the scaler hour of production time of each scaler for all slopes. Hour 

measurements for each journeyman scaler or apprentice scaler starts when each scaler is equipped and 

starts to actively scale the slope and ends when each scaler has descended to the bottom of the rock slope 

at the end of the work shift. 

Do not measure hours for safety scaling. 

Do not measure hours for the scaling foreperson. 

Do not measure disposal of scaled debris and vegetation. 

Payment

262.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 262 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 263

207

Section 263. — DRAPED ROCKFALL PROTECTION

Description

263.01 This work consists of installing draped rockfall protection. 

Material 

263.02 Conform to the following Subsections: 

Anchorage devices 722.01

Draped rockfall protection fabric 710.09

Hollow-core self-drilling anchors 722.07(a)

Non-shrink grout 701.04(b)(2)

Rockfall protection hardware 717.01(f)

Water for cementitious materials 725.01(a)

Wire rope 709.03

Wire rope anchors 722.07(b)

Construction Requirements

263.03 Qualifications. At least 30 days before starting rockfall protection work, submit the following for 

approval: 

(a) On-site supervisor. A résumé describing experience on at least five projects installing draped 

rockfall protection systems on steep slopes within the past 5 years. Include project names, locations, 

and contact information for project owners; 

(b) Drill operators. A résumé describing experience installing at least 1000 linear feet of ground 

anchors on steep slopes within the past 3 years. Include project names, locations, and contact 

information for project owners; 

(c) Rope supported laborers. A résumé for rope supported laborers conforming to

Subsection 262.02; and 

(d) Draped rockfall protection fabric material supplier. Include the following:

(1) Documentation showing the manufacturer has at least 5 years’ experience manufacturing the 

specified products used in similar system applications and capacities. Include details of the 

manufacturer’s testing procedures and certification of a QA program; and 

(2) Include summaries of at least 5 past projects with similar site conditions where draped rockfall 

protection systems were installed using the supplier’s cable nets and steel fabric material, as 

applicable. Include owner names and contact information.

263.04 Submittals. At least 30 days before starting draped rockfall protection work, submit the following 

according to Subsection 104.06: 

(a) Design. Submit the proposed draped rockfall protection design and calculations. 
Section 263

208

(b) Materials. Do not order material until the applicable material submittals are approved.

(1) An inclusive list with technical data sheets for each proposed system component including 

draped rockfall protection fabric, grout, tendon anchors, wire ropes, wire rope anchors, thimbles, 

ferrules, and other fastening hardware.

(2) Drawings for temporary yokes or load frames used for anchor proof testing including load 

cells, test jack and master gauges, and calibration data performed by an independent testing 

laboratory within 90 days of the submittal for each device used. Recalibrate each device used every 

90 days from the originally submitted calibration date.

(c) Equipment.

(1) List of equipment to be used for rockfall protection work, including equipment capacities, 

intended uses, and rental rates.

(2) Provide calibration data, including a graph of torque versus tension for each torque wrench to 

be used. Include certifications showing calibration testing was conducted by an independent 

laboratory within 90 days of the date submitted. 

(d) Work plan. Include the following in the work plan:

(1) Explain the safety procedures on how personnel and equipment will perform work so that the 

public, construction personnel, and equipment exposures to hazardous and potentially hazardous 

conditions are minimized. Include temporary rockfall mitigation measures, special designs, and 

installation procedures deemed necessary to safely perform the rockfall protection work;

(2) A list of materials, devices, and equipment used, and the methods that will be incorporated to 

protect existing underground and above-ground facilities, and minimize impacts to the 

environment; 

(3) Description of how personnel and equipment will install draped rockfall protection fabric 

materials on the project slope locations, including temporary anchoring needed;

(4) A list of materials, equipment, and the methods for drilling, installing, grouting, and testing 

ground anchors; including the mix design for grouting operations; and 

(5) Procedure for attaching draped rockfall protection fabric materials to upper support ropes, 

adjacent draped rockfall protection fabric panels, and other temporary and permanent supports. 

Include methods and equipment for delivering and placing on the designed slope locations. 

263.05 General. Perform safety scaling that the Contractor deems necessary according to Section 262. 

Before installing draped rockfall protection, complete work required according to Sections 260, 262, and 

267, and other on-slope rock stabilization work as applicable. 

If applicable, treat exposed steel surfaces according to Section 563. Verify the draped rockfall protection 

work limits. Perform required scaling, rock bolting and doweling, unlined and lined drain holes in rock, 

and other on-slope rock stabilization work before connecting the draped rockfall protection fabric to the 

ground anchors and support ropes. 
Section 263

209

Store, handle, and install draped rockfall protection without damaging the rockfall protection system, 

colored finish, or galvanized finish. Repair galvanized finishes according to Section 563. Replace 

damaged portions of the rockfall protection system.

Construct the draped rockfall protection system using panels comprised of double-twist wire mesh, high 

tensile strength wire mesh, or cable net with wire mesh backing as specified in the plans. Install the draped 

rockfall protection from the top working downward, contouring the draped rockfall protection fabric 

material with the existing ground topography to the bottom limits of the required installation, without 

creating loose draped rockfall protection fabric pockets that trap falling rocks. Trim draped rockfall 

protection fabric material as needed and treat field cuts according to Section 563. 

263.06 Upper Support Ground Anchors. Permanently mark proposed anchor locations as approved. 

Install anchors only at approved locations. Install ground anchors by centering the anchors plumb or 

normal to the existing slope at least 2 inches off the bottom of the hole and according to the following 

field conditions as applicable. 

(a) Type I soil installation. Excavate a minimum 5.5-foot deep, 12-inch diameter hole to receive the 

anchor. Install galvanized wire rope with the anchor end possessing a factory installed ferrule that has 

a minimum tensile strength equal to that of the wire rope used. Completely fill anchor holes with minor 

concrete, to encapsulate anchors within holes. Construct minor concrete according to Section 601. 

(b) Type II soil installation. Use sacrificial drill bits to install hollow-core self-drilling anchors with 

a minimum diameter of 11⁄4 inches to a minimum depth of 5.5 feet, attached to 3⁄4-inch diameter 

galvanized wire ropes with factory installed couplers that possess a minimum tensile strength equal to 

that of the wire ropes used. Completely fill drilled holes with non-shrink grout, to encapsulate anchors 

within drilled holes. 

(c) Rock installation. Excavate a minimum 5.5-foot deep, 2-inch diameter hole to receive the anchor. 

Install the ferrule-end wire rope specified under Subsection 263.06(a). Use non-shrink grout to fill 

anchor holes according to Subsection 263.06(b).

After filling anchor holes with non-shrink grout or concrete, allow cementitious material to cure, and do 

not disturb or apply loads to anchors for at least 3 days. 

263.07 Testing Ground Anchors. Perform axial pullout proof tests on 5 percent of the installed upper 

support ground anchors, with at least three tests performed. Complete testing before connecting system 

components to anchors. Perform the test by applying a 20-kip test load to the anchor for 10 minutes, using 

a temporary yoke or load frame that does not apply bearing pressures on the ground within 3 feet of the 

anchor. Proof tests for an anchor will be accepted when the anchor maintains the test load for 10 minutes 

with no loss of load. 

Replace anchors that do not pass axial pullout proof testing at no additional cost to the Government. 

263.08 Wire Ropes and Draped Rockfall Protection Fabrics. Install ground anchors by centering the 

anchors plumb or normal to the existing slope at least 2 inches off the bottom of the hole and according 

to the following field conditions as applicable. Attach tag lines to upper support ground anchors only after 

the required proof testing under Subsection 263.07 has been completed. 

Set wire rope lengths in the field, terminating each wire rope run with a loop end. Attach support ropes to 

tag lines with the required shackles. Attach draped rockfall protection fabrics to support ropes, and the 
Section 263

210

upper 12 feet of adjacent fabric panels by lacing wire rope through each draped rockfall protection fabric 

and panel cell and around adjacent support and seaming ropes. 

Use 1⁄4-inch diameter wire rope for lacing on draped rockfall protection systems consisting of double-twist 

wire mesh and high tensile strength wire mesh, and 5

/16-inch diameter wire rope for draped rockfall 

protection systems consisting of cable nets with wire mesh backing.

On draped rockfall protection systems consisting of double-twist wire mesh, overlap adjacent draped 

rockfall protection fabric panels at least 3 inches.

On draped rockfall protection systems consisting of high tensile strength wire mesh or cable net with wire 

mesh backing, connect adjacent draped rockfall protection fabric panels according to the manufacturer’s 

recommendations at horizontal and vertical seams. 

Increase overlaps as needed to cover the work limits and minimize field cuts. Lace additional wire ropes 

through draped rockfall protection fabric cells to join overlapping draped rockfall protection fabrics 

overlapping greater than 3 inches. 

Do not use hog ring fasteners to join overlapping draped rockfall protection fabrics consisting of cable 

nets with wire mesh backing panels.

Set the bottoms of draped rockfall protection fabric panels, between 3 and 8 feet above the ditch line, and 

attach fabric bottoms to the existing slope according to the manufacturer’s recommendations.

263.09 Acceptance. See Table 263-1 for sampling, testing, and acceptance requirements.

Material for draped rockfall protection will be evaluated under Subsections 106.02, 106.03, and 106.04. 

Submit a production certificate for wire ropes and tendon anchors. 

Construction of draped rockfall protection will be evaluated under Subsections 106.02 and 106.04. 

Drain holes in rock will be evaluated under Section 267. 

Minor concrete will be evaluated under Section 601. 

Rock bolts and dowels will be evaluated under Section 260. 

Safety scaling will be evaluated under Section 262. 

Treating exposed steel surfaces, treating galvanized steel field cuts, and repairing damaged galvanizing 

will be evaluated under Section 563. 

Measurement

263.10 Measure the Section 263 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring draped rockfall protection by the square yard, measure the completed in place work 

performed on the ground surface, excluding overlaps and areas trimmed off. 
Section 263

211

Payment

263.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 263 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 263-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Non-shrink 

grout 

(701.04(b)(2))

Measured &

tested for

conformance

(106.04)

Flow – ASTM C939

1 per mix 

design Source of

material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

– 

Compressive 

strength (3-day 

and 7-day)

– ASTM C109

1 set from 

each batch of 

grout

Source of

material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

– 

Proof test for 

draped 

rockfall 

protection 

anchors

Measured &

tested for

conformance

(106.04)

Deformation – Subsection 

263.07

5% of 

installed 

anchors but 

not less

than 3 

Installation No

Within 24 

hours after 

completion 

of test

– 

Note: Collect samples from the end of the grout line at the point of applications.
Section 264

213

Section 264. — MIDSLOPE ROCKFALL ATTENUATOR

Description

264.01 This work consists of installing midslope rockfall attenuators.

Material 

264.02 Conform to the following Subsections: 

High-strength low-alloy structural steel 717.01(b)

Hollow-core self-drilling anchors 722.07(a)

Midslope rockfall attenuator materials 710.10

Non-shrink grout 701.04(b)(2)

Rockfall protection hardware 717.01(f)

Rockfall protection nuts and washers 717.01(g)

Structural carbon steel 717.01(a)

Threaded bar ground anchors 722.07(c)

Water for cementitious materials 725.01(a)

Wire rope 709.03

Wire rope anchors 722.07(b)

Construction Requirements

264.03 Qualifications. Provide an on-site supervisor with experience installing midslope rockfall 

attenuator systems, and drill operators with experience installing ground anchors. At least 30 days before 

starting rockfall protection work, submit the following for approval: 

(a) On-site supervisor. A résumé describing experience on at least five projects installing midslope 

rockfall attenuator systems on steep slopes within the past 5 years. Include project names, locations, 

and contact information for project owners; 

(b) Drill operators. A résumé describing experience installing at least 1000 linear feet of ground 

anchors on steep slopes within the past 3 years. Include project names, locations, and contact 

information for project owners; 

(c) Rope supported laborers. A résumé for rope supported laborers conforming to

Subsection 262.02; and 

(d) Cable net panel and wire mesh backing suppliers. Include the following: 

(1) Evidence showing the manufacturer has at least 5 years’ experience manufacturing the 

specified products used in similar system applications and capacities. Include details of the 

manufacturer’s testing procedures and certification of a QA program. 

(2) A list of at least 5 past projects with similar site conditions where attenuators were installed 

using the supplier’s cable nets and steel fabric material. Include owner names and contact 

information. 
Section 264

214

264.04 Submittals. At least 30 days before starting midslope rockfall attenuator work, submit the 

following according to Subsection 104.06:

(a) Materials. 

(1) A list with brochures and data sheets for system appurtenances to be used including the cable 

nets and wire mesh backing, anchors, support system, lacing wire rope, wire mesh fasteners, 

anchor bars, wire rope anchors, grout, wire rope, clips, thimbles, ferrules, steel rings, and other 

fastening hardware; and

(2) Drawings for temporary yokes or load frames used for anchor proof testing. Include load cells, 

test jack and master gauges, and calibration data performed by an independent testing laboratory 

within 90 days of the submittal for each device used. Recalibrate each device that experiences 

damage or has been involved in an uncontrolled fall. 

(b) Equipment. 

(1) List equipment to be used for rockfall protection work, including equipment capacities and 

intended uses; and 

(2) Identify the manufacturer of the cable tension meter that will be used during installation of the 

midslope rockfall attenuator. Provide documentation that the cable tension meter has been 

calibrated by an independent testing laboratory within 90 days of use on the project. 

Manufacturer’s calibration with same certification requirements will be accepted in place of 

independent certification for new instruments. Provide an identification number for each 

component (or a set such as sheaves used as a unit).

(c) Work plan.

(1) A description of safety procedures minimizing exposure to hazardous and potentially 

hazardous conditions to the public, construction personnel, and equipment. Include temporary 

rockfall mitigation measures, special designs, and installation procedures deemed necessary to 

safely perform the rockfall protection work; 

(2) A list of materials, devices, and equipment used, and the methods that will be incorporated to 

protect existing facilities (underground, on the ground surface, and above-ground) and minimize 

impacts to the environment according to Section 107;

(3) A list of materials, equipment, and the methods for drilling, installing, grouting, and testing 

ground anchors, including the mix design for grouting operations; and 

(4) Procedures for attaching cable net panels with wire mesh backing to upper support ropes, 

adjacent steel fabric panels, and other temporary and permanent supports. Include methods and 

equipment for delivering and placing on the designed slope locations. 

264.05 General. Do not order materials until the applicable material submittals are approved.

Before installing midslope rockfall attenuators, complete work required according to Sections 260, 262, 

and 267, and other on-slope rock stabilization work as applicable. 
Section 264

215

Perform safety scaling that the Contractor deems necessary according to Section 262. 

Verify the midslope rockfall attenuator work limits. Perform required scaling, rock bolting and doweling, 

unlined and lined drain holes in rock, and other on-slope rock stabilization work before connecting the 

cable net panels with wire mesh backing to the ground anchor and support ropes. 

If applicable, treat exposed steel surface according to Section 563. Store, handle, and install midslope 

rockfall attenuator systems without damaging the midslope rockfall attenuator, colored finish, or 

galvanized finish. Repair galvanized finishes and weathering agents according to Section 563. Replace 

damaged portions of the midslope rockfall attenuator. 

Construct the midslope rockfall protection at the locations shown in the plans or as directed. Construct 

plates, holes, welds, swivels, and foundations for support posts as shown in the plans. Locate the posts, 

ropes, and wire rope anchors as shown in the plans. Install the midslope rockfall attenuator system within 

the required tolerances as shown in the plans for alignment and orientation. Construct midslope rockfall 

attenuators with a maximum top support wire rope length of 160 feet. If the required installation length is 

longer than 160-feet, use a connection post and start a new top support wire rope. 

Install and attach the cable net panels and the wire mesh backing as shown in the plans. Use 9/16-inch wire 

seaming rope for connecting the net panels to the horizontal top B rope, truncating the seaming rope at 

each post, and restarting it for the next span between posts as shown in the plans. Connect corner cable K 

to the end post swivel and at least two cells into the cable net fabric at a connection. Use a 9

/16-inch wire 

rope for corner cable K. Repair damaged galvanizing after erection according to Subsection 563.12(b).

Set the bottoms of attenuator net fabric panels as directed according to the geologic conditions.

(a) Foundations. Excavate and prepare new foundations according to Section 209. Use the post 

foundation shown in the plans. Space posts at 40 feet or less. Provide a proposed layout in plan between 

new post alignments that shows the angles in the vertical and horizontal alignment between posts and 

layout a profile showing the ground surface elevation and top attenuator support rope elevation for 

approval. 

If threaded ground anchor bars cannot be inserted into the drill holes due to caving conditions, use a 

hollow-core self-drilling ground anchor with a sacrificial drill bit to advance the anchor into the ground 

as shown in the plans. Orient the hollow-core anchor bars as shown in the plans. Determine the 

required anchor length necessary to provide a minimum axial pullout capacity of 30-kips for each selfdrilling anchor. Fully encapsulate each ground anchor in either non-shrink grout or minor concrete 

according to Section 601. 

(b) Wire rope tightening. At every midslope rockfall attenuator post, tighten C ropes and F ropes 

until they are taut. A taut rope is defined as one that has the values shown in Table 264-1 as measured 

by a tension meter. Tighten C ropes and F ropes before loading and tightening the B rope. 

Tighten the B rope to ensure that when the rope is loaded with the attenuator net, the vertical sag 

between posts is 12 to 18 inches from horizontal. 
Section 264

216

Table 264-1 

Wire Rope Tension Meter Values

Rope F or C Vertical 

Angle (degrees)

Minimum Allowable Rope 

Tension (lbf)

30±2 370

45±2 550

50±2 to 60±2 770

Calibrate the cable tension meter at no more than a 180-day interval, or at any lesser time, due to 

site-specific conditions, wear, or abuse of any component. 

264.06 Testing Anchors. Sample each grout batch used to construct anchors and submit required samples 

to an independent testing laboratory for 3-day and 7-day compressive strength testing. Submit results and 

samples for verification testing.

Verify the wire rope anchor capacities by conducting axial pullout tests on every 103-kip capacity anchor, 

and 25 percent of the 58-kip capacity anchors as selected by the CO. Provide a pullout test load that is 

60 percent of the ultimate wire rope anchor capacity shown in the plans. For pullout proof testing, an 

anchor is acceptable when it sustains the specified capacity for 10 minutes with no loss of load. Test 

against a temporary yoke or load frame with no part of the yoke or load frame within 3 feet of the anchor. 

If a wire rope anchor fails during testing, test all wire rope anchors. Replace failed wire rope anchors. 

Complete wire rope anchor testing before connecting system components to the anchors. 

Verify that the 11⁄4-inch diameter hollow-core self-drilling ground anchors provide at least 30-kip axial 

pullout capacity for each anchor. Conduct the axial pullout test on at least one ground anchor, as selected 

by the CO, from each foundation where hollow-core self-drilling ground anchors are used. Provide a 

pullout proof test load that is 60 percent of the minimum pullout strength requirement. An anchor is 

acceptable when it sustains the specified capacity for 10 minutes with no loss of load. Test against a 

temporary yoke or load frame with no part of the yoke or load frame within 3 feet of the anchor or the 

other four ground anchors associated with that post foundation if already installed. If a hollow-core 

self-drilling ground anchor fails, test all anchors associated with that post foundation. Modify and replace 

failed ground anchors and then retest. Complete anchor testing before constructing the remaining portion 

of the foundation. Replace failed ground anchors. 

264.07 Acceptance. See Table 264-2 for sampling, testing, and acceptance requirements.

Material for midslope rockfall attenuator will be evaluated under Subsections 106.02 and 106.03. Submit 

a production certification for wire ropes and anchor tendons. 

Construction and erection of midslope rockfall attenuator will be evaluated under Subsections 106.02 and 

106.04. 

Drain holes in rock will be evaluated under Section 267. 

Minor concrete will be evaluated under Section 601. 

Rock bolts and dowels will be evaluated under Section 260. 

Slope scaling and safety scaling will be evaluated under Section 262. 
Section 264

217

Treating exposed steel surfaces, treating galvanized steel field cuts, and repairing damaged galvanizing 

will be evaluated under Section 563. 

Measurement

264.08 Measure the Section 264 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Measure the midslope rockfall attenuator by the square yard of covered area of the installed cable net 

panel with wire mesh backing portion of the system on the slope, excluding overlaps and areas trimmed 

off.

Payment

264.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 264 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 264-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Non-shrink 

grout 

(701.04(b)(2))

Measured &

tested for

conformance

(106.04)

Flow – ASTM C939 1 per mix 

design

Source of

Material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

Compressive 

strength (3-day 

& 7-day)

– ASTM C109

1 set from 

each batch 

of grout

Source of

Material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

Proof test for 

anchors

Measured &

tested for

conformance

(106.04)

Deformation – Subsection 

264.06

Subsection 

264.06 Installation No

Within 24 

hours after 

completion 

of test
Section 265

219

Section 265. — ROADSIDE ROCKFALL PROTECTION

Description

265.01 This work consists of installing roadside rockfall protection. 

Construction Requirements

265.02 Qualifications. Provide an on-site supervisor with experience installing gabion barriers and 

flexible rockfall barrier systems, and drill operators with experience installing ground anchors. At least 30 

days before starting rockfall protection work, submit the following for approval: 

(a) On-site supervisor. A résumé describing experience on at least five projects installing gabion 

barriers and flexible rockfall barrier fence systems within the past 5 years. Include project names, 

locations, and contact information for project owners; 

(b) Drill operators. A résumé describing experience installing at least 1000 linear feet of ground 

anchors for flexible rockfall barrier systems within the past 3 years. Include project names, locations, 

and contact information for project owners; and 

(c) Manufacturer of the flexible rockfall barrier systems. Include written evidence demonstrating 

the manufacturer has at least 5 years’ experience with manufacturing and supplying systems used in a 

similar application and capacity. 

265.03 Submittals. At least 30 days before starting roadside rockfall protection work, submit a work plan 

according to Subsection 104.06. Include the following: 

(a) Evidence of certification for the flexible rockfall barrier systems according to European 

Assessment Document (EAD 340059-00-0106), including performance values for energy level 

classification, maximum energy level (MEL), service energy level (SEL), classification for residual 

height for MEL, and elongation at the MEL. Include evidence no more than 1 year old from the 

manufacturer that the flexible rockfall barrier system supplied has been tested and verified to equal or 

exceed the flexible rockfall barrier system requirements as shown in the plans; 

(b) A list with brochures and data sheets for system appurtenances to be used. Include the welded or 

twisted wire mesh for gabion barriers, and the following for flexible rockfall barrier system; mesh 

fabrics, anchors, support system, lacing wire rope, wire mesh fasteners, anchor bars, wire rope anchors, 

grout, wire rope, clips, thimbles, ferrules, steel rings, and other fastening hardware; 

(c) Manufacturer’s design and detail drawings showing full, detailed dimensions of component parts 

and layout of posts, post anchorage systems, post foundations, anchors and support ropes, system and 

material specifications, and assembly plan for the flexible rockfall barrier system. Include post 

foundation dimensions and offset relative to centerline; 

(d) Methods, equipment, and materials for preparing the alignment for the gabion barriers and flexible 

rockfall barrier systems;

(e) Methods, equipment, and materials for designing and installing the post anchorage systems and 

foundations for the flexible rockfall barrier system as required by the manufacturer. Include the 
Section 265

220

construction sequence including the required curing time for foundations and anchors before installing 

other system components or applying external loads; 

(f) A manual detailing the required flexible rockfall barrier system maintenance procedures, as 

specified by the manufacturer; and 

(g) Methods, materials, and equipment for drilling, installing, grouting, and testing anchors for flexible 

rockfall barrier system. Include the following: 

(1) Mix design for grouting operations; 

(2) Manufacturer’s recommendations for anchor test loads; 

(3) Working drawings for the temporary yoke or load frame to be used for the anchor proof testing; 

and 

(4) Calibration data performed by an independent testing laboratory within 90 days of the submittal 

for each load cell, test jack pressure gauge, and master pressure gauge to be used. 

265.04 General. Install roadside rockfall protection at the locations and with the requirements shown in 

the plans.

Construct roadside rockfall protection consisting of gabion barriers and flexible rockfall barrier systems 

as shown in the plans. 

Perform safety scaling that the Contractor deems necessary according to Section 262. 

Repair galvanized finishes according to Section 563. If applicable, treat exposed steel surfaces according 

to Section 563. 

Recalibrate each load cell, test jack pressure gauge, and master pressure gauge every 90 days from the 

originally submitted calibration date. 

265.05 Gabion Barriers. Conform to 

265.06 Flexible Rockfall Barrier Systems. Design, provide, and install roadside rockfall protection 

fences according to the manufacturer’s recommendations and as shown in the plans. Include all applicable 

posts, post anchorage systems and foundations, anchors, support wire ropes, braking elements, and mesh 

panels.

Section 253. 

Provide barrier panels made of interlocking nominal 7- to 12-inch diameter openings backed by a finer 

mesh placed on the roadside of the fence to prevent smaller rock from moving past the barrier as shown 

in the plans. 

(a) Equipment. List equipment to be used for roadside rockfall protection fence work. Include 

equipment capacities and intended uses.

(b) Design. Complete required design according to the manufacturer’s recommendations for all 

component parts including, but not limited to, the layout of posts, post anchorage systems, post 

foundations, braking elements, anchors, and support ropes. Design a system that meet or exceeds the 
Section 265

221

requirements shown in the plans, including system height, energy level classification, MEL, SEL, 

classification for residual height for MEL, and elongation at the MEL. 

(c) Installation. Locate the barrier panel at the centerline offset shown in the plans.

Prepare the alignment of the flexible rockfall barrier system by clearing debris that is accumulated in 

the roadside ditch. Dispose of the material according to Subsection 203.07. 

Erect the post anchorage systems, anchors, and posts according to the approved drawings, the 

construction sequence, and the manufacturer’s recommendations. Install posts within the required 

manufacturer’s tolerances for alignment and orientation.

Install and fasten top and bottom support wire ropes according to the manufacturer’s 

recommendations. Fasten wire ropes only after the tested anchors have been accepted in writing.

Install and connect the rockfall mesh according to the manufacturer’s recommendations. 

(d) Post anchorage systems. Locate, anchor, and install posts according to the manufacturer’s 

recommendations and the approved drawings. Do not exceed the manufacturer’s spacing 

recommendations for the posts, center to center. Perform excavation and foundation preparation work 

according to Section 209. 

Perform foundation work for the posts and anchors according to approved drawings, construction 

sequence, and the manufacturer’s recommendations. Foundations may be either precast or 

cast-in-place. If cast-in-place systems are used, do not disturb or apply any load to any of the post 

anchorage systems until the concrete has cured at least 5 days or as recommended by the manufacturer, 

whichever is greater.

(e) Anchors. Locate, orient, and install anchors according to the manufacturer’s recommendations and 

approved drawings for support of system appurtenances. Include posts, top and bottom support wire 

ropes, and other elements as specified by the manufacturer.

(f) Anchor testing. Verify anchor capacities by conducting axial pullout proof tests on all the end post 

base anchors, lateral anchors for support and lateral ropes, and upslope anchors; and 25 percent of the 

intermediate post base anchors, as selected by the CO. Provide test loads as specified by the 

manufacturer.

Proof tests will be accepted when an anchor maintains the test load for 10 minutes without loss of 

load. Conduct the test against a temporary yoke or load frame with no part of the yoke or load frame 

within 3 feet of the anchor. If more than two of the tested anchors fail, test all anchors. Replace failed 

anchors. 

Collect samples of the grout from two batches of grout that is being used for grouting and submit grout 

cubes to an independent testing firm for breaking strength testing. Provide 3-day and 7-day unconfined 

compression test results to the CO. The CO may also request samples for testing.

Complete anchor testing before conducting additional work on the post anchorage systems or 

connecting any system components to any anchors. 
Section 265

222

(g) Wire ropes and mesh panels. Install and fasten support wire ropes according to the 

manufacturer’s recommendations. Install and connect the mesh panels and backing material according 

to the manufacturer’s recommendations.

(h) Manufacturer certification. Conduct an on-site review of the completed flexible barrier systems 

with a manufacturer’s representative. Provide written certification from the manufacturer to the CO 

for approval that the flexible rockfall barrier systems have been installed according to the 

manufacturer’s recommendations. 

265.07 Flexible Rockfall Barrier System Test Results and Reporting. Submit test results. Maintain 

daily records of installation work. Include the following: 

(a) Drawings depicting the location of each anchor, wire rope anchor, and post anchorage anchor. 

Note anchor designation, date drilled, the general drilling conditions, materials encountered, the 

location of significant drilling changes (such as geologic contacts, voids, or open fractures), dates of 

grouting operations, total anchor length, grout mix, grout volume, average grout pressure, hole 

diameter, and installation comments. Submit as-built drawings according to Subsection 104.06(c).

(b) Anchor proof test data forms. Include the anchor designation, date of testing operation, signature 

of testing operator or inspector, identification numbers of jacking equipment, and comments.

265.08 Acceptance. See Table 265-1 for sampling, testing, and acceptance requirements.

Design of flexible rockfall barrier systems will be evaluated under Subsection 106.02. 

Material for flexible rockfall barrier systems will be evaluated under Subsections 106.02, 106.03, and 

106.04. 

Construction of flexible rockfall barrier systems will be evaluated under Subsections 106.02 and 106.04. 

Gabion barriers will be evaluated under Section 253. 

Safety scaling will be evaluated under Section 262. 

Treating exposed steel surfaces, treating galvanized steel field cuts, and repairing damaged galvanizing 

will be evaluated under Section 563. 

Measurement

265.09 Measure the Section 265 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring roadside rockfall protection fence by the linear foot, measure along the alignment of the 

support posts between the terminal end posts.

When measuring roadside rockfall protection gabion barriers by the cubic yard, measure in the structure. 
Section 265

223

Payment

265.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 265 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 265-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Non-shrink 

grout 

(701.04(b)(2))

Measured &

tested for

conformance

(106.04)

Flow – ASTM C939

1 per mix 

design Source of

Material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

– 

Compressive 

strength (3-day 

& 7-day)

– ASTM C109

1 set from 

each batch 

of grout

Source of

Material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

– 

Proof test for 

flexible 

rockfall 

barrier 

anchors

Measured &

tested for

conformance

(106.04)

Deformation – Subsection 

265.06(f)

Subsection 

265.06(f) Installation No

Within 24

hours after 

completion 

of test

– 
Section 266 

225

Section 266. — ANCHORED WIRE MESH SYSTEM

Description

266.01 This work consists of providing and installing an anchored wire mesh system. 

266.02 Conform to the following Subsections: 

Material 

Anchor nails 722.05

Anchor plates 717.01(h)

High tensile strength steel wire mesh 710.10(d)(2)

Non-shrink grout 701.04(b)(2)

Rockfall protection hardware 717.01(f)

Rockfall protection nuts and washers 717.01(g)

Turf reinforcement mat 713.18

Water for cementitious materials 725.01(a)

Wire mesh fastener 710.09(c)

Wire rope 709.03

Wire rope anchors 722.07(b)

Construction Requirements

266.03 Qualifications. Provide an on-site supervisor with experience installing anchored mesh systems, 

and drill operators with experience installing ground anchors. At least 21 days before starting rockfall 

protection work, submit the following for approval: 

(a) On-site supervisor. A résumé describing experience on at least three projects installing anchored 

mesh systems within the past 3 years. Include project names, locations, and contact information for 

project owners; 

(b) Drill operators. A résumé describing experience installing at least 1000 linear feet of anchor nails

for anchored wire mesh systems within the past 3 years. Include project names, locations, and contact 

information for project owners; 

(c) Rope supported laborers. A résumé for rope supported laborers conforming to

Subsection 262.02; and 

(d) High tensile strength steel wire mesh suppliers. Include the following: 

(1) Evidence showing the manufacturer has at least 5 years’ experience manufacturing the 

specified products used in similar system applications and capacities. Include details of the 

manufacturer’s testing procedures and certification of a QA program; and 

(2) Include summaries of at least 5 past projects with similar site conditions anchored wire systems 

were installed using the supplier’s high tensile strength steel wire mesh. Include owner names and 

contact information.
Section 266 

226

266.04 Submittals. At least 21 days before starting anchored wire mesh installation work, submit the 

following according to Subsection 104.06:

(a) Materials. Identify the high tensile strength steel wire mesh suppliers, and submit the following:

(1) An inclusive list with brochures and data sheets for system appurtenances to be used. Include 

the high tensile strength steel wire mesh, anchor nails, anchor plates, grout, lacing wire rope, wire 

mesh fastener, wire rope thimbles, ferrules, and other fastening hardware; and

(2) At least two samples of each available color and texture for the turf reinforcement mat in a 

range of earth-tone colors representative of the adjacent landscape.

(b) Equipment.

(1) List of equipment to be used for anchored wire mesh installation, including equipment 

capacities and intended uses; and 

(2) Calibration data, including a graph of torque versus tension for each torque wrench to be used. 

Include certifications showing calibration testing was conducted by an independent laboratory 

within 90 days of the date submitted. 

(c) Work plan.

(1) A description of safety procedures minimizing exposure to hazardous and potentially 

hazardous conditions to the public, construction personnel, and equipment. Include temporary 

rockfall mitigation measures, special designs, and installation procedures deemed necessary to 

safely perform the rockfall protection work; 

(2) A list of materials, devices, and equipment used, and the methods that will be incorporated to 

protect existing facilities (underground, on the ground surface, and above-ground) and minimize 

impacts to the environment according to Section 107;

(3) A list of equipment and methods for installing the high-tensile strength steel wire mesh system 

including temporary anchoring; 

(4) Methods and equipment for installing and connecting adjacent wire mesh panels and attaching 

them to temporary supports. Explain how mesh panels will be placed on the slope in a top-down 

method. Detail how panels overlap on the slope to maintain direct contact with the slope to prevent 

bulges or loose areas in the finished mesh; 

(5) Methods and equipment for drilling, grouting, and attaching anchoring boundary ropes and 

seam ropes; 

(6) Methods and equipment for drilling, grouting, and installing anchor nails. Describe how anchor 

plates for the mesh system will be installed to obtain direct contact with the ground; 

(7) Methods to ensure borehole stability during excavation and grout placement in holes. If open 

joints, seams, or loose material is encountered, the methods, equipment, and materials used to 

control excessive grout injection volumes; and
Section 266 

227

(8) Details for installing, stressing, and testing anchor nails.

266.05 Installation. 

(a) General. Provide an anchored wire mesh system that utilizes rock and soil reinforcement with 

anchor plates and a homogenous high-tensile-strength steel wire mesh consisting of a singlecomponent wire type installed into direct contact with the slope to be stabilized. 

Perform safety scaling that the Contractor deems necessary according to Section 262. 

Before installing anchor wire mesh systems, complete work required according to Sections 260, 262, 

and 267, and other on-slope rock stabilization work as applicable. 

Repair galvanized finishes according to Section 563. If applicable, treat exposed steel surface 

according to Section 563. 

Provide uniform high-tensile strength steel wire mesh to construct the anchored wire mesh system 

installation. Complete the portion of the roadway cut in overburden soils according to Section 204

before placing the anchored wire mesh system. Minimize bridging mesh over exposed gaps and 

protruding boulders between anchors if present and maximize the wire mesh fabric contact with the 

ground surface. Remove mesh bulges or loose mesh that is not in contact with the surface by removing 

and resetting the mesh. Do not twist, pinch, or fold mesh together to tighten loose mesh or bulged 

mesh. Do not pinch, crush, or damage mesh or turf reinforcement mat under the anchor plate or in the 

annulus space between the plate and anchor nail. Additional anchor nails may be required to remove 

areas of loose mesh.

If shown in the plans, place a permanent turf reinforcement mat, type 5.C between the natural slope 

and the steel wire mesh according to Section 629. Secure the turf reinforcement mat to the slope face 

according to Subsection 629.06(a)(1) or 629.06(a)(3). Provide a permanent turf reinforcement mat 

with an approved color and texture. 

(b) Wire mesh installation. Install wire mesh panels at the locations shown in the plans. Construct 

the anchored wire mesh system from the top down following the manufacturer’s installation guide. 

Extend the anchor nails and wire mesh at least three rows of mesh openings above the crest of the 

slope. The wire mesh should be temporarily secured at the top of the slope to facilitate the installation 

procedure. Construct required temporary anchoring according to the approved submittal plan. 

No equipment operation is allowed on slope areas after wire mesh has been placed.

Overlap adjacent wire mesh panels at least 3 inches to provide at least one mesh opening of overlap 

between panels. Increase the wire mesh overlap as necessary to fully cover the required slope area 

shown in the plans. Lace mesh panel side seams to an adjacent panel using a 1⁄4-inch diameter lacing 

wire rope or connect panels with wire mesh fasteners meeting the mesh manufacturer’s 

recommendations. If the overlap between panels is too great to fully secure panel edges with a single 

lacing wire rope, use additional lacing wire ropes to secure panel edges or multiple rows of wire mesh 

fasteners. Secure both ends of lacing wire rope installations by looping the end of the rope back onto 

itself and fastening it with wire rope clips according to the manufacturer’s specifications. Anchor wire 

mesh installations so they conform to the slope surface as much as practical.
Section 266 

228

Place a 1⁄2-inch diameter boundary rope along edges of the anchored wire mesh. Anchor the boundary 

rope at the end of each boundary rope with additional anchor nails as needed and connect the ends of 

boundary rope to the anchor nails according to the manufacturer’s recommendations. More than 4 

boundary ropes may be required depending on the final shape of the anchored mesh area and 

arrangement of the anchor nails. Attach boundary ropes to the wire mesh and anchor plates according 

to the manufacturer’s recommendations.

Diagonal cutting of the high tensile strength mesh is not allowed.

Remove required temporary anchoring according to the approved submittal plan. 

(c) Anchor nail installation. Anchor nail installations are required for the mesh system. The areas 

that will receive anchor nails are shown in the plans along with the general pattern for the anchors. 

The pattern shown in the plans indicates the estimated number of anchors for the anchored wire mesh 

system. The actual pattern constructed will be adjusted to fit the slope shape and stabilization 

requirements as directed. Schedule a test installation to demonstrate procedure for anchor nail 

installation and testing.

Requirements for the anchor nail installation are as follows:

(1) For each anchor nail, drill a minimum 3-inch diameter hole perpendicular to the slope surface. 

Over-drill each hole at least 6 inches beyond the required anchor length. Refer to plans for the 

minimum depth of anchor nails. 

(2) Install anchor nails and grout according to the manufacturer’s recommendations. Use positive 

displacement grout pumps according to Subsection 256.07(b)(1). Control grout pressures to avoid 

ground heaving or fracturing, and fill grout tube with grout if it remains in the hole. Flush surplus 

water and diluted grout from lines before injection and replace leaky fittings before continuing 

grouting operations. Clean excess grout off rock surfaces, anchor nails, and bearing plates. Perform 

QC of the grout by performing minimum compressive strength. Record the quantity of injected 

grout and the grout pressure for each installation. Notify the CO of grout quantity overruns 

including the reason for the overrun and proposed actions to minimize future overruns. Obtain 

approval for alternative grouting methods.

(3) Excavate as shown in the plans around each nail head to ensure optimal load transfer from the 

anchor nail to the anchor plate to the wire mesh fabric. Install anchor plates, washers, nuts, and 

associated hardware according to the manufacturer’s recommendations and the plans. 

(4) Tension each anchor nail no more than one week after completing grouting. Tension in the 

anchor nail with a calibrated torque wrench to loads shown in the plans. If the tension load cannot 

be achieved, replace the anchor nail with an additional nail installed in a separate hole. Additional 

anchors may be needed to supplement the anchor nail spacing patterns shown in the plans to 

accommodate slope geometry. Obtain approval for all anchor locations. 

(5) Lock off each anchor to the specified design load capacity as shown in the plans. 

266.06 Acceptance. See Table 266-1 for sampling, testing, and acceptance requirements.

Material for the anchored wire mesh system installations will be evaluated under Subsections 106.02 and 

106.03. 
Section 266 

229

Construction and erection of anchored wire mesh installations will be evaluated under Subsections 106.02

and 106.04. 

Submit a production certification for wire ropes and anchor nails.

Drain holes in rock will be evaluated under Section 267. 

Rock bolts and dowels will be evaluated under Section 260. 

Safety scaling will be evaluated under Section 262. 

Treating exposed steel surfaces, treating galvanized steel field cuts, and repairing damaged galvanizing 

will be evaluated under Section 563. 

Measurement

266.07 Measure the Section 266 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring anchored wire mesh system pay items by the square yard, measure the completed in 

place work performed on the ground surface, excluding overlaps and areas trimmed off. 

Do not measure anchor nails required for the anchored wire mesh.

Measure additional anchors as described under Subsection 266.05(a) per each additional anchor installed. 

Payment

266.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 266 pay items listed in the bid schedule. Payment will be full compensation for the work described 

in this Section. See Subsection 109.05. 
Table 266-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Non-shrink 

grout 

(701.04(b)(2))

Measured &

tested for

conformance

(106.04)

Flow – ASTM C939

1 per mix 

design Source of

Material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

– 

Compressive 

strength (3-day 

& 7-day)

– ASTM C109

1 set from 

each batch 

of grout

Source of

Material

Yes, if 

requested

Within 24 

hours after 

completion 

of test

– 

Proof test for 

anchor nails

Measured &

tested for

conformance

(106.04)

Deformation – Subsection 

266.05(c)(4) Each nail Installation No

Within 24 

hours after 

completion 

of test

– 
Section 267 

231

Section 267. — DRAIN HOLES IN ROCK

Description

Material 

Construction Requirements

267.01 This work consists of constructing unlined and lined drain holes in rock. 

267.02 Conform to the following Subsections: 

267.03 Qualifications. At least 30 days before starting drain hole in rock work, submit the following for 

approval:

Lined drain holes in rock 708.06(e)

Packaged repair mortar 701.05(b)

Water for cementitious materials 725.01(a)

(a) On-site supervisor. A résumé for each on-site supervisor describing at least 2 years’ experience 

in supervising construction of drain holes in rock of similar lengths and scope to those shown in the 

plans and in similar geotechnical conditions; 

(b) Drill operator. A résumé for each drill operator describing at least 1 year’s experience in the 

construction of drain holes; and 

(c) Rope supported laborers. A résumé for rope supported laborers conforming to

Subsection 262.02. 

267.04 Submittals. At least 30 days before starting drain hole in rock work, submit the following 

according to 

267.05 General. Verify location, elevation, spacing, and orientation of the drain hole installations. The 

exact locations of the drain holes will be determined by the CO. 

Subsection 104.06:

(a) Proposed construction sequence and schedule; 

(b) Drain hole access and drilling plan. Include details on the method for constructing the drain holes 

and measures proposed to contend with excessive drain flow during construction. Include narratives 

and drawings to describe the access, and the horizontal drilling and installation plan; 

(c) List of materials with brochures and data sheets;

(d) List of equipment to be used. Include equipment capacities and intended uses, and;

(e) Examples of drilling logs for documenting the drain diameter, drain length, advancement rates, 

materials encountered, and the presence of water and estimated flows for each drilled hole.

Perform safety scaling that the Contractor deems necessary according to Section 262. 
Section 267 

232

Construct drain holes in rock that do not intersect or affect existing rock bolts and rock dowels. Complete 

work according to Sections 260 and 262 before constructing drain holes in rock.

Dispose of removed vegetation according to Subsection 203.07. 

267.06 Drilling Holes. Schedule a meeting between the drilling foreperson, the drill operator, and the CO 

to review the drilling plan before starting drilling work.

Provide equipment that can drill straight, uniform-diameter holes with the diameter and length as shown 

in the plans. Install unlined horizontal drain holes inclined upwards as shown in the plans. 

Maintain a log of material types, production rates, and estimated water flows encountered during drilling. 

Once the planned length of each drain is achieved, flush each hole until water is observed to be relatively 

clear.

Dispose of drilling water and drill flushing according to Federal, state, and local rules and regulations. 

267.07 Lined Drain Holes. Install slotted PVC pipe from the terminus of the drilled hole to 5 feet from 

the face of the rock face. Install solid PVC pipe for the remaining 5 feet and to the outlet drain. Join the 

slotted PVC pipe to the solid PVC pipe with approved couplings. 

267.08 Acceptance. Material for drain holes in rock will be evaluated under 

Provide a 6-inch minimum thickness of mortar at the rock face. Add water for workability and molding.

Subsections 106.02 and 

106.03. 

Construction of drain holes in rock will be evaluated under Subsections 106.02 and 106.04. 

Rock bolts and dowels will be evaluated under Section 260. 

Slope scaling and safety scaling will be evaluated under Section 262. 

Measurement

267.09 Measure the 

267.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 267 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring drain holes in rock by the linear foot, measure the length of the drilled hole from the 

termination of the hole to the rock slope face.

Payment

Section 267 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 268

233

Section 268. — HORIZONTAL DRAINS

Description

268.01 This work consists of constructing horizontal drains, including collector systems. 

Material 

268.02 Conform to the following Subsection: 

Horizontal drains 708.06(d)

Construction Requirements

268.03 Qualifications. Provide an on-site supervisor and installation personnel with experience installing 

and testing horizontal drains. At least 30 days before starting horizontal drain work, submit a résumé for 

each individual describing their experience on at least five horizontal drain projects of similar complexity 

within the past 5 years for approval. Include project names, locations, and contact information for project 

owners. 

268.04 General. Verify location, elevation, spacing, and orientation of the horizontal drains’ installation.

Provide pipe and fittings with an outside diameter of at least 11⁄2 inches or as specified. Provide slotted 

pipe with three rows of slots cut circumferentially in the pipe 120 degrees apart. Make the width of the 

slots 0.01 inch, with the total slot opening area equal to 0.46 square inch per foot of pipe. Provide 

couplings, cleanouts, elbows, and other fixtures required for collection of water made of material that are 

compatible with the installed drain pipe.

The locations for installing horizontal drains shown in the plans are approximate. The exact locations will 

be determined by the CO. Pipe drains that start more than 12 inches or end more than 3.5 feet per 100-foot 

installed pipe from their planned locations, are damaged in construction, or are improperly installed will 

be rejected.

268.05 Drilling Holes. Drill holes with rotary equipment that can drill 3- to 6-inch diameter holes up to 

600 feet to designated lines and grades through soil and rock formations. Keep a log of material types, 

production rates, and estimated water flows encountered during drilling. Install horizontal drains as shown 

in the plans. During drilling operations, determine the elevation of the drilled hole at 100-foot intervals 

and at the upper end of the completed horizontal drain hole by inserting tubes or pipes and measuring 

liquid levels or by other approved means. 

Dispose of drilling water and water encountered during drilling according to Federal, state, and local rules 

and regulations. 

268.06 Installing Horizontal Drain. Tightly plug the entrance end of the slotted pipe with a rounded or 

pointed extension that does not extend more than 6 inches beyond the end of the pipe. Insert the pipe 

inside the drill rod and then retract the drill rod so the drilled hole is cased with the slotted pipe from the 

back of the hole to within 20 feet of the outlet. Connect additional pipe as necessary to form a continuous 

tube. Use unslotted pipe for the last 20 feet at the outlet end.
Section 268

234

Seal the space between the drilled hole and the un-slotted pipe for at least 10 feet at the outlet end with an 

approved impermeable material. Do not seal the space between the drilled hole and the slotted pipe. 

268.07 Installing Outlet Drains and Collector Systems. Attach outlet drain pipe to the ends of horizontal 

drains by a tee or street ell. Install a collector system of the type, kind, and size as shown in the plans. 

For pipe drain installations draining directly to daylight, cover the outlet end of the pipe with a removable 

screen made of 0.055-inch diameter galvanized wires with approximately 1⁄2- by 1⁄2-inch mesh openings. 

268.08 Acceptance. Material for horizontal drains will be evaluated under Subsections 106.02 and 

106.03. 

Construction of horizontal drains will be evaluated under Subsections 106.02 and 106.04. 

Measurement

268.09 Measure the Section 268 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

268.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 268 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
235

DIVISION 300 

AGGREGATE AND BASE COURSES
Section 301

236

Section 301. — UNTREATED AGGREGATE COURSES

Description

301.01 This work consists of constructing aggregate courses on a prepared surface.

Material 

301.02 Conform to the following Subsections: 

Subbase, base, and surface course aggregate 703.05

Water for construction 725.01(c)

Construction Requirements

301.03 General. Prepare the surface according to Section 204 or 303 as applicable.

After a representative quantity of aggregate is produced, submit target values within the required gradation 

range along with a representative 300-pound sample at least 14 days before incorporating the aggregate 

into the work. 

301.04 Mixing and Spreading. Determine the optimum moisture content according to AASHTO T 180, 

Method D. Mix the aggregate and adjust the moisture content to obtain a uniform mixture with a moisture 

content within 2 percent of the optimum moisture content. Spread and shape the mixture on the prepared 

surface in a uniform lift.

Place mixture in a lift no more than 6 inches in compacted thickness. If more than one lift is necessary, 

compact each lift according to Subsection 301.05 before placing the next lift. Route hauling equipment 

uniformly over the full width of the surface to minimize rutting or uneven compaction. 

301.05 Compacting. Determine the maximum density of the mixture according to AASHTO T 180, 

Method D. 

Compact the full width of each lift. Roll from the sides to the center, parallel to the centerline of the road. 

Along curbs, headers, walls, and places not accessible to the roller, compact the material with approved 

tampers or compactors.

Compact each lift to at least 95.0 percent of maximum density. Determine the in-place density and 

moisture content according to AASHTO T 310 or other approved test procedures. 

301.06 Surface Tolerance. If grade finishing stakes are required, finish the surface to within ±0.05 feet 

from staked line and grade elevation. 

If AMG methods are used, finish the surface to within ±0.05 feet from the design line and grade elevation.

If grade finishing stakes are not required and AMG methods are not used, shape the surface to the required 

template and check the surface with a 10-foot metal straightedge. Defective areas are surface deviations 

more than 1⁄2 inch in 10 feet between two contacts of the straightedge with the surface.
Section 301

237

Correct defective areas by loosening the material, adding or removing material, reshaping, and 

compacting. 

301.07 Maintenance. Maintain the aggregate course to the correct line, grade, and cross-section by 

blading, watering, rolling, or combination thereof until placement of the next course. Correct defects 

according to Subsection 301.06.

301.08 Acceptance. See Table 301-1 for sampling, testing, and acceptance requirements.

Aggregate gradation and surface course plasticity index will be evaluated under Subsection 106.05. Other 

aggregate quality properties will be evaluated under Subsections 106.02 and 106.04. 

(a) Aggregate gradation. The upper and lower specification limits are equal to the calculated mean 

of all test results plus or minus the allowable deviations shown in Tables 703-1 and 703-2, except as 

follows:

(1) If the calculated mean value for a tested sieve exceeds the maximum gradation range value 

shown in Table 703-1, then the upper specification is equal to the maximum gradation value in 

Table 703-1 plus or minus the allowable deviation in Table 703-2. 

(2) If the calculated mean value for a tested sieve is less than the minimum gradation range value 

shown in Table 703-1, then the lower specification is equal to the minimum gradation value in 

Table 703-1 plus or minus the allowable deviation in Table 703-2. 

(b) Plasticity index. The upper and lower specification limits for surface courses are shown in 

Subsection 703.05(c)(3). 

Construction of untreated aggregate courses will be evaluated under Subsections 106.02 and 106.04. 

Measurement

301.09 Measure the Section 301 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring aggregate by the cubic yard, measure in place.

When measuring aggregate by the square yard, measure the length horizontally along the centerline of the 

roadway. Measure the width horizontally to include the top of aggregate width, including designed 

widenings. 

Payment

301.10 The accepted quantities will be paid at the contract price per unit of measurement adjusted 

according to Subsection 106.05 for the Section 301 pay items listed in the bid schedule. Payment will be 

full compensation for the work prescribed in this Section. See Subsection 109.05. 
Table 301-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

quality

(703.05(a), 

(b), & (c)) 

Measured &

tested for

conformance

(106.04 & 

105) 

LA abrasion

(coarse) − AASHTOT 96

1 per

type &

source

of material

Source of

material Yes

Before

using

in work

Not required

if using

Government

-furnished

sources

Soundness

using

sodium sulfate

(coarse & fine)

− AASHTO

T 104 " " " " " 

Fractured

faces − ASTMD5821 " " " " " 

Liquid limit −

AASHTO

R58 & T 89,

Method A

" " " " " 

Surface course

aggregate

(703.05(c)) 

Measured & 

tested for 

conformance 

(106.04 & 

105)

Plasticity index −

AASHTO

R 58, T 89,

& T 90

1 per

type &

source

of material

Crusher

belt or

after

processing

Yes

Before 

using in 

work

Not required

if using

Government

-furnished

sources
Table 301-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source (continued)

Subbase, base,

or

surface course

aggregate

(703.05(b) & 

(c)) 

Process

control

(153.03) 

Gradation − AASHTO

T 11 & T 27

2 per

day per

stockpile 

minimum

Crusher

belt No 24 hours

Not required

if using

a precrushed

commercial

source

Fractured faces − ASTM

D5821 " " " " " 

Surface course

aggregate

(703.05(c)) 

" Plasticity index −

AASHTO

R 58, T 89,

& T 90

2 per

day per

stockpile 

minimum

Crusher belt

or after

processing

No 24 hours

Not required

if using

a precrushed

commercial

source

Production

Subbase

course

Grading

A & B

Statistical

(106.05) 

Gradation

AASHTO

T 27 & T 11

1 per

1000 tons

From

windrow

or

roadbed

after

processing

Yes 4 hours −

No. 4 I 

No. 200 I 

Other

specified

sieves

II
Table 301-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Base course

Grading C,

D, & E

Statistical

(106.05) 

Gradation

AASHTO

T 27 & T 11

1 per

1000 tons

From 

windrow

or roadbed

after

processing

Yes 4 hours −

3⁄8 in I 

No. 4 I 

No. 200 I 

Other

specified sieves II

Subbase &

base course

Grading A,

B, C,

D, & E

Measured &

tested for

conformance

(106.04) 

Liquid limit −

AASHTO

R 58 & T 89,

Method A

1 per

1000 tons

From 

windrow

or roadbed

after 

processing

Yes 4 hours −

Moisturedensity

(maximum 

density)

−

AASHTO

T 180,

Method D(1)

1 per

type &

source

of material

Stockpile

or 

production

output

" " −

Density −

AASHTO

T 310

or other 

approved

procedures

1 per

500 tons

In-place

after

compaction

No End

of shift −

Moisture

content

(in-place)

− " " " " " −
Table 301-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Surface

course

aggregate

Statistical

(106.05) 

Gradation

AASHTO

T 27 & T 11

1 per

1000 tons

From 

windrow

or roadbed

after

processing

Yes 4 hours −

No. 4 I 

No. 40 I 

No. 200 I 

Other specified

sieves II

Plasticity index I 

AASHTO

R 58, T 89,

& T 90

" " " " −

Measured &

tested for

conformance

(106.04) 

Moisturedensity

(maximum 

density)

−

AASHTO

T 180,

Method D(1)

1 per

type &

source

of material

Stockpile or

production

output

Yes " −

Density −

AASHTO

T 310 or

other 

approved

procedures

1 per

500 tons

In-place 

after 

compaction

No End of shift −

Moisture

content

(in-place)

− " " " " " −

Fractured

faces − ASTMD5821

1 per

1000 tons

From 

windrow

on roadbed

after

processing

Yes 4 hours −
Table 301-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Product

Subbase, base,

& surface

course

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

− Subsection

301.06 As directed Surface of

final course No

Before

placement

of next

lift or as

requested

−

(1) At least 5 points per proctor.
Section 302

243

Section 302. — CRUSHED AGGREGATE

Description

302.01 This work consists of providing and placing crushed aggregate. 

Material 

302.02 Conform to the following Subsections: 

Crushed aggregate 703.06

Water for construction 725.01(c)

Construction Requirements

302.03 Preparing Surface. 

(a) Roadway aggregate. Prepare the surface according to Section 204 or 303 as applicable.

(b) Bedding and backfill aggregate. Shape, compact, and finish the surface to the required line, 

grade, elevation, and cross-section according to Section 209. 

(c) Shoulder finishing aggregate. Remove slide material, vegetation, and other debris from existing 

shoulders including shoulders in parking areas, turnouts, and other widened areas. Repair soft and 

unstable areas according to Subsection 204.07. Reshape shoulders to the widths and slopes shown in 

the plans. Dispose of waste at designated sites or according to Subsection 204.14. 

302.04 Mixing and Spreading. 

(a) Roadway aggregate. Mix the aggregate and adjust the moisture content to obtain a uniform 

mixture. Adjust the moisture content to obtain proper compaction. Spread and shape in uniform lifts 

no more than 6 inches compacted thickness. If more than one lift is necessary, compact each lift 

according to Subsection 302.05(a) before placing the next lift.

(b) Bedding and backfill aggregate. Spread and shape in uniform lifts no more than 6 inches 

compacted thickness. If more than one lift is necessary, compact each lift according to 

Subsection 302.05(b) before placing the next lift.

(c) Shoulder finishing aggregate. Mix the aggregate and adjust the moisture content to obtain a 

uniform mixture. Adjust the moisture content to obtain proper compaction. Spread and shape in 

uniform lifts no more than 6 inches compacted thickness.

302.05 Compacting and Finishing Crushed Aggregate. 

(a) Roadway aggregate. If no compaction method is specified, use either method. Finish the surface 

according to Subsection 301.06. 

(1) Method 1. Compact each lift according to Subsection 204.11(a). Roll from the sides to the 

center, parallel to the centerline of the road. Compact the material along curbs, headers, walls, and 

places not accessible to a roller with approved tampers or compactors.
Section 302

244

Compactive effort may be decreased if in-place densities show that less compactive effort is 

required under Method 2. 

(2) Method 2. Compact each lift according to Subsection 301.05. 

(b) Bedding and backfill aggregate. Compact each lift according to Subsection 209.10. 

(c) Shoulder finishing aggregate. Uniformly compact each lift to ensure it does not exhibit heaving, 

pumping, rutting, or shearing. Finish surface according to Subsection 301.06.

302.06 Acceptance. See Table 302-1 for sampling, testing, and acceptance requirements.

Crushed aggregate will be evaluated under Subsections 106.02 and 106.03. Submit a production 

certification including gradation and quality properties for each source. 

Construction of crushed aggregate will be evaluated under Subsections 106.02 and 106.04. 

Measurement

302.07 Measure the Section 302 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring crushed aggregate by the cubic yard, measure in place.

When measuring crushed aggregate by the square yard, measure the length horizontally along the 

centerline of the roadway. Measure the width horizontally to include the top of aggregate width, including 

designed widenings. 

Payment

302.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 302 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 302-1 

Sampling, Testing, and Acceptance Requirements

Material 

or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Crushed

aggregate

Measured &

tested for

conformance

(106.04) 

Moisturedensity −

AASHTO

T 180,

Method D(1)

1 per

aggregate

supplied

Production

output

or stockpile

Yes 4 hours

Not 

required 

for 

shoulder 

finishing

Gradation(2) − AASHTO T 

11 & T 27

1 per 

500 tons

From the 

windrow or 

roadbed 

after 

processing.

" 

Before 

placing 

next lift

For

Method 2

compactio

n 

only

Density −

AASHTO

T 310

or other 

approved

procedures

1 per 

500 tons

In-place

after

compaction No End ofshift " 

Crushed

aggregate

Process

control

(153.03) 

Moisture

content

(in-place)

−

AASHTO

T 310

or other 

approved

procedures

1 per 

500 tons

In-place

after

compaction

No End of shift

Not 

required 

for 

shoulder 

finishing

Finished Product

Crushed

aggregate

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

− Subsection

301.06 As directed Surface of

final course No

Before

placement

of next

lift or as

requested

−

(1) At least 5 points per proctor.

(2) Sampling and testing only required for roadway aggregate. Conform to the approved certification.
Section 303

246

Section 303. — ROAD RECONDITIONING

Description

303.01 This work consists of reconditioning ditches, shoulders, roadbeds, aggregate surfaces, and 

roadways. 

Material 

303.02 Conform to the following Subsection: 

Water for construction 725.01(c)

Construction Requirements

303.03 General. Dispose of waste at designated sites or according to Subsection 204.14.

303.04 Ditch Reconditioning. Remove slide material, sediment, vegetation, and other debris from 

existing ditches and culvert inlets and outlets. Reshape ditches and culvert inlets and outlets to achieve 

positive drainage and uniform ditch width, depth, and grade or as shown in the plans. 

303.05 Shoulder Reconditioning. Remove slide material, vegetation, and other debris from existing 

shoulders including shoulders in parking areas, turnouts, and other widened areas. Repair soft and unstable 

areas according to Subsection 204.07. Reshape shoulders to the widths and slopes shown in the plans. 

303.06 Roadbed Reconditioning. Remove organic, deleterious, and material larger than 6 inches from 

the top 6 inches of subgrade. Repair soft and unstable areas according to Subsection 204.07. Scarify 

surface to a 6-inch depth. Remove irregularities and shape to a uniform surface. Finish earth surfaces to 

within 0.05 feet and rock surfaces to within 0.10 feet of required line, grade, and cross-section. Compact 

according to Subsection 204.11. 

303.07 Aggregate Surface Reconditioning. Repair soft and unstable areas to the full aggregate surface 

depth and according to Subsection 204.07. Scarify to the depth of aggregate surfacing shown in the plans. 

If no depth is indicated in the plans, scarify to a 6-inch depth. Remove irregularities and shape to a uniform 

surface. Compact and finish the surface according to Subsections 301.05 and 301.06. 

303.08 Roadway Reconditioning. Perform applicable work described in Subsections 303.03 through 

303.07. Maintain existing cross slope and crown or shape and grade as shown in the plans. 

303.09 Acceptance. See Table 303-1 for sampling, testing, and acceptance requirements.

Road reconditioning work will be evaluated under Subsections 106.02 and 106.04. 

Measurement

303.10 Measure the Section 303 pay items listed in the bid schedule according to Subsection 109.02. 
Section 303

247

Payment

303.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 303 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 303-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Existing

roadbed

material or

aggregate

surfacing

Measured &

tested for

conformance

(106.04) 

Classification – AASHTO

M 145

1 per

soil type Roadbed Yes

Before

using

in work

– 

Moisturedensity – 

AASHTO

T 180,

Method D(1)

or AASHTO

T 99,

Method C(1)

1 per

mixture

& change

in material

Processed

material No " – 

Density – 

AASHTO

T 310 or

other 

approved

procedures

1 per

2000 yd2

In-place

after

compaction

" End

of shift

For

Subsection

204.11(c)

cases only

Process

control

(153.03) 

Moisture

content

(in-place)

– 

AASHTO

T 310 or

other 

approved

procedures

1 per

2000 yd2

In-place

after

compaction

No End

of shift −

Finished Product

Aggregate

surface

reconditioning

(303.07) 

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

– Subsection

301.06 As directed

Surface

of final

course

No

Before

placement

of next

lift or as

requested

−

(1) At least 5 points per proctor.
Section 304

249

Section 304. — FULL DEPTH RECLAMATION

Description

304.01 This work consists of pulverizing an existing pavement and base in-place, adding crushed 

aggregate if required, mixing this material with water, and shaping and compacting the mix to produce a 

base.

Material 

304.02 Conform to the following Subsections: 

Crushed aggregate 703.06

Water for construction 725.01(c)

Construction Requirements

304.03 General. Maintain the existing cross-section or construct to proposed cross-section. 

Protect manholes, valve covers, and other buried facilities from damage.

304.04 Adding Crushed Aggregate. Add crushed aggregate as required to bring the finished surface to 

the established line, grade, and cross-section.

304.05 Pulverizing. Provide a road reclaimer that is:

(a) Self-propelled; 

(b) Specifically manufactured for in-place reclamation;

(c) Capable of reducing the existing material to the required size; 

(d) Equipped with at least an 8-foot cutting width; 

(e) Equipped with standard automatic depth controls adjustable in increments of 1⁄2 inch; and 

(f) Equipped with sufficient horsepower to constantly pulverize to the required depth in a single pass.

Pulverize the existing roadway material using the reclaimer until 100 percent passes the 11⁄2-inch sieve. 

Reprocess or remove larger particles and dispose of them according to Subsection 203.07. 

304.06 Mixing and Spreading. Add water as necessary to adjust the moisture content of the mixture to 

within 2 percent of the optimum for compaction. Mix to produce a homogenous full depth mixture. Spread 

the mixture uniformly to provide a final compacted shape according to the established line, grade, and 

cross-section.

304.07 Compacting and Finishing. If no compaction method is specified, use either method. Finish the 

surface according to Subsection 301.06. 
Section 304

250

(a) Method 1. Compact full depth reclamation (FDR) material full width according to 

Subsection 204.11(a). 

(b) Method 2. Collect representative samples of the pavement and base from the project. Process and 

blend these materials to achieve a gradation representative of the in-place pulverized material. 

Compact FDR material according to Subsection 301.05. 

304.08 Maintenance. Maintain the FDR material according to Subsection 301.07. 

304.09 Acceptance. See Table 304-1 for sampling, testing, and acceptance requirements.

Crushed aggregate will be evaluated under Subsections 106.02 and 106.03. 

Construction of full depth reclamation will be evaluated under Subsections 106.02 and 106.04. 

Measurement

304.10 Measure the Section 304 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

304.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 304 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 304-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Pre-Production (reclaimed material)

FDR material

Measured &

tested for

conformance

(106.04) 

Moisturedensity – 

AASHTO

T 180,

Method D(1)

1 sample at 

production 

start-up 

location

Production 

start-up 

location

Yes Before 

production

For 

Method 2 

compaction 

only

Production

FDR

material

Measured &

tested for

conformance

(106.04) 

Moisturedensity – 

AASHTO

T 180,

Method D(1)

1 per

change

in material

Behind

reclaimer

before

compaction

Yes

Before

using

in work

– 

Density – AASHTO

T 310

1 per

2000 yd2

In-place 

after

compaction

No End of

shift

For

Method 2

compaction

only

Process

control

(153.03) 

Moisture

content

(in-place)

– 

AASHTO

T 255

or other

approved

methods

1 per

3500 yd2 

minimum

FDR 

material 

after

compaction

No

Upon

completion

of test

−

Gradation – AASHTO

T 27 " 

Behind

reclaimer

before

compaction

" " 

Minus

11⁄2-in sieve

requirement

only

Finished Product

Finished

FDR

material

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

– Subsection

301.06 As directed

Completed

FDR

surface

No

Before

placement

of next

layer or as

requested

−

(1) At least 5 points per proctor.
Section 305

252

Section 305. — FULL DEPTH RECLAMATION WITH CEMENT

Description

305.01 This work consists of pulverizing an existing pavement and base in-place, adding crushed 

aggregate if required, mixing this material with cement and water, and shaping and compacting the mix 

to produce a stabilized base.

Material 

305.02 Conform to the following Subsections: 

Crushed aggregate 703.06

Hydraulic cement 701.01

Water for construction 725.01(c)

Construction Requirements

305.03 Proportioning. Collect representative samples of the pavement and base from the project. Process 

and blend these materials to achieve a gradation representative of the in-place pulverized material.

Estimate the median cement content by percent of total mix weight to meet the requirements shown in 

Table 305-1. At this median cement content and at cement contents 1 or 2 percent above and below this 

median, determine the optimum moisture content, maximum density, and the parameters shown in 

Table 305-1. Choose range of cement contents to properly bracket the strength requirements shown in 

Table 305-1. 

Table 305-1 

Soil-Aggregate-Cement Mix Design Parameters

Property Requirement

Unconfined compressive strength,

ASTM D1633, Method A(1)

 Average strength range (3 specimens) 200 to 400 psi 

 Maximum strength of a single specimen break 500 psi or less

Loss in mass, AASHTO T 135 & T 136, 12 cycles 14% maximum

(1) At 7-day cure at 70 °F according to ASTM D1632.

Submit a mix design for approval at least 14 days before production which includes the following: 

(a) Optimum cement content conforming to the requirements shown in Table 305-1; 

(b) Maximum density and moisture content at the optimum cement content according to 

AASHTO T 134, at least 5 points; 

(c) Source of cement and imported crushed aggregate including certifications;

(d) Results of tests and applicable charts and graphs;
Section 305

253

(e) Gradation and proportion of imported crushed aggregate; 

(f) Proportion of base material to pavement and gradation of the mix; 

(g) 200-pound sample of the pavement, base, and imported crushed aggregate, if requested; and 

(h) 20-pound sample of portland cement, if requested.

Start production only after the mix design is approved. If the mix design is rejected, submit a new mix 

design for approval. 

305.04 General. Establish existing pavement cross-section according to Subsection 152.05. Maintain the 

established cross-section or construct to proposed cross-section. 

Protect manholes, valve covers, and other buried facilities from damage.

305.05 Production Start-Up Procedures. If an asphalt overlay is required, do not start FDR production

until the asphalt overlay mix design has been approved. 

(a) Preparatory phase meeting. Conduct a pre-stabilization preparatory phase meeting according to 

Subsection 153.06(a) at least 7 days before the start of stabilizing operations. 

Before the preparatory phase meeting, convert the approved mix design cement percentage to pounds 

per square yard and submit to the CO. 

(b) Control strip. Provide 7 days’ notice before starting production. 

On the first day of production, stabilize a 1000-foot control strip, one-lane wide, at the designated lift 

thickness and mix design proportions. Construct the control strip on the project at an approved 

location. 

Construct the control strip using construction procedures intended for the entire project. Take nuclear 

gauge density readings behind each roller pass to determine the roller pattern necessary to achieve the 

specification requirements in Subsection 305.10. Cease production after construction of the control 

strip until the stabilized base and the control strip are evaluated for acceptance.

Repeat the control strip process until an acceptable control strip is produced. See Subsection 106.01

for the disposition of material in rejected control strips. Accepted control strips may remain in place 

and will be accepted and measured as a part of the completed base. When a control strip is accepted, 

full production may start. 

Use these start-up procedures when changing construction procedures, when resuming production after a 

termination of production due to unsatisfactory quality according to Subsection 106.04, or the starting of 

a new construction season.

305.06 Adding Crushed Aggregate. Conform to Subsection 304.04. 

305.07 Pulverizing. Conform to Subsection 304.05. 

305.08 Applying Cement. Do not add cement when the underlying surface is frozen, muddy, or when 

conditions allow for excessive loss to eroding or blowing. Start cement application when the air 
Section 305

254

temperature is above 40 °F and is expected to stay above 40 °F for 48 hours. Apply cement by one of the 

following methods:

(a) Dry method. Use a metered mechanical spreader to uniformly apply the cement. Use canvas (or 

similar) skirts around the spreader box to minimize dust.

(b) Slurry method. Use approved equipment and dispersal processes to uniformly apply a cement 

and water slurry without pooling or run off. Equip slurry tanks with an agitator to keep the cement 

suspended in water. Apply the slurry to the pulverized material with 60 minutes from time water first 

contacts the cement. Make successive passes over the material if necessary to obtain the proper 

moisture and cement content for mixing and compacting. 

305.09 Mixing. Start mixing within 30 minutes after cement application. Use a road reclaimer conforming 

to Subsection 304.05. Add water as necessary to adjust the moisture content of the mixture to within 

2 percent of optimum as indicated in the approved mix design. Continue mixing until the cement is 

uniformly distributed within the in situ material creating a homogeneous full depth layer. Complete mixing 

within 1 hour of the cement application. 

305.10 Compacting and Finishing. Compact the processed material uniformly to at least 95 percent of 

maximum density as determined from AASHTO T 134. Provide rollers sized and configured to achieve 

the required compaction and finishing. Operate rollers according to the manufacturer’s recommendations. 

Compact the processed material full width by rolling from the sides to the center, parallel to the centerline 

of the road. Along curbs, headers, walls, and places not accessible to the roller, compact the material with 

approved tampers or compactors.

During compaction and final grading maintain the moisture content of the mixture to within 2 percent of 

optimum. Do not leave areas of stabilized material uncompacted or undisturbed for more than 30 minutes. 

Complete compaction within 1 hour after mixing. 

Finish the compacted surface according to Subsection 301.06 to produce a surface that is smooth, dense, 

and free of compaction planes, ridges, or loose material. Clean the compacted surface of loose material, 

dirt, or other deleterious material by approved methods. Complete finishing operations within 4 hours 

from the start of mixing including corrections to irregularities in the surface.

305.11 Construction Joints. If cement application operations are delayed or stopped for more than 

2 hours, make a transverse construction joint by cutting back into the completed work to form an 

approximately vertical face. Tie new work into the completed work by remixing approximately 36 inches 

of the completed course.

305.12 Micro-cracking. Micro-crack the finished compacted surface 48 to 72 hours after completion of 

compaction using a minimum 10-ton vibratory steel drum roller, set at maximum amplitude, advancing at 

approximately 3 feet per second, and make three full passes, or as approved. 

305.13 Curing. Allow material to cure at least 24 hours before placing the next course. Cure by one of 

the methods below:

(a) Water method. Keep the surface continuously moist by applying water through a spray bar 

equipped with nozzles producing a fine, uniform spray. During the first 24 hours of curing, use a water 

truck with side spray to avoid driving on the newly stabilized layer. Prevent damage to the finished 

surface. Maintain a moist surface until next course is placed. 
Section 305

255

(b) Prime coat method. Seal the surface by placing an inverted prime coat according to 

Subsection 411.06(b). Provide and maintain a continuous film over the surface. Apply prime coat 

within 72 hours after compacting and finishing. Keep surface moist according to Subsection 305.13(a)

until prime coat is placed.

Do not allow traffic and construction equipment on stabilized base until it is sufficiently stable to withstand 

marring and permanent deformation. Restrict traffic according to Section 156. Limit traffic speeds to 

20 miles per hour. 

305.14 Maintenance. Maintain the cement stabilized layer to the correct line, grade, and cross-section 

until placement of the next course. If the cement stabilized layer loses stability, density, or finish before 

placement of the next course, reprocess, recompact, and add cement as necessary to restore the strength 

of the damaged material. 

Overlay the stabilized base within 14 days after completing finishing operations according to 

Subsection 305.10. 

305.15 Acceptance. See Table 305-2 for sampling, testing, and acceptance requirements.

Crushed aggregate will be evaluated under Subsections 106.02 and 106.03. 

Cement will be evaluated under Subsections 106.02 and 106.03. 

Construction of full depth reclamation with cement will be evaluated under Subsections 106.02 and 

106.04. 

Prime coat will be evaluated under Section 411. 

Measurement

305.16 Measure the Section 305 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

305.17 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 305 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 305-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

Full depth

reclamation

(FDR) with

cement

mixture

Measured &

tested for

conformance

(106.04) 

All – Subsection

305.03

1 per

submitted

mix design

Existing

roadway Yes

14 days 

minimum

before

production

– 

Production Start-up (control strip)

FDR with

cement

material

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27

3 

minimum

Behind

reclaimer

before

compaction

No

Upon

Completion

of test

Minus

11⁄2-in

sieve

requirement

only

Moisturedensity

(maximum 

density)

– AASHTO

T 134

1 

minimum " Yes " 

5 points 

per proctor 

minimum

Moisture

content

(in-place)

– AASHTO

T 255

3 

minimum

In-place

after

compaction

No " −

Density −

AASHTO

T 310

or other

approved

methods

Subsection

305.05(b) " " " −
Table 305-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material 

or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

FDR with

cement

material

Measured &

tested for

conformance

(106.04) 

Moisturedensity

(maximum

density)

– AASHTO

T 134

1 per

change

of material

Behind

reclaimer

before

compaction

Yes

Before

using in

work

5 points 

per proctor 

minimum

Density – 

AASHTO

T 310

or other

approved

procedures

1 per

2000 yd2

In-place

after

compaction

No End of

shift – 

Process

control

(153.03) 

Gradation – AASHTO

T 27

1 per

3500 yd2 

minimum

Behind

reclaimer

before

compaction

" 

Upon

completion

of test

Monitor 

percent

passing the

11⁄2-in

& No. 4

sieves

Moisture

content

(in-place)

– 

AASHTO

T 255 

or other 

approved

methods

" 

In-place

after

compaction

" " −

Unconfined

compression

strength

(7-day)

– Table 305-1 1 per day 

minimum

Behind

reclaimer

before

compaction

" 7 days 7-day

cure

Finished Product

FDR with

cement

material

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

– Subsection

301.06 As directed

Completed

FDR 

surface

No

Before

placement

of next

layer or as

requested

−
Section 306

258

Section 306. — FULL DEPTH RECLAMATION WITH ASPHALT

Description

306.01 This work consists of pulverizing an existing pavement and base in-place, adding crushed 

aggregate if required, mixing this material with emulsified asphalt or foamed asphalt, and shaping and 

compacting the mix to produce a stabilized base. 

Material 

306.02 Conform to the following Subsections: 

Asphalt binder 702.01

Crushed aggregate 703.06

Emulsified asphalt 702.02

Fly ash 701.03(a)

Portland cement 701.01(a)

Water for construction 725.01(c)

Construction Requirements

306.03 Proportioning. Collect representative samples of the pavement and aggregate base from the 

project. Replace removed pavement with asphalt concrete conforming to Section 403, Type II or approved 

cold patch material.

Design a mix according to FLH T 522. Conform to the requirements shown in Table 306-1. If using 

foamed asphalt, provide a binder conforming to the requirements shown in Table 306-2. Submit the mix 

design and the following for approval 30 days before production: 

(a) Optimum emulsified or foamed asphalt binder content based on total mass of mixture;

(b) Source and grade of emulsified or foamed asphalt binder; 

(c) Optimum moisture content for compaction based on total mass of mixture;

(d) Recommended cement or fly ash content;

(e) Maximum wet and dry density for the mixture at the recommended proportions of binder, water, 

and cement or fly ash according to AASHTO T 180, Method D; 

(f) Gradation and proportion of imported crushed aggregate; 

(g) Results of tests and applicable graphs;

(h) A representative 350-pound sample of pavement, base, and imported crushed aggregate, if 

requested;

(i) Three 1-gallon samples of emulsified or asphalt binder, if requested; 

(j) 15-pound sample of portland cement or fly ash, if requested; and 
Section 306

259

(k) Optimum percent of injection water for foaming based on total mass of asphalt binder (if using 

foamed asphalt for the binder).

Start production only after the mix design is approved. Submit a new mix design if there is a change in a 

material source.

Table 306-1 

Asphalt Stabilized Base Course Mix Design Requirements

Binder type Material or Property Requirement

Emulsified asphalt and foamed 

asphalt

Indirect tensile strength, AASHTO T 283(1)

Tensile strength wet 25 psi minimum

Tensile strength ratio 60% minimum

(1) Follow the modified AASHTO T 283 procedures as indicated in FLH T 522.

Table 306-2 

Foamed Asphalt Binder Property Requirements

Property Requirement

Foamed asphalt expansion characteristics at 320, 338, & 356 °F(1)

Asphalt expansion ratio 10 minimum

Half-life of foamed expansion 6 seconds minimum

(1) See FLH T 522 for test procedures.

306.04 General. Establish existing pavement cross-section according to Subsection 152.05. Maintain the 

established cross-section or construct to proposed cross-section. 

Protect manholes, valve covers, and other buried facilities from damage.

306.05 Production Start-Up Procedures. If an asphalt overlay is required, do not start FDR production 

until the asphalt overlay mix design has been approved.

(a) Preparatory phase meeting. Conduct a pre-stabilization preparatory phase meeting according to 

Subsection 153.06(a) at least 7 days before the start of stabilizing operations. 

(b) Control strip. Provide 7 days’ notice before starting production. 

On the first day of production, stabilize a 1000-foot-long control strip, one-lane wide, and at the 

designated lift thickness. Construct the control strip on the project at an approved location. 

Construct the control strip using the construction procedures intended for the entire project. Cease 

production after construction of the control strip until the stabilized base and the control strip are 

evaluated and verified for acceptance.

After the reclaimer has pulverized and mixed one reclaimer width for 100 feet of the control strip and 

before compaction, dig a test pit to evaluate the mixing and distribution of the asphalt. If homogeneous 

mixing is not occurring, modify the process and pulverize, mix, and verify another 100 feet. Continue 

until acceptable mixing and distribution of asphalt is obtained. 

Take three random loose mix samples within the control strip and verify that 100 percent passes the 

2-inch sieve. 
Section 306

260

Take nuclear gauge density readings behind each roller pass according to AASHTO T 310 to 

determine the roller pattern necessary to achieve at least 97 percent of the maximum wet density. 

Determine the maximum wet density by sampling processed material from behind the reclaimer 

(before compaction) and testing the material according to AASHTO T 180, Method D. 

Repeat the control strip process until an acceptable control strip is produced. See Subsection 106.01

for the disposition of material in rejected control strips. Accepted control strips may remain in place 

and will be accepted and measured as a part of the completed base.

(c) Control strip verification. The control strip is verified when the specified density, gradation, and 

moisture content are obtained. Full production may start once the control strip is verified. Provide the 

CO with the reclaimer speed, emulsified or foamed asphalt application temperature, and asphalt and 

water line pressures used on the verified control strip.

Use these start-up procedures when changing construction procedures, when resuming production after a 

termination of production due to unsatisfactory quality according to Subsection 106.04, or the starting of 

a new construction season.

306.06 Adding Crushed Aggregate. Conform to Subsection 304.04. 

306.07 Pulverizing and Mixing. 

(a) If using emulsified or foamed asphalt, provide a road reclaimer that is:

(1) Self-propelled; 

(2) Specifically manufactured for in-place reclamation;

(3) Capable of reducing the existing material to the required size; 

(4) Equipped with at least an 8-foot cutting width; 

(5) Equipped with standard automatic depth controls adjustable in increments of 1⁄2 inch; 

(6) Equipped with independent asphalt application nozzles that can be turned off individually and 

verified open and working from within the operator cabin; and 

(7) Equipped with an asphalt and water application control system including full width spray bars 

and positive displacement pumps automatically interlocked to the machine speed. 

(b) In addition to the above, if using foamed asphalt, provide a road reclaimer that is:

(1) Equipped with an exterior test nozzle to verify proper foaming action; 

(2) Equipped with individual expansion chambers for each nozzle where asphalt binder and water 

are injected under pressure through individual orifices for atomization and foam expansion; 

(3) Equipped with an internal electric heat cleaning system to self-clean foaming nozzles;

(4) Equipped with maximum nozzle spacing of 6 inches; and
Section 306

261

(5) Equipped with a compressor that can provide at least 45 pounds per square inch of pressure.

Use the reclaimer to pulverize the existing roadway material in-place until 100 percent passes the 11⁄2-inch 

sieve. Reprocess or remove larger particles and dispose of them according to Subsection 203.07. 

306.08 Applying Cement or Fly Ash. Do not apply cement or fly ash when conditions allow for excessive 

loss to blowing. Use a metered mechanical spreader to uniformly apply cement or fly ash on the roadway 

surface. Use skirts around the spreader box to minimize dust. 

306.09 Applying Asphalt. 

(a) Requirements for emulsified and foamed asphalt. Apply emulsified or foamed asphalt when 

the surface and air temperatures in the shade are at least 50 oF. Do not start applying emulsified asphalt 

when fog, precipitation, or temperatures below 35 oF are anticipated within 48 hours. 

Automatically adjust the asphalt and water flow based on the reclaimer speed and recycled material 

mass for the approved mix design. Maintain the asphalt temperature within the range recommended 

by the supplier. 

If the lane width exceeds the width of the reclaimer, complete pulverizing and mixing operations in 

continuous one lane-width segments up to 1⁄2 mile in length. Mix the pulverized roadway material with 

emulsified asphalt binder, other additives, and the necessary mixing water for optimum dispersion. If 

two passes are used, shape and compact the reclaimed material with a steel drum roller after the first 

pass to provide depth control for the second pass of the reclaimer. Add the required quantity of 

emulsified or foamed asphalt during the final pass of the reclaimer.

Verify that the emulsified or foamed asphalt is evenly dispersed and coating the pulverized material. 

Dig test pits within the mix at least every 1⁄4 mile and observe the distribution of the emulsified or 

foamed asphalt in each pit.

(b) Additional requirements for foamed asphalt. Do not use foamed asphalt with an application 

temperature below 320 °F.

Do not apply foamed asphalt on previously treated foamed asphalt areas. 

306.10 Compacting and Finishing. Compact and finish each segment before starting mixing operations 

on the next segment. Maintain the moisture content of the mixture within 2 percent of optimum.

Compact the processed material uniformly to at least 97 percent of the maximum wet density as 

determined from the control strip. If the material changes, reestablish the maximum wet density according 

to Subsection 306.05(b). Determine the in-place density according to AASHTO T 310. 

Use at least three rollers: primary, secondary, and finish rollers sized and configured to achieve the 

required compaction and finish. Operate rollers according to the manufacturer’s recommendations. 

Compact the processed material full width by rolling the material between the reclaimer wheel paths first 

then from the sides to the center, parallel to the centerline of the road. Along curbs, headers, walls, and 

places not accessible to the roller, compact the material with approved tampers or compactors.

Shape and grade the mixture to the correct lines, grades, and cross-section. Finish the compacted surface 

according to Subsection 301.06 to produce a surface that is smooth, dense, and free of compaction planes, 
Section 306

262

ridges, or loose material. Clean the compacted surface of loose material, dirt, and other deleterious 

material by approved methods. Do not leave uncompleted segments at the end of the workday. 

306.11 Construction Joints.

(a) Longitudinal joints. Make longitudinal joints coincide with each change in cross slope, regardless 

of the overlap width. Provide a minimum longitudinal overlap of 6 inches.

(b) Transverse joints. After full depth reclamation operations stop, ensure continuity across 

transverse joints by cutting back into the completed work for a distance recommended by the 

manufacturer of the reclaimer.

306.12 Curing and Maintenance. 

(a) Emulsified asphalt. Keep traffic and equipment off the stabilized base for at least 1 hour after 

completing compaction. Do not allow traffic and construction equipment on the stabilized base until 

it is sufficiently stable to withstand marring and permanent deformation.

(b) Foamed asphalt. After completing compaction, moisten the surface and roll with a pneumatictire roller to create a tight and closed surface. Do not allow traffic and construction equipment on the 

stabilized base until compaction and surface moistening is complete. Continue to keep the surface 

moist until placement of the next course or final surface.

If shown in the plans, place a fog seal on the surface of the stabilized base after final compaction according 

to Section 406. 

Route hauling and other construction equipment uniformly over the full width of the recycled surface to 

minimize non-uniform compaction. 

Maintain the stabilized base to the correct line, grade, and cross-section until placement of the next course 

or final riding surface. If the stabilized base loses stability, density, or finish before placement of the next 

course, reprocess and recompact as necessary to restore the strength of the damaged material.

Overlay the stabilized base material within 14 days after completing finishing operations according to 

Subsection 306.10. 

306.13 Acceptance. See Table 306-3 for sampling, testing, and acceptance requirements.

Cement or fly ash will be evaluated under Subsections 106.02 and 106.03. 

Crushed aggregate will be evaluated under Subsections 106.02 and 106.03. 

Emulsified and foamed asphalt will be evaluated under Subsections 106.03 and 106.04. 

Construction of full depth reclamation with asphalt will be evaluated under Subsections 106.02 and 

106.04. 
Section 306

263

Measurement

306.14 Measure the Section 306 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

306.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 306 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 306-3 

Sampling, Testing, and Acceptance Requirements

Material or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Emulsified

asphalt

Measured &

tested for

conformance

(106.04) 

Quality − Subsection

702.02

1 per

type &

source

of material

Asphalt

supplier Yes

30 days 

minimum

before

production 

−

Asphalt

binder

(foamed)

" " −

Subsection

702.01 & 

Table 306-2

" " " " −

Mix Design

Full depth

reclamation

(FDR) with

asphalt

mixture

Measured &

tested for

conformance

(106.04) 

All −

Subsection

306.03 & 

FLH T 522

1 per

submitted

mix design

Existing

roadway Yes

30 days 

minimum

before

production

−
Table 306-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (control strip)

Asphalt

binder

(foamed)

Measured &

tested for

conformance

(106.04) 

Binder

temperature − Subsection

306.09

1 

minimum

Temperature

gauge(3) No

Upon

completing

test

−

Half-life &

expansion 

ratio

− Table 306-2 & 

FLH T 522 " Test nozzleon reclaimer " " −

FDR with

asphalt

material

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27

3 

minimum

Behind

reclaimer

before

compaction

No

Upon

completing

test

Minus

11⁄2-in

sieve

requirement

only

Moisturedensity

(wet density)(1)

−

AASHTO

T 180,

Method D

1 

minimum " " " −

Moisture

content

(in-place)

– AASHTO

T 255

3 

minimum

In-place

after

compaction

" " −

Density − AASHTO

T 310 " 

In-place

after

compaction

" " Report

wet density

Visual

inspection

(106.02) 

Homogeneous

mixing − Subsection

306.05(b)

Subsection

306.05(b)

Behind

reclaimer

before

compaction

No

Upon

completing

test

−
Table 306-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material 

or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

FDR

asphalt

material

Measured &

tested for

conformance

(106.04) 

Moisturedensity

(wet density)(1)

−

AASHTO

T 180,

Method D

1 per

change in

material

Behind

reclaimer

before

compaction

No

Before

using in

work

−

Density − AASHTO

T 310

1 per

2000 yd2

In-place

after

compaction

" End of

shift

Report

wet

density

Process

control

(153.03) 

Gradation − AASHTO

T 27

1 per

3500 yd2 

minimum

Behind

reclaimer

before

compaction

No

Upon

completion

of test

−

Moisture

content − AASHTOT 255

1 per

lane mile " " " −

Homogeneous

mixing − Subsection

306.05(b)

1 per

3500 yd2 

minimum

" " " −

Binder

content

of mix

− Calculation

(yield rate)

1 per

tank load 

minimum

− " " −

Indirect

tensile

strength(2)

−

AASHTO

T 283

(as modified

by FLH T 522)

1 per

15,000 yd2 " " 4 days −
Table 306-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material 

or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Asphalt

binder

(foamed)

Process

control

(153.03) 

Binder

temperature − Subsection

306.09

1 per

tank load

Temperature

gauge(3) No

Upon

completing

test

−

Half-life &

expansion

ratio

− Table 306-2 & 

FLH T 522 " Test nozzleon reclaimer " " −

Finished Product

FDR with

asphalt

material

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

– Subsection

301.06

As 

directed

Completed

FDR surface No

Before

placement

of next

layer or as

requested

−

(1) At least 5 points per proctor.

(2) Immediately after collecting sample, transport to a field material laboratory and compact for indirect tensile strength testing. Keep sample in 

moisture proof container.

(3) Measure asphalt binder temperature with a calibrated thermometer.
Section 307 

Section 307. — RESERVED
Section 308

269

Section 308. — EMULSIFIED ASPHALT-TREATED BASE COURSE

Description

308.01 This work consists of constructing a course of emulsified asphalt-treated base on a prepared 

surface.

Material 

308.02 Conform to the following Subsections: 

Emulsified asphalt 702.02

Subbase or base course aggregate 703.05(b)

Water for construction 725.01(c)

Construction Requirements

308.03 General. Prepare the surface according to Section 204 or 303 as applicable.

After a representative quantity of aggregate is produced and at least 14 days before incorporating the 

aggregate into the work, submit the following:

(a) Proposed target values for base aggregate within the gradation ranges shown in Table 703-1 for 

the required grading; and

(b) A representative 400-pound aggregate sample. 

Stop placement and resubmit new target values if the calculated mean value for a tested sieve differs from 

the target value by more than the allowable deviation for that sieve.

308.04 Mixing and Spreading. Use a stationary pugmill with weighing, volumetric, or other gauging 

equipment that can control the material entering the mixer. Interlock the controls for the aggregate feed 

with the emulsified asphalt and water controls to ensure uniform introduction of material into the mixer.

Determine the optimum moisture content of the mixture according to AASHTO T 180, Method D. Add 

aggregate and water to the mixer before the emulsified asphalt. Add 1 percent emulsified asphalt by mass 

of aggregate. Adjust the total liquid content (emulsified asphalt and water) to within 1 percent of the 

optimum moisture content at the time of compaction. Mix until particles are uniformly coated. Haul and 

place the treated aggregate immediately after mixing. Do not store emulsified asphalt-treated aggregates 

in stockpiles.

Spread the mixture on the prepared surface in a uniform lift. Shape the mixture to the required line, grade, 

and cross-section. Route hauling equipment uniformly over the full width of the surface to minimize 

non-uniform compaction.

308.05 Compacting. Compact the mixture according to Subsection 301.05. 

308.06 Surface Tolerance. Finish the surface according to Subsection 301.06. 
Section 308

270

308.07 Maintenance. Maintain the emulsified asphalt-treated aggregate base course according to 

Subsection 301.07. 

308.08 Acceptance. See Table 308-1 for sampling, testing, and acceptance requirements.

Emulsified asphalt will be evaluated under Subsections 106.02 and 106.03. 

Aggregate gradation, 

  Index (SEP), and fractured faces will be evaluated under Subsection 106.05.

(a) Aggregate gradation. The upper and lower specification limits are equal to the calculated mean 

of all test results plus or minus the allowable deviations shown in Tables 703-1 and 703-2, except as 

follows:

(1) If the calculated mean value for a tested sieve exceeds the maximum gradation range value 

shown in Table 703-1, then the upper specification is equal to the maximum gradation value in 

Table 703-1 plus or minus the allowable deviation in Table 703-2. 

(2) If the calculated mean value for a tested sieve is less than the minimum gradation range value 

shown in Table 703-1, then the lower specification is equal to the minimum gradation value in 

Table 703-1 plus or minus the allowable deviation in Table 703-2. 

(b) SEP. See Table 308-1, Note (2). The lower specification limit is 1.000. 

(c) Fractured faces. The lower specification limit is 50 percent.

Other aggregate quality properties will be evaluated under Subsections 106.02 and 106.04. 

Construction of emulsified asphalt-treated base course will be evaluated under Subsections 106.02 and 

106.04. 

Measurement

308.09 Measure the Section 308 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring emulsified asphalt-treated aggregate base by the cubic yard, measure in place.

When measuring emulsified asphalt-treated aggregate base by the square yard, measure the length 

horizontally along the centerline of the roadway. Measure the width horizontally to include the top of 

emulsified asphalt-treated aggregate base width and allowable widening. 

Payment

308.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 308 pay items listed in the bid schedule, except the emulsified asphalt-treated aggregate base 

course contract price will be adjusted according to Subsection 106.05. Payment will be full compensation 

for the work prescribed in this Section. See Subsection 109.05. 
Table 308-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

quality

(703.05) 

Measured &

tested for

conformance

(106.04 & 

105) 

LA abrasion

(coarse) − AASHTO T 96

1 per rock 

type

but not less 

than 5 per

material 

source(1)

Source of

material Yes

Before

using

in work

Not required

if using

Governmentfurnished

sources

Durability 

index − AASHTO T 210 " " " " " 

Soundness

using

sodium sulfate

− AASHTO

T 104 " " " " " 

Aggregate 

base,

Grading

C, D, & E

(703.05) 

Process

control

(153.03) 

Gradation − AASHTO

T 11 & T 27

2 per

day per 

stockpile 

minimum

Crusher

belt No 24hours

Not required

if using

Governmentfurnished

sources

Fractured 

faces − ASTMD5821 " " " " " 
Table 308-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Aggregate 

base,

Grading C, D, 

& E

Measured &

tested for

conformance

(106.04) 

Moisturedensity

(maximum 

density)

−

AASHTO

T 180,

Method D(3)

1 per

type &

source

of material

Stockpile or

Production

output

Yes

Before

using in

work

−

Emulsified

asphalt-treated

aggregate 

base,

Grading

C, D, & E

(703.05) 

Statistical

(106.05) 

Gradation – 

AASHTO

T 30

1 per

1000 tons

In-place,

after

compaction

Yes 4 hours −

3⁄8 in I 

No. 4 I 

Other 

specified 

sieves

II

Fractured

faces I ASTM D5821 " " " " −

Sand

equivalent −

AASHTO T 

176,

Alternate

Method No. 2,

Reference

Method

" 

Belt feed

before

adding

emulsified

asphalt

" " −

SEP I (2) " − No − −

Emulsified

asphalt-treated

aggregate 

base,

Grading 

C, D, & E

Measured &

tested for

conformance

(106.04) 

Density −

AASHTO

T 310 or

other approved

procedures

1 per

500 tons

but not less 

than

1 per lift

In-place,

after

compaction

No

Before

placing next

lift

−
Table 308-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Product

Emulsified

asphalt-treated

aggregate base

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

– Subsection

301.06 As directed Completed

base surface No

Before 

placing next 

lift or

as requested

−

(1) Submit at least five reports, but at least one report per rock type for each source. Submit reports dated within 1 year of intended use and 

include rock type and sample location. Obtain samples representative of aggregates being provided.

(2) SEP is a measure of a material’s ability to perform based on the quality and quantity of fines present. Quality is represented by the sand 

equivalent (SE) and quantity is represented by the percent passing the No. 200 sieve (PP200). SEP is computed as follows:

For SE ≥ 29, 

  and for SE < 29, 

Where: SE = Plastic fines in graded aggregates and soils by using the sand equivalent test. See AASHTO T 176, Alternate Method No.2, 

Reference Method.

P200 = Material finer than the No. 200 sieve in mineral aggregates by washing. See AASHTO T 11.

(3) At least 5 points per proctor.
Section 309

274

Section 309. — COLD CENTRAL PLANT RECYCLED ASPHALT BASE 

COURSE

Description

309.01 This work consists of constructing one or more courses of cold central plant recycled asphalt base 

using milled asphalt material.

Material 

309.02 Conform to the following Subsections: 

Engineered emulsion 702.02(d)

Hydraulic cement 701.01

Lime for asphalt mixtures 725.03(c)

Water for construction 725.01(c)

Construction Requirements

309.03 Composition of Mix (Job-Mix Formula). Collect representative samples of the recycled asphalt 

pavement to be used. Reduce oversize particles to no more than 11⁄2 inches. Replace removed pavement 

with asphalt concrete conforming to Section 403, Type II.

Design a mix according to Table 309-1. Submit the JMF and the following for approval 30 days before 

production: 

(a) Optimum engineered emulsion content based on total mass of mixture;

(b) Source of engineered emulsion; 

(c) Optimum moisture content for dispersion and compaction based on total mass of mixture; 

(d) Lime or cement content, if required;

(e) Results of tests and applicable charts and graphs;

(f) A representative 300-pound sample of pavement, if requested; 

(g) Three 1-gallon samples of engineered emulsion, if requested; and

(h) A 2-pound sample of lime or cement, if requested.

Start production only after the mix design is approved. Submit a new mix design if there is a change in a 

material source.
Section 309

275

Table 309-1 

Cold Central Plant Asphalt Base Course Mix Design Parameters

Property Requirement

Indirect tensile strength, AASHTO T 283(1) 

 Tensile strength dry 70 psi minimum

 Tensile strength ratio 70% minimum

Raveling test, ASTM D7196, 4-hour cure at 50 °F, 50% humidity

 Average mass loss 5% maximum

(1) Follow Section 7 for laboratory-mixed, laboratory-compacted specimens. Compact the mixture to the 

design air voids. Instead of Subsection 7.5, cure samples for at least 16 hours and no more than 48 hours at 

140°F until constant weight is attained. Instead of the Subsection 10.4 saturation range, use a target range 

from 55 to 75 percent saturation. Do not use the conditioning cycles in Sections 10.4.9 and 10.4.10. Instead, 

condition the sample in a water bath at 77°F for 24 hours.

309.04 Equipment. 

(a) Pugmill and proportioning equipment. Provide the following: 

(1) Capable of continuously mixing the milled material with emulsified asphalt, water, lime, and 

other additives to produce a uniform and homogenous mixture; 

(2) Belt scale for continuous weighing of milled and sized material with an interlocked computer 

controlled liquid metering device that can automatically adjust the flow of asphalt emulsion to the 

mass of milled material coming into the mixer;

(3) Proportioning equipment that can apply emulsified asphalt and water to within ±0.2 percent of 

the required quantity by mass of milled material; and

(4) Proportioning equipment with a digital meter for monitoring the flow rate and total milled 

material, emulsified asphalt, and water applied.

(b) Paver. Provide a paver conforming to Subsection 401.05 that can pick up the entire windrow and 

feeding it into the paver hopper. Do not heat the screed.

(c) Rollers. Provide double-drum steel-wheel and pneumatic-tire rollers in sufficient quantity and size 

to obtain the required density. Provide pneumatic-tire rollers weighing at least 30 tons. 

309.05 Weather Limitations. Do not start work when fog, precipitation, frost, or temperatures below 

35 oF are anticipated within 24 hours. 

Place cold central plant recycled asphalt base on a dry, unfrozen surface when the air temperature in the 

shade is 50 oF and rising and the pavement surface temperature is 40 oF and rising. 

309.06 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-recycling preparatory phase meeting according to 

Subsection 153.06(a) at least 7 days before the start of recycling operations. 

(b) Control strip. Provide 7 days’ notice before starting production of a cold central plant recycled 

asphalt base.
Section 309

276

On the first day of production, produce sufficient cold central plant recycled asphalt base to construct 

a 1500-foot-long control strip, one-lane wide, and at the designated lift thickness. Construct the control 

strip on the project at an approved location. 

Construct the control strip using the production, lay-down, and compaction procedures intended for 

the entire mix. Document roller pattern and if roller was operated in vibratory or static mode. Provide 

frequency and amplitude settings if operated in vibratory mode. Provide this documentation to the CO 

after completion of the control strip.

Stop production after construction of the control strip until the cold central plant recycled asphalt base 

and the control strip are accepted. 

Repeat the control strip process until an accepted control strip is produced. See Subsection 106.01 for 

the disposition of material in rejected control strips. Accepted control strips may remain in place and 

will be accepted and measured as a part of the completed pavement. When a control strip is accepted, 

full production may start. 

Use these start-up procedures when changing construction procedures, resuming production after a 

termination of production due to unsatisfactory quality according to Subsection 106.04, or starting a new 

construction season. 

309.07 Mixing. Obtain milled material under Section 413. Reduce oversize particles to no more than 11⁄2 

inches.

Combine milled material with emulsified asphalt, water, and lime or cement at the approved application 

rates to produce a homogenous and uniformly coated mixture. Maintain the emulsified asphalt temperature 

within the range recommended by the supplier. 

Adjust application rates in coordination with the CO based upon material variations. 

309.08 Spreading, Compacting, and Finishing. Transport material according to Subsection 401.11. 

(a) Spreading. Spread and finish the recycled asphalt base to the required line, grade, and crosssection.

(b) Compacting. Start compaction within 60 minutes of spreading. Use pneumatic-tire rollers until 

no displacement is observed. Use steel-wheel rollers, in static or low-amplitude vibratory mode, to 

achieve final density and eliminate pneumatic-tire roller marks. Do not park or idle rollers on 

uncompacted material. Compact the recycled mix using the following equipment, sequence, and 

number of roller passes: 

(1) Six to twelve roller passes with a self-propelled pneumatic-tired roller having smooth 

pneumatic tires staggered in position to provide overlap between the front and rear tires, with a 

weight of at least 2000 pounds per wheel and a contact pressure of 80 pounds per square inch; 

(2) Four to eight roller passes with a double-drum, vibratory roller having a minimum mass of 

5.5 tons and equipped with frequency and amplitude controls; and 

(3) Four to six roller passes with a static steel-wheel roller with a pressure of at least 250 pounds 

per square inch.
Section 309

277

Compact the material with approved tampers or compactors along curbs, headers, walls, and places 

not accessible to the roller.

(c) Finishing. Produce a surface that is smooth, dense, and free of ruts, ridges, and loose material. 

Measure the surface using a 10-foot metal straightedge at right angles and parallel to the centerline. 

Defective areas are deviations between the surface and the bottom of the straightedge more than 3⁄8 

inch measured between two contacts of the straightedge or deviations more than 3⁄8 inch measured at 

the end of the straightedge. 

309.09 Construction Joints. 

(a) Longitudinal joints. Make longitudinal joints coincide with each change in cross slope. Provide 

a longitudinal overlap of at least 4 inches.

(b) Transverse joints. At the start of each day’s recycling operations or after a 2-hour work stoppage, 

cut back into the completed work to ensure uniform material and depth across transverse joints. 

309.10 Curing and Maintenance. Keep traffic and construction equipment off the recycled asphalt base 

for initial curing at least 2 hours after completing compaction and until it is sufficiently stable to withstand 

raveling, marring, and permanent deformation. Route hauling and other construction equipment uniformly 

over the full width of the recycled asphalt base to minimize non-uniform compaction.

After initial curing, place a fog seal according to Section 406 on the surface of the recycled asphalt base 

at a rate of 0.05 to 0.10 gallon per square yard. 

Maintain the recycled asphalt base to the correct line, grade, and cross-section. Provide additional rolling 

with a steel-wheel roller to recompact and maintain a dense surface. Use a power broom to remove loose 

particles. If the recycled asphalt base ravels or loses stability, density, or finish, reprocess, recompact and 

finish according to Subsection 309.08 as necessary to restore the strength of the damaged material.

Overlay the recycled asphalt base when the moisture content is less than 2.5 percent according to 

AASHTO T 255, but within 14 days after completing finishing operations regardless of moisture content. 

309.11 Acceptance. See Table 309-2 for sampling, testing, and acceptance requirements.

Cement and lime will be evaluated under Subsections 106.02 and 106.03. 

Engineered emulsion will be evaluated under Subsections 106.02 and 106.03. 

Milled material will be evaluated under Subsections 106.02 and 106.04. 

Construction of the cold central plant recycled asphalt base course will be evaluated under 

Subsections 106.02 and 106.04. 

Fog seal will be evaluated under Section 406. 

Measurement

309.12 Measure the Section 309 pay items listed in the bid schedule according to Subsection 109.02. 
Section 309

278

Payment

309.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 309 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 309-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Engineered 

emulsion

(702.02(d)) 

Process

control

(153.03) 

Application

rates – Calculationof yield rate

1 per

tank load 

minimum

– " " – 

Finished Product

Cold

recycled

asphalt

base

Measured &

tested for

conformance

(106.04) 

Surface

tolerance – 

Straightedge

measurement,

Subsection

309.08(c)

Continuously,

after

compaction

Finished

recycled 

base

surface

No 24

hours – 
Section 310

280

Section 310. — COLD IN-PLACE RECYCLED ASPHALT BASE COURSE

Description

310.01 This work consists of constructing cold in-place recycled asphalt base course with a self-propelled 

recycling train.

Material 

310.02 Conform to the following Subsections: 

Crushed aggregate 703.06

Engineered emulsion 702.02(d)

Hydraulic cement 701.01

Lime for asphalt mixtures 725.03(c)

Water for construction 725.01(c)

Construction Requirements

310.03 Composition of Mix (Job-Mix Formula). Collect representative samples of the existing 

pavement to be milled. Replace removed pavement with asphalt concrete conforming to Section 403, Type 

II or approved cold patch material.

Design a mix according to FLH T 524 and Table 310-1. Submit the JMF and the following for approval 

30 days before production: 

(a) Optimum emulsified asphalt binder content based on total mass of mixture;

(b) Source and grade of emulsified asphalt binder; 

(c) Optimum moisture content for dispersion and compaction based on total mass of mixture; 

(d) Cement or lime content, if needed; 

(e) Maximum density for the mixture;

(f) Bulk specific gravity for the mixture; 

(g) Results of tests and applicable charts and graphs;

(h) A representative 300-pound sample of pavement, if requested;

(i) Three, 1-gallon samples of emulsified asphalt binder, if requested; and

(j) A 15-pound sample of cement or lime, if requested. 

Start production only after the mix design is approved. Submit a new mix design if there is a change in a 

material source.
Section 310

281

Table 310-1

Cold In-Place Recycled Asphalt Base Course Mix Design Parameters

Property Requirement

Indirect tensile strength, AASHTO T 283(1) 

Tensile strength dry 70 psi minimum

Tensile strength ratio 70% minimum

Raveling test, ASTM D7196, 4-hour cure at 50 °F, 50% humidity(2) 

Average mass loss 5% maximum

(1) Follow the modified AASHTO T 283 procedures as indicated in FLH T 524.

(2) Use the listed testing conditions for the raveling test, unless otherwise directed.

310.04 General. Establish existing pavement cross-section according to Subsection 152.05. Maintain the 

established cross-section or construct to proposed cross-section. 

Protect manholes, valve covers, and other buried facilities from damage.

Clear, grub, and remove vegetation and debris within the area to be disturbed according to Section 201. 

Clean the pavement and edge of pavement of loose material, dirt, vegetation, and other deleterious 

material.

310.05 Equipment. Provide a self-propelled recycling train with the following major units:

(a) Pavement milling machine. Provide the following: 

(1) Automatic depth controls to maintain the cutting depth to within ±1⁄4 inch; 

(2) Automatic system to maintain cross slope;

(3) Capable of milling the existing asphalt pavement material to the required depth in a single pass; 

and 

(4) 12.5 feet minimum cutter width.

(b) Crushing unit. Capable of screening and crushing material to the required size before mixing with 

emulsified asphalt.

(c) Pugmill and proportioning equipment. Provide the following: 

(1) Capable of continuously mixing the milled material with emulsified asphalt, water, lime, and 

other additives to produce a uniform and homogenous mixture; 

(2) Belt scale for continuous weighing of milled and sized material with an interlocked computer 

controlled liquid metering device that can automatically adjust the flow of asphalt emulsion to the 

mass of milled material coming into the mixer;

(3) Proportioning equipment that can apply emulsified asphalt and water to within ±0.2 percent of 

the required quantity by mass of milled material;

(4) Proportioning equipment with a digital meter for monitoring the flow rate and total milled 

material, emulsified asphalt, and water applied; and 
Section 310

282

(5) Capable of placing the mixture in a windrow without segregation. 

(d) Paver. Provide a paver conforming to Subsection 401.05 that can pick up the entire windrow and 

feeding it into the paver hopper. Do not heat the screed.

(e) Rollers. Provide double-drum steel-wheel and pneumatic-tire rollers in sufficient quantity and size

to obtain the required density. Provide pneumatic-tire rollers weighing at least 30 tons. 

310.06 Weather Limitations. Do not start work when fog, precipitation, frost, or temperatures below 

35 oF are anticipated within 24 hours. 

Place cold in-place recycled asphalt base on a dry, unfrozen surface when the air temperature in the shade 

and the road surface temperature are 50 oF and rising. 

310.07 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-recycling preparatory phase meeting according to 

Subsection 153.06(a) at least 7 days before the start of recycling operations. 

(b) Control strip. Provide 7 days’ notice before starting production.

Construct a control strip on the project at an approved location. Recycle a control strip that is one lane 

wide, 1500 feet long, and the designated lift thickness. Use the construction procedures intended for 

the entire project. Stop production after construction of the control strip until the recycled base and 

the control strip are evaluated and accepted.

Acquire three random samples of milled material from the control strip after the material has passed 

through the crushing unit, but before emulsified asphalt is added for Type A compaction. Verify that 

100 percent passes the 11⁄2-inch sieve. Take density readings behind each roller pass to determine the 

roller pattern necessary to achieve the maximum in-place density (break point of compaction curve) 

according to ASTM D2950. Use the bulk specific gravity value from the mix design as a benchmark 

for evaluating the maximum in-place density achieved.

Repeat the control strip process until an acceptable control strip is produced. See Subsection 106.01

for the disposition of material in rejected control strips. Accepted control strips may remain in place 

and will be measured as a part of the completed base course.

Full production may start when a control strip is verified. Provide the CO with the maximum in-place 

density achieved (Type A compaction), and application rates of the emulsified asphalt, water, and 

other additives used on the accepted control strip.

Use these start-up procedures when changing construction procedures, resuming production after a 

termination of production due to unsatisfactory quality according to Subsection 106.04, or starting of a 

new construction season.

310.08 Pavement Recycling and Mixing. Mill the existing pavement to the required depth and width. 

Reduce oversize particles to a maximum size of 11⁄2 inches.

If cement or lime is required at the milling head or in the pugmill, incorporate cement or hydrated lime 

slurry to within ±10 percent of the approved application rate. Produce the cement or lime slurry using 
Section 310

283

water in a slurry production unit equipped with scales and meters accurate to within 0.5 percent by mass. 

Agitate the transport and feed tanks to provide a consistent and pumpable lime slurry. 

Combine milled material with emulsified asphalt, water, and cement or lime at the approved application 

rates to produce a homogenous and uniformly coated mixture. Maintain the emulsified asphalt temperature 

within the range recommended by the supplier. 

Do not disturb underlying material. Synchronize the recycling rate to allow for continuous operation of 

recycling train equipment.

Continuously monitor and evaluate the milling, mixing, and placing operations to ensure optimum quality 

of the recycled asphalt base course. Adjust application rates in coordination with the CO based upon 

material variations.

310.09 Spreading, Compacting, and Finishing.

(a) Spreading. Spread and finish the recycled mix to the required cross-section.

(b) Compacting. Start compaction within 60 minutes of spreading. Use pneumatic-tire rollers until 

no displacement is observed. Use steel-wheel rollers, in static or low-amplitude vibratory mode, to 

achieve final density and eliminate pneumatic-tire roller marks. Do not park or idle rollers on 

uncompacted material. Compact using the designated type: 

(1) Type A compaction. Use roller patterns established during the control strip. Compact the 

recycled mix to obtain a minimum density of 97 percent of the control strip density. Measure 

in-place density according to ASTM D2950. If an area fails to meet required density, rework and 

recompact the area.

If application rates of the emulsified asphalt from the approved mix design are changed by more 

than ±0.2 percent by mass of milled material, or if other material conditions distinctly change, 

reestablish roller pattern according to Subsection 310.07. 

(2) Type B compaction. Compact the recycled mix using the following equipment, sequence, and 

number of roller passes: 

(a) Four to six roller passes with a double drum, vibratory roller having a mass of at least 

5.5 tons and equipped with frequency and amplitude controls. 

(b) Four to six roller passes with a pneumatic-tire roller having a mass of at least 2000 pounds 

per wheel and a contact pressure of at least 80 pounds per square inch. 

(c) Two to four roller passes with a static steel-wheel roller with a pressure of at least 

250 pounds per square inch. 

Compact the material with approved tampers or compactors along curbs, headers, walls, and places 

not accessible to the roller.

(c) Finishing. Produce a surface that is smooth, dense, and free of ruts, ridges, and loose material. 

Measure the pavement surface using a 10-foot metal straightedge at right angles and parallel to the 

centerline. Defective areas are deviations between the surface and the bottom of the straightedge more 
Section 310

284

than 3⁄8 inch measured between two contacts of the straightedge or deviations more than 3⁄8 inch 

measured at the end of the straightedge.

(d) Fog seal. Place a fog seal according to Section 406 on the surface of the recycled asphalt base. 

Use emulsified asphalt diluted to 50 percent by volume with water and apply it at a rate of 0.05 to 

0.15 gallon per square yard. If necessary, place blotter according to Section 406. 

310.10 Construction Joints. 

(a) Longitudinal joints. Make longitudinal joints coincide with each change in cross slope. Provide 

a minimum longitudinal overlap of 6 inches.

(b) Transverse joints. At the starting of each day’s recycling operations or after extended work 

stoppages, cut back into the completed work to ensure uniform material and depth across transverse 

joints. 

310.11 Curing and Maintenance. Keep traffic and construction equipment off the recycled asphalt base 

for at least 2 hours after completing compaction and until it is sufficiently stable to withstand raveling, 

marring, and permanent deformation. Route hauling and other construction equipment uniformly over the 

full width of the recycled asphalt base to minimize non-uniform compaction. 

Maintain the recycled asphalt base to the correct cross-section. Provide additional rolling with a steelwheel roller to recompact and maintain a dense surface. Use a power broom to remove loose particles. If 

the recycled asphalt base ravels or loses stability, density, or finish, reprocess and recompact as necessary 

to restore the strength of the damaged material.

Overlay the recycled asphalt base when the moisture content of the recycled asphalt base is less than 

2.5 percent according to AASHTO T 255, but within 14 days after completing finishing operations 

regardless of moisture content.

310.12 Acceptance. See Table 310-2 for sampling, testing, and acceptance requirements.

Blotter material will be evaluated under Subsection 106.03. 

Cement and lime will be evaluated under Subsections 106.02 and 106.03. 

Emulsified asphalt binder will be evaluated under Subsections 106.03 and 106.04. 

Construction of the cold in-place recycled asphalt base course will be evaluated under Subsections 106.02

and 106.04. Type A compaction will be evaluated under Subsection 106.04. 

Pavement smoothness will be evaluated under Subsections 106.02 and 106.04. 

Measurement

310.13 Measure the Section 310 pay items listed in the bid schedule according to Subsection 109.02. 
Section 310

285

Payment

310.14 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 310 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 310-2

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Emulsified 

asphalt

(702.02) 

Measured &

tested for

conformance

(106.04) 

Quality – Subsection

702.02

1 per

type &

source

of material

Asphalt

supplier Yes

30 days 

minimum

before

production

– 

Design

Emulsified

asphalt mix

design

Measured &

tested for

conformance

(106.04) 

All – 

Subsection

310.03 & 

FLH T 524

1 per

submitted

mix design

Existing

roadway Yes

30 days

minimum 

before

production

For

Type A

compaction

only

Production Start-up (control strip)

Emulsified

asphalt

mixture

Measured &

tested for

conformance

(106.04) 

Gradation – AASHTO

T 27

3 

minimum

Before

emulsion

addition

No

Upon

completing

test

– 

Bulk specific

gravity

(density)

– FLH T 524 1 

minimum

Loose mix

in windrow " " 

For

Type A

compaction

only

Density – 

ASTM

D2950 &

Subsection

310.07

Subsection

310.07

In-place

after

compaction

" " " 

Depth of cut – – 3 

minimum

Both ends

of milling

drum

" " – 
Table 310-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Emulsified

asphalt

(702.02) 

Measured &

tested for

conformance

(106.04) 

Bulk specific

gravity

(density)

– FLH T 524

1 per

change in

material

Loose mix

in windrow No

Upon

completion

of test

For Type A

compaction 

only

Density – 

ASTM

D2950 &

Subsection

310.07

1 per

2000 yd2

In-place 

after

compaction

" End of

shift " 

Depth of cut – – 

1 per

500 ft

Both ends 

of

milling 

drum

" " – 

Process

control

(153.03) 

Gradation – AASHTO

T 27

1 per

3500 yd2 

minimum

Before

emulsion

addition

No

Upon

completion

of test

– 

Indirect

tensile

strength(1)

– FLH T 524 1 per

3500 yd2 " " 4 days " 

Emulsified

asphalt

(702.02) 

" Application

rates – 

Calculation

of yield rate,

Subsection

310.08

1 per

tank load 

minimum

– " " – 
Table 310-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Product

Cold

recycled

asphalt

base

Measured &

tested for

conformance

(106.04) 

Surface

tolerance – 

Straightedge

measurement,

Subsection

310.09(c)

Continuously,

after

compaction

Finished

recycled 

base

surface

No 24

hours – 

(1) Transport samples immediately to a field material laboratory for indirect tensile strength compaction. Compact within 1 hour of sampling.
Section 311

289

Section 311. — STABILIZED AGGREGATE SURFACE COURSE

Description

311.01 This work consists of constructing a stabilized aggregate surface course.

Material 

311.02 Conform to the following Subsections: 

Calcium chloride, magnesium chloride, and lignosulfonate 725.02

Surface course aggregate 703.05(c)

Water for construction 725.01(c)

Construction Requirements

311.03 Proportioning. Determine the maximum density and optimum moisture content according to 

AASHTO T 180, Method D for the surface course aggregate with and without calcium chloride at the 

target percentage. Use the proctor with calcium chloride to monitor yield and final compaction of the 

mixture.

The target calcium chloride content is 1.85 percent by dry mass of aggregate. The target water content is 

from 2 percent below the optimum moisture content to optimum moisture content. 

311.04 General. Set target values within the gradation ranges shown in Table 703-1, grading G. Store 

calcium chloride in closed, weatherproof containers. 

Conduct a pre-stabilization preparatory phase meeting at least 7 days before the start of stabilization 

operations according to Subsection 153.06(a). 

Prepare the surface on which the stabilized aggregate surface course is placed according to Section 204 or 

303, as applicable. Start the placement of surface course aggregate within 5 days of completing roadway 

reconditioning, unless otherwise approved. 

(a) Weather requirements. Start application or mixing operations when the following conditions are 

met:

(1) The mean daily temperature is not expected to fall below 40 °F for a 7-day cure period after 

the calcium chloride is incorporated;

(2) The ambient air temperature is 40 °F or above, and is not expected to fall below 40°F within 

48 hours; 

(3) No precipitation is occurring or forecast to occur within 24 hours; and 

(4) The underlying surface is not frozen or muddy. 

(b) Control of mixture. Continuously monitor calcium chloride content, moisture content, and 

aggregate yield according to Section 153 during production and placement. Stop production and 

provide immediate corrective action if yield calculations, moisture content measurement, or other 
Section 311

290

observations indicate specifications are not being met. Report moisture content and calcium chloride 

yield twice daily. Adjust operations as approved to ensure an accurate yield is maintained.

Maintain the accuracy of the quantities of calcium chloride, aggregate, and water content within the 

following tolerances during pugmill or in-place mixing and placement:

(1) Calcium chloride. 1.85 percent ±0.15 percent by dry mass of aggregate. Use an independent 

measuring device with display, accurate to ±0.05 percent of the mass of calcium chloride.

(2) Water. ±1.0 percent by mass (maintain moisture content from 2 percent below optimum to 

optimum).

(3) Aggregate. ±2.0 percent by mass.

Calculate the calcium chloride yield according to the following formulas:

 

 

Where: 

T = Target calcium chloride content in decimal percent

γ = Maximum dry density of aggregate, lb/ft3 

W = Width of calcium chloride application, ft

D = Depth of mixing calcium chloride, ft

Incorporate calcium chloride using pugmill mixing as described in Subsection 311.05 or in-place 

mixing as described in Subsection 311.06. 

311.05 Pugmill Mixing. 

(a) Calcium chloride mixing. Use a stationary pugmill with weighing or metering equipment that can

accurately control the material entering the mixer. Interlock the metering controls for the aggregate 

feed with those of the calcium chloride and water to ensure uniform introduction of material into the 

mixer.

Take calcium chloride yield samples using an approved method at least twice daily during production. 

If yield test results indicate a rate outside the contract tolerances, correct the rate and perform 

additional yield testing. 

Do not produce more treated aggregate than can be placed within 7 days, unless approved. Do not 

produce treated aggregate when precipitation is anticipated before the treated aggregate can be placed. 

Do not use treated aggregate that has been exposed to precipitation before placement without approval.

(b) Placement. Follow the requirements of Subsection 311.06(a). 
Section 311

291

311.06 In-Place Mixing.

(a) Surface course aggregate placement. Transport and place the surface course aggregate after 

preparation of the surface and approval of the surface. Process the aggregate to full depth and width 

with a motor grader into a uniform windrow within one hour of delivery on the roadway, adjusting the 

moisture content to obtain a homogenous mixture with a moisture content within 2 percent below the 

optimum moisture content to optimum moisture content. Spread the material on the prepared surface 

in a uniform lift. Shape the road to the required cross-section. Compact according to Subsection 311.07

by the end of the shift. Do not allow hauling vehicles to drive on the placed aggregate before windrow 

processing except where required to allow traffic to pass or to dump subsequent loads.

(b) Calcium chloride mixing. Incorporate calcium chloride within 14 days of placement of surface 

course aggregate, unless otherwise approved. Apply calcium chloride in a uniform layer across the 

full width of the surface to be mixed. Use distributor equipment that can meter the application rate 

from the operator’s cab accurate to ±0.05 percent of the mass of calcium chloride.

As an alternative, rotary mixing machines that can closely meter calcium chloride and additional 

mixing water into the mixing process may be used if the required application rates are met and the 

application rates can be continuously controlled from the operator’s cab accurate to ±0.05 percent of 

the mass of calcium chloride.

Verify the application rate by performing calcium chloride weight yield tests twice daily for each 

distributor. If yield test results indicate a rate outside the contract tolerances, then correct the 

application rate and perform additional yield testing. The CO may increase the test frequency. Do not 

spread more calcium chloride than can be incorporated within one hour. 

Use rotary mixing equipment to uniformly incorporate the calcium chloride and additional mixing 

water into the surface course aggregate or surface course aggregate and existing aggregate to a 

compacted depth of 4 inches +0.0 inch/-0.5 inch. Mix the material one-lane at a time.

(c) Processing. After mixing is complete, ensure a uniform product free of segregation, streaking, and 

inconsistent moisture content by processing the treated material with a motor grader to full depth and 

width. Shape the road to the required cross-section. To the extent practical prevent hauling equipment 

from traveling on recently placed calcium chloride treated aggregate. If not practical route hauling 

equipment uniformly over the full width of the surface to minimize rutting or uneven compaction. 

311.07 Compacting and Finishing. Maintain the moisture content from 2 percent below optimum to 

optimum. Compact each lift full width. Roll from the sides to the center, parallel to the centerline of the 

road. Along curbs, headers, walls, and places not accessible to the roller, compact the material with 

approved tampers or compactors.

Provide pneumatic tired rollers for initial compaction that have a minimum ballasted weight of 15 tons 

and have a minimum tire overlap of 1.5 inches. Provide single smooth drum rollers for final compaction 

to provide a smooth and uniform finished surface. 

(a) Pugmill mixed. Compact each lift of treated surface course aggregate to at least 95 percent of 

maximum dry density according to the proctor performed with calcium chloride. Meet compaction 

requirements for sections of roadway before the end of the work shift. Determine the in-place density 

and moisture content according to AASHTO T 310 or other approved test procedures. 
Section 311

292

(b) In-place mixed. Compact the untreated surface course aggregate placed each shift to at least 

95 percent of maximum dry density of the respective proctor by the end of shift. The CO may approve 

alternative test procedures if requested and if calcium chloride is to be incorporated within 2 days of 

aggregate placement.

After calcium chloride incorporation, compact each layer to at least 95 percent of maximum dry 

density as determined in Subsection 311.03 for aggregate combined with calcium chloride. Meet 

compaction requirements before the end of the work shift. Determine the in-place density and moisture 

content according to AASHTO T 310 or other approved test procedures. 

(c) Finishing. Finish the mixture to produce a surface that is smooth, dense, and free of compaction 

planes, ridges, or loose material. Compact the aggregate foreslopes to ensure they are dense and 

recoverable. Shape the surface to the required template and check the surface with a 10-foot metal 

straightedge. Defective areas are surface deviations more than 1⁄2 inch in 10 feet between two contacts 

of the straightedge with the surface, or noticeable dips, bumps or other undulations identified through 

visual inspection or vehicle ride inspection. 

Correct defective areas by loosening the material full depth, adding or removing material as required, 

adjusting moisture content, reshaping, and compacting. Submit alternative methods of correction, 

including patching or filling of potholes for approval. 

311.08 Acceptance. See Table 311-1 for sampling, testing, and acceptance requirements.

Calcium chloride will be evaluated under Subsections 106.02 and 106.03. 

Aggregate gradation, plasticity index, fractured faces, and liquid limit will be evaluated under 

Subsection 106.05. Other aggregate quality properties will be evaluated under Subsections 106.02 and 

106.04. 

(a) Aggregate gradation. The upper and lower specification limits are equal to the calculated mean 

of all test results plus or minus the allowable deviations shown in Tables 703-1 and 703-2, except as 

follows:

(1) If the calculated mean value for a tested sieve exceeds the maximum gradation range value 

shown in Table 703-1, then the upper specification is equal to the maximum gradation value in 

Table 703-1 plus or minus the allowable deviation in Table 703-2. 

(2) If the calculated mean value for a tested sieve is less than the minimum gradation range value 

shown in Table 703-1, then the lower specification is equal to the minimum gradation value in 

Table 703-1 plus or minus the allowable deviation in Table 703-2. 

(b) Fractured faces. If aggregate is produced from a gravel source, use the specification limit shown 

in Subsection 703.05. 

(c) Liquid limit. The specification limit is shown in Subsection 703.05. 

(d) Plasticity index. The specification limit is shown in Subsection 703.05. 

Aggregate stabilization construction will be evaluated under Subsections 106.02 and 106.04. 
Section 311

293

Compaction of surface course aggregate will be evaluated under Subsection 106.04. 

Preparation of the surface for placement of surface course aggregate will be evaluated under Section 204

or 303, as applicable. 

Measurement

311.09 Measure the Section 311 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

311.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 311 pay items listed in the bid schedule, except the stabilized aggregate surface course contract 

price will be adjusted according to Subsection 106.05. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 311-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Surface course 

aggregate 

quality 

(703.05) 

Measured &

tested for

conformance

(106.04 & 

105) 

LA abrasion 

(coarse) – AASHTO T 96

1 per

Type but 

not less than

5 per source 

of 

material(2)

Source of

material Yes

Before 

using in 

work

Not required 

if using 

Government

-furnished 

sources

Soundness 

using sodium 

sulfate (coarse

& fine)

– AASHTO 

T 104 " " " " " 

Durability 

Index (coarse & 

fine)

– AASHTO 

T 210 " " " " " 

Accelerated 

weathering – WFL W DMSO " " " " " 

Surface course 

aggregate 

(703.05) 

Process 

control 

(153.03) 

Gradation – AASHTO 

T 27 & T 11

1 per 

6 hours of 

production 

but not less 

than 2 per 

day per 

stockpile

Flowing 

aggregate 

stream (bin 

or belt 

discharge) 

or conveyor 

belt

Yes End of 

shift " 

Fractured faces – ASTM D5821 " " " " " 

Liquid limit – 

AASHTO R 58 

& T 89, 

Method A

" " " " – 

Plasticity index – AASHTO R 58 

& T 90 " " " " " 
Table 311-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Proportioning

Proportioning 

(311.03) 

Measured & 

tested for 

conformance 

(106.04) 

Moisturedensity −

AASHTO 

T 180, 

Method D(1)

1 per mixture 

& change in 

material

Processed 

material 

before 

incorporating 

in work

Yes, if 

requested

Before 

using in 

work

Report 

proportion 

of 

aggregate, 

calcium 

chloride, & 

water

Production

Surface course 

aggregate 

(703.05) 

Statistical 

(106.05) 

Gradation – 

AASHTO T 27 

& T 11

1 per 

1000 tons but 

not less 

than 3 

In-place 

mixing: from 

windrow 

immediately 

after 

processing

Pugmill 

mixing: 

flowing 

aggregate 

stream (bin 

or belt 

discharge) or 

conveyor belt 

before adding 

stabilizer

Yes, if 

requested 4 hours −

No. 4 I 

No. 40 I 

No. 200 I 

Other II
Table 311-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Surface 

course 

aggregate 

(703.05) 

Statistical 

(106.05) 

Liquid limit II

AASHTO R 58 

& T 89, 

Method A

1 per 

1000 tons 

but not less 

than 3 

In-place 

mixing: 

from 

windrow 

immediately 

after 

processing

Pugmill 

mixing: 

flowing 

aggregate 

stream

Yes, if 

requested 4 hours – 

Fractured faces I ASTM D5821 " " " " – 

Plasticity index I AASHTO R 58 

& T 90 " " " " – 

Mixture 

(311.03) 

Process control 

(153.03) 

Moisture 

content of 

aggregates

– AASHTO 

T 255

2 per day 

minimum " No " 

Measured & 

tested for 

conformance 

(106.04) 

In-place density 

& moisture 

content

– 

AASHTO 

T 310 or other 

approved 

procedures

1 per 

500 tons or 

3000 yd2

In-place 

after 

compaction

No 4 hours – 

(1) At least 5 points per proctor.

(2) Submit at least five reports, but at least one report per rock type for each source. Submit reports dated within 1 year of intended use. Obtain 

samples representative of aggregates being provided. Include rock type and sample location on test reports.
Section 312

297

Section 312. — DUST PALLIATIVE

Description

312.01 This work consists of providing and applying one or more applications of dust palliative on a 

prepared surface.

Material 

312.02 Conform to the following Subsections:

Calcium chloride, magnesium chloride, and lignosulfonate 725.02

Water for construction 725.01(c)

Construction Requirements

312.03 General. Provide equipment for applying, spreading, and processing dust palliative. Make the 

equipment available for inspection and approval before use. Do not apply dust palliative when 

precipitation is anticipated within 24 hours of application, or when the ground is frozen. Apply when the 

ambient air temperature is 40 °F or above. 

Protect structures, trees, and other objects identified by the CO from splatter or marring. Use multiple 

applications at a reduced rate if necessary to prevent runoff. 

312.04 Surface Preparation and Application. 

(a) Single application. Blade and shape the roadbed. Leave 1 to 2 inches of loose material on the 

surface. Water the loose material so it is visibly moist. Thoroughly mix the moist, loose material.

Apply water, calcium chloride, magnesium chloride, or lignosulfonate liquid at an approved rate from 

0.25 to 0.50 gallons per square yard. Process the dust palliative uniformly throughout the loose 

material. Moisten the mixture as necessary and compact by operating rollers over the full width of 

each layer until visual displacement ceases.

Double application of calcium chloride or magnesium chloride liquid.

(1) First application. Scarify, blade, and shape the roadbed. Leave 3 inches of loose material on 

the surface. Water the loose material so it is visibly moist. Thoroughly mix the moist, loose 

material.

Apply calcium chloride or magnesium chloride liquid solutions using distributor equipment at an 

approved rate from 0.50 to 1.0 gallons per square yard. Use a tractor rotary tiller, or other approved 

mixing device, immediately behind the distributor to incorporate the liquid solution into the full 

width of loose material. Shape the surface to the required line and grade and compact according to 

Subsection 204.11(a). 

Allow at least one week of curing time between the first and second applications. 

(2) Second application. Apply calcium chloride or magnesium chloride liquid to the finished 

surface at an approved rate no more than 0.20 gallons per square yard. 
Section 312

298

312.05 Opening to Traffic. Keep traffic off the treated surface until the dust palliative has penetrated and 

cured to prevent excessive pickup under traffic. 

312.06 Acceptance. Dust palliative material (calcium chloride liquid, magnesium chloride liquid, and 

lignosulfonate liquid) will be evaluated under Subsection 106.03. Provide a commercial certification that 

includes the date, identification number (truck or trailer), net mass, and brand name with each shipment. 

For liquid dust palliatives provide the net volume and specific gravity at 60 °F, percent solids by mass, 

and pH. 

Construction of dust palliative treatments will be evaluated under Subsections 106.02 and 106.04. 

Measurement

312.07 Measure the Section 312 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

312.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 312 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 313

299

Section 313. — AGGREGATE-TOPSOIL COURSE

Description

313.01 This work consists of providing and placing an aggregate, topsoil, and seed mixture on a prepared 

shoulder or other surface.

Material 

313.02 Conform to the following Subsections: 

Aggregate for aggregate-topsoil course 703.13

Seed 713.04

Topsoil 713.01

Water for construction 725.01(c)

Construction Requirements

313.03 Preparing Surface. Complete the adjoining pavement before placing an aggregate-topsoil course 

on the shoulder. Scarify the area where the mixture is to be placed to a depth of 3 inches. Reduce clods 

and sod to a maximum size of 4 inches.

313.04 Mixing, Placing, and Compacting. Provide a mixture of 50±10 percent aggregate and 

50±10 percent topsoil by volume with sufficient water for compaction.

Mix the components into a uniform mixture. Spread the mixture on the prepared surface in a uniform lift. 

Shape the mixture to the required line, grade, and cross-section. Remove clods and stones greater than 

2 inches in diameter. Before compaction, dry seed the mixture surface at a rate of 75 pounds per acre 

according to Section 625. 

Uniformly compact the mixture to ensure it does not exhibit heaving, pumping, rutting, or shearing. After 

compaction, dry seed the surface again at a rate of 75 pounds per acre. 

Before opening the roadway to traffic, clean the roadway surface of excess aggregate, topsoil, and seed 

material.

313.05 Acceptance. Aggregate for aggregate-topsoil will be evaluated under Subsections 106.02 and 

106.03. 

Seed and topsoil will be evaluated under Subsections 106.02 and 106.03. 

Construction of aggregate-topsoil course will be evaluated under Subsection 106.02. 

Measurement

313.06 Measure the Section 313 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring aggregate-topsoil course by the cubic yard, measure in the hauling vehicle. 
Section 313

300

Payment

313.07 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 313 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 314

301

Section 314. — STOCKPILED AGGREGATES

Description

314.01 This work consists of providing and placing aggregate in a stockpile for future use by the 

Government. 

Material 

314.02 Conform to the following Section: 

Aggregate 703

Construction Requirements

314.03 General. Conform to the gradation and quality requirements specified in the Section identified for 

the material.

After a representative quantity of aggregate is produced, submit proposed target values for the appropriate 

sieve sizes along with a representative sample size as specified in the Section identified for the material.

Set target values within the gradation ranges shown in the applicable table for the required grading.

314.04 Stockpile Site. Prepare a plan of operation. Perform work within a Government-furnished source 

only after a plan of operation for the development of the source is approved. 

Obtain CO approval before preparing sites. Prepare sites to prevent contamination of the stockpiles.

Prepare sites as follows:

(a) For new sites, clear and grub according to Section 201; 

(b) Grade, shape, and compact the site to a uniform cross-section that drains; and

(c) Place, compact, and maintain at least a 6-inch lift of crushed aggregate over the stockpile site and 

access roads for stabilization.

Obtain CO approval before stockpiling aggregates. 

314.05 Stockpile. Build aggregate stockpiles in layers no more than 36 inches in thickness. Make the side 

slopes of each layer no flatter than 1V:1.5H. Spread aggregates with trucks or other approved pneumatictire equipment. Complete each layer before depositing aggregates on the next layer. Do not allow 

aggregates from the layer being built to run down over lower layers. Do not drop aggregates from a bucket 

or spout in one location to form a cone-shaped pile. Do not push aggregates into piles. Make the stockpiles 

neat and regular in shape.

Do not track dirt or other foreign matter onto the stockpile material.

Space stockpiles far enough apart or install partitions to prevent the mixing of aggregate gradations.
Section 314

302

Protect stockpiles with an approved cover. 

314.06 Acceptance. Aggregate for stockpiling will be evaluated under the Section identified for the 

material. See the table for sampling, testing, and acceptance requirements in the applicable Section, except 

the point of sampling for aggregate is from the stockpile.

Subbase, base, surface course, and chip seal aggregate gradation, and surface course plasticity index will 

be evaluated under Subsection 106.05. Other aggregate quality properties will be evaluated under 

Subsections 106.02 and 106.04. 

Construction of stockpiles will be evaluated under Subsections 106.02 and 106.04. 

Clearing and grubbing will be evaluated under Section 201. 

Measurement

314.07 Measure the Section 314 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring aggregate by the cubic yard, measure in place.

Payment

314.08 The accepted quantities will be paid at the contract price per unit of measurement adjusted 

according to Subsection 106.05 for the Section 314 pay items listed in the bid schedule. Payment will be 

full compensation for the work prescribed in this Section. See Subsection 109.05. 
Section 315

303

Section 315. — RECYCLED AGGREGATE

Description

315.01 This work consists of providing and placing recycled aggregate using asphalt concrete pavement 

millings and existing aggregate.

Material 

315.02 Conform to the following Subsection: 

Water for construction 725.01(c)

Construction Requirements

315.03 General. Prepare the surface according to Section 204 or 303, as applicable. Provide recycled 

aggregate obtained under Section 304 or 413 with 100 percent passing the 11⁄2-inch sieve. 

315.04 Mixing and Spreading. Place recycled aggregate to the limits shown in the plans. Place enough 

material to bring the final surface to established line, grade, and cross-section. 

Mix the recycled aggregate to its full depth. During mixing add water to provide the optimum moisture 

content for compaction. After mixing, spread to the thickness and cross-section shown in the plans. 

315.05 Compacting. If no compaction method is specified, use either method. 

(a) Method 1. Compact each lift according to Subsection 204.11(a). Roll from the sides to the center, 

parallel to the centerline of the road. Compact the material along curbs, headers, walls, and places not 

accessible to a roller with approved tampers or compactors.

Compactive effort may be decreased if in-place densities show that less compactive effort is required 

under Method 2. 

(b) Method 2. Compact each lift according to Subsection 301.05. 

Produce a surface that is smooth, dense, and without ruts, ridges, and loose material.

315.06 Surface Tolerance. Finish the surface according to Subsection 301.06. 

315.07 Maintenance. Maintain the recycled aggregate according to Subsection 301.07.

315.08 Acceptance. See Table 315-1 for sampling, testing, and acceptance requirements.

Recycled aggregate will be evaluated under Subsections 106.02 and 106.04. 

Construction of recycled aggregate will be evaluated under Subsections 106.02 and 106.04. 

Preparation of the surface for placement of recycled aggregate will be evaluated under Section 204 or 303, 

as applicable.
Section 315

304

Measurement

315.09 Measure the Section 315 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring recycled aggregate by the cubic yard, measure in place.

Payment

315.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 315 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 315-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sampl

e 

Reporting

Time Remarks

Production

Crushed

aggregate

Measured &

tested for

conformance

(106.04) 

Moisturedensity −

AASHTO

T 180,

Method D(1)

1 per

aggregate

supplied

Production

output

or stockpile

No 4 hours

For

Method 2

compaction

only

Density −

AASHTO

T 310

or other 

approved

procedures

1 per

1500 yd2

per lift

In-place

after

compaction

" End of

shift " 

Crushed

aggregate

Process

control

(153.03) 

Moisture

content

(in-place)

−

AASHTO

T 310

or other 

approved

procedures

1 per

1500 yd2

per lift

In-place

after

compaction

No End of

shift

For

Method 2

compaction

only

Finished Product

Crushed

aggregate

Measured &

tested for

conformance

(106.04) 

Surface

tolerance

& grade

− Subsection

315.06 As directed Surface of

final course No

Before

placement

of next

lift or as

requested

−

(1) At least 5 points per proctor.
306

DIVISION 400 

ASPHALT PAVEMENTS AND 

SURFACE TREATMENTS 
Section 401 

307

Section 401. — ASPHALT CONCRETE PAVEMENT

BY GYRATORY MIX DESIGN METHOD

Description

401.01 This work consists of constructing asphalt concrete pavement using HMA or WMA.

Material 

401.02 Conform to the following Subsections: 

Antistrip additive 702.05

Asphalt binder 702.01

Asphalt concrete aggregate 703.07

Mineral filler 725.05

Construction Requirements

401.03 Composition of Mix (Job-Mix Formula). Provide asphalt concrete mixes of aggregate, asphalt 

binder, RAP, and additives that meet the applicable material requirements and the appropriate design 

parameters shown in Table 401-1 and can be placed and compacted as specified. Volumetric mix 

properties will be determined at Ndesign according to AASHTO T 312 and AASHTO R 35. Short-term 

condition samples according to AASHTO R 30 at the manufacturer’s recommended compaction 

temperature. Include the material finer than the No. 200 sieve when determining the AASHTO T 84 fine 

aggregate specific gravity and absorption. 

Apply asphalt concrete mix design requirements for HMA to the development of the WMA mix design. 

Provide modifications to the process required for WMA technology. Submit modifications to the asphalt 

concrete mix design process for WMA according to Appendix X.2 of AASHTO R 35 for approval. 

(a) RAP. Limit the quantity of RAP by mass in the JMF to 20 percent.

(b) Baghouse fines. If used, document how baghouse fines are reintroduced and measured. Submit 

target values for the percent of baghouse fines reintroduced to the JMF if they are a separate stockpile.
Table 401-1 

Gyratory Asphalt Concrete Mix Design Requirements, AASHTO R 35

Design

ESAL

(Million)

Gyratory Compaction Level

(Percent Theoretical Maximum

Specific Gravity, Gmm) 

AASHTO T 312

Minimum Voids in the Mineral Aggregate (VMA), 

percent(1)(4) Voids Filled

with

Asphalt

(VFA), 

percent

Dust-to-Binder

Ratio(3)

Minimum

Tensile

Strength

Ratio 

(TSR)

AASHTO

T 283

Nominal Maximum Size Aggregate(2)

Ninitial Ndesign Nmax 1 inch 3⁄4 inch 1⁄2 inch 3⁄8 inch No. 4 sieve

< 0.3 6 

(≤91.5%)

50

(96.0%)

75

(≤98.0%)

12.0 13.0 14.0 15.0 −

70.0 to 80.0

0.8 to 1.6

0.80

0.3 to < 3 7 

(≤90.5%)

75

(96.0%)

115

(≤98.0%) 65.0 to 78.0

3 to 30 8 

(≤89.0%)

100

(96.0%)

160

(≤98.0%) 65.0 to 78.0

− 6 

(≤91.5%)

50

(96.0%)

75

(≤98.0%) − − − − 16.0 76.0 to 80.0 0.6 to 2.0

(1) If mineral filler or hydrated lime is used, include in the calculation for compliance with the VMA.

(2) The NMSA is one size greater than the first sieve to retain more than 10 percent of the combined aggregate.

(3) Dust-to-binder ratio is the total percent of material passing the No. 200 sieve divided by the effective asphalt content. Dust includes lime, bag house fines, and other 

mineral matter.

(4) Provide historical reference of satisfactory construction of mixtures submitted with VMA exceeding the minimum value by more than 3 percent, for approval.
Section 401

309

(c) Antistrip additive. Use at least 1 percent Type 3 (lime) of the total weight of aggregates including 

RAP. Type 1 (liquid) antistrip additive may be used instead of Type 3 (lime) antistrip additive if the 

requirements shown in Table 401-2 are met.

Table 401-2

Antistrip Requirements Using Hamburg Wheel-Track Testing, AASHTO T 324(1),(2)

PG Binder

Grade

Testing 

Temperature

Maximum Allowable 

Rut Depth Number of Passes Stripping Inflection 

Point

PG 58 & lower 45 °C

12.5 mm 20,000 None Greater than PG 58 & less 

than PG 76 50 °C

PG 76 & higher 55 °C

(1) Report the plot of the rut depth versus number of passes for each test for each deformation location. Report the 

number of passes at maximum rut depth, the maximum rut depth, creep and strip slopes, the stripping inflection point, 

testing temperature, compaction method (slab or Superpave gyratory compactor cylindrical specimen), and air voids 

of the specimens.

(2) Perform two tests at each additive rate and perform one set of control specimens with no additive.

(d) Submittals. Submit written JMFs and associated material with Form FHWA 1641, Worksheet for 

Superpave Asphalt Concrete Mix Design, for verification at least 30 days before the control strip. 

Include a signed statement prepared by the testing laboratory that certifies the proposed JMF meets 

requirements and can be compacted in the field during production. For each proposed JMF, submit 

the following:

(1) Aggregate and mineral filler.

(a) Target values: 

(1) Target value for percent passing each specified sieve size for the aggregate blend; and

(2) Designate target values within the gradation band specified for the NMSA grading 

shown in Table 703-3. Allowable deviations are shown in Table 703-2; 

(b) Source and percentage of each stockpile to be used; 

(c) Average gradation of each stockpile; 

(d) Representative samples from each stockpile. Use split samples of material taken at the same 

time samples are taken for testing by the Contractor’s laboratory.

(1) 600 pounds of aggregates proportioned by each stockpile according to the JMF; 

(2) 2 pounds of mineral filler, if proposed for the JMF; and

(e) Results of aggregate quality tests performed within 1 year of use.

(2) Asphalt binder.

(a) Target asphalt binder content;

(b) Five 1-gallon samples of the asphalt binder; 
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(c) Test results from the manufacturer according to AASHTO M 320 for the asphalt binder 

including a temperature-viscosity curve; 

(d) Mixing temperature range and minimum compaction temperature for the asphalt binder; 

and 

(e) Laboratory mixing and compaction temperatures used for mix design. 

(3) Antistrip additives. If part of the JMF:

(a) Type 1 (liquid) antistrip additive:

(1) Target liquid antistrip additive dosage rate by weight of total binder; 

(2) Test results according to AASHTO T 324 and Table 401-2; 

(3) 1 pint of liquid antistrip additive;

(4) Name of product; 

(5) Manufacturer; and

(6) Manufacturer’s SDS and product data sheets. 

(b) Type 3 (lime) antistrip additive:

(1) 1 pound of lime additive; 

(2) Name of product; 

(3) Manufacturer;

(4) Manufacturer’s SDS and product data sheets; and 

(5) Dosage rate.

(4) RAP. If part of the JMF:

(a) Source and percentage of RAP;

(b) Gradation of the RAP; 

(c) Effective specific gravities of each stockpile;

(d) Percent asphalt binder in RAP by total mass according to AASHTO T 308; 

(e) 100-pound representative sample of each RAP stockpile; and

(f) Optional RAP data sheet of Form FHWA 1641. 
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(5) WMA technology and additive information. 

(a) 1-gallon WMA additive sample with method for incorporating it in the asphalt concrete 

mix design process;

(b) WMA manufacturer’s usage recommendations including additive target rates;

(c) Documentation of past WMA technology field applications including project type, project 

owner, tonnage placed, asphalt concrete mix design, mixture volumetrics, and performance; 

(d) Laboratory mixing and compacting temperature;

(e) Asphalt binder performance grade test data over the range of WMA additive percentages 

proposed for use if applicable; 

(f) Compatibility of WMA additive with asphalt binder and antistrip additive; and

(g) Temperature range for field asphalt concrete mix production, delivery, lay-down and 

compaction. 

(e) Verification. The verification process starts when required documentation and material are 

received. After the JMF is verified, start asphalt concrete mix production for the control strip.

(1) Aggregate gradations. The Contractor’s aggregate gradation is verified if the CO’s gradation 

on the JMF design aggregate structure using the Contractor’s aggregate and RAP stockpile 

percentage recommendations is within the Contractor’s target value gradation plus or minus the 

tolerance shown in Table 401-3. 

Table 401-3 

Aggregate Gradation Verification Tolerances

Sieve Size Tolerance,

percent (±)

1 in 3.0

3⁄4 in 3.0

1⁄2 in 3.0

3⁄8 in 3.0

No. 4 3.0

No. 8 3.0

No. 16 2.0

No. 30 2.0

No. 50 2.0

No. 200 1.0

(2) RAP asphalt binder content and gradation. The RAP asphalt binder content results are 

verified if the CO’s result for each stockpile is within ±0.75 percent by total mass using AASHTO 

T 308. Submit the RAP dry gradation, burned gradation, asphalt content, and specific gravity

information as shown on the RAP data sheet of Form FHWA 1641. 

(3) Bulk specific gravity of aggregate (Gsb). The coarse and fine Gsb are verified if the CO’s 

results are within 0.013 for AASHTO T 85 and 0.030 for AASHTO T 84. 
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(4) VMA. The VMA result is verified if the CO’s result is above the specification limit in 

Table 401-1. Do not exceed 3 percent above the minimum VMA requirement without approval. 

(5) VFA. The VFA result is verified if the CO’s result is within the specification limit in 

Table 401-1. 

(6) Air voids (Va). The Va result is verified if the CO’s result at the same design asphalt binder 

content is between 3.0 and 5.0 percent.

(7) TSR. The TSR result is verified if the CO’s result meets the requirements shown in 

Table 401-1. 

(f) Changes and resubmissions. If a JMF is rejected or the source of material is changed, submit a 

new JMF for verification. Allow up to 30 days for the CO to evaluate a change after receipt of required 

documentation and material. Approved changes in target values will not be applied retroactively for 

payment. 

The CO will deduct JMF evaluation costs resulting from the following:

(1) Contractor-requested changes to the approved JMF;

(2) Contractor requests for more than one JMF evaluation; and

(3) Additional testing necessary due to the failure of a submitted JMF.

401.04 Mixing Plant. Use mixing plants conforming to AASHTO M 156. 

(a) Drum dryer-mixer plants.

(1) Bins. Provide a separate bin in the cold aggregate feeder for each individual aggregate stockpile 

in the asphalt concrete mix. Use bins of sufficient size to keep the plant in continuous operation 

and of proper design to prevent overflow of material from one bin to another. 

(2) Stockpiling procedures. Separate aggregate into at least three stockpiles with different 

gradations. 

(b) Batch plants.

(1) Hot aggregate bin. Provide a bin with three or more separate compartments for storage of the 

screened aggregate fractions to be combined for the asphalt concrete mix. Make the partitions 

between the compartments tight and of sufficient height to prevent spillage of aggregate from one 

compartment into another.

(2) Load cells. Calibrated load cells may be used in batch plants instead of scales.

(3) RAP. Modify batch plants so RAP is introduced into the asphalt concrete mix after bypassing 

the dryer. Design the cold feed bin, conveyor system, and special bin adjacent to the weigh hopper, 

if used, to avoid segregation and sticking of the recycled asphalt pavement material. Heat aggregate 

to a temperature that will transfer sufficient heat to the recycled asphalt pavement material to 

produce an asphalt concrete mix of uniform temperature within the range specified in the approved 

JMF.
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(c) WMA plant modifications. 

(1) Modify the mixing plant as required by the manufacturer to introduce the WMA technology. 

Interlock the WMA additive delivery system with the automated proportioning system. 

(2) Incorporate additives and WMA technologies into the asphalt concrete mix according to the 

manufacturer’s recommendations. Deliver and store of additives according to the manufacturer’s 

recommendations.

(3) Modify the plant burner and drum flights to operate at lower production temperatures. 

401.05 Equipment. 

(a) Pavers. Provide pavers that are:

(1) Self-contained, power-propelled units with adjustable vibratory screeds with full-width screw 

augers;

(2) Heated for the full width of the screed;

(3) Capable of spreading and finishing courses of asphalt concrete mix in widths at least 12 inches 

more than the width of one lane; 

(4) Equipped with a receiving hopper having sufficient capacity to ensure a uniform spreading 

operation; 

(5) Equipped with automatic feed controls, which are properly adjusted to maintain a uniform 

depth of material ahead of the screed;

(6) Operable at forward speeds consistent with satisfactory asphalt concrete mix lay down;

(7) Capable of producing a smooth-finished surface without segregating, tearing, shoving, or 

gouging; 

(8) Equipped with automatic screed controls with sensors that can sense grade from an outside 

reference line, sensing the transverse slope of the screed, and providing the automatic signals that 

operate the screed to maintain grade and transverse slope; and

(9) If required, provide a screed mounted safety edge device that can: 

(a) Maintain contact with the road shoulder surface;

(b) Allow automatic transition to intersections and obstructions; and

(c) Constrain and reduce the volume of the asphalt concrete material head to increase the 

density of the extruded profile.

Do not use conventional single plate strike-off.
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314

(b) Material transfer vehicle (MTV). If required, provide an MTV with the following: 

(1) Independently operated with its own operator; 

(2) Independent from the paver; 

(3) A loading system with the ability to receive mixtures from the hauling equipment;

(4) A minimum storage capacity of 13 tons with a remixing system in the MTV storage bin;

(5) A discharge conveyor to deliver the mixture to the paver hopper; and 

(6) A mass no more than the maximum legal loadings on structures.

Pick-up machines, hopper inserts, and material transfer devices are not considered MTVs.

401.06 Surface Preparation. Clean the existing surface of loose material, dirt, or other deleterious 

material by approved methods. Apply an asphalt tack coat to contact surfaces of pavements, curbs, gutters, 

manholes, and other structures according to Section 412. 

401.07 Weather Limitations. Place asphalt concrete mix on a dry, unfrozen surface when the air 

temperature in the shade is above 35 °F and rising. For HMA, conform to Table 401-4. For WMA, adjust 

Table 401-4 minimum lay-down temperatures according to the manufacturer’s recommendations.

Table 401-4 

Asphalt Concrete Mix Placement Temperature

Compacted Lift

Thickness < 2 Inches 2 to 3 Inches > 3 Inches

Road Surface

Temperature, °F Minimum Lay-Down Temperature, °F(1)

< 35 (2) (2) (2) 

35 to 39.9 (2) (2) 280

40 to 49.9 (2) 285 275

50 to 59.9 295 280 270

60 to 69.9 285 275 265

70 to 79.9 280 270 265

80 to 89.9 270 265 260

≥ 90 265 260 255

(1) Do not heat the asphalt concrete mix above the temperature specified in the approved 

asphalt concrete mix design.

(2) Do not pave.

401.08 Asphalt Preparation. Uniformly heat the asphalt binder to provide a continuous supply of heated 

asphalt binder from storage to the mixer. Do not heat asphalt binder above 365 °F.

If a liquid heat stable antistrip additive is used, meter it into the asphalt binder transfer lines at a bulk 

terminal or mixing plant. Inject the additive for at least 80 percent of the transfer or mixing time to obtain 

uniformity. 
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401.09 Aggregate Preparation. If lime is used as an antistrip, adjust the aggregate moisture to at least 

4 percent by mass of aggregate. Mix the lime uniformly with the aggregate before introducing the 

aggregate into the dryer or dryer drum. Use calibrated weighing or metering devices to measure the 

quantity of lime added to the aggregate. 

For batch plants, heat, dry, and deliver aggregate for pugmill mixing at a temperature sufficient to produce 

an asphalt concrete mix temperature within the approved range. Adjust flames used for drying and heating 

to prevent damage to and contamination of the aggregate. Additional plant adjustments may be required 

to provide dry aggregate at the reduced mixing temperatures of WMA.

Control plant operations so the moisture content of the asphalt concrete mix behind the paver is no more 

than 0.5 percent according to AASHTO T 329. 

Before starting asphalt concrete mix production, obtain approval of synchronized metering and weighing 

devices used to introduce a constant rate of lime and water.

Add lime to the aggregate by one of the following methods: 

(a) Method A. Add lime to the combined cold feed aggregate using an enclosed in-line cold feed 

mechanical pugmill mixer. Use a twin-shaft, continuous mixing pugmill with adjustable mixing 

paddles. Adjust the retention time of the mixture in the pugmill so no unmixed lime is visible after the 

lime and aggregate exit the pugmill. 

(b) Method B. Add lime to the produced aggregates during stockpiling using a pugmill. Distribute the 

lime according to the stockpile ratios stated in the asphalt concrete mix design.

A minimum moisture content of 2 percent by dry weight for coarse aggregate and 4 percent by dry 

weight for fine aggregate is required at the time the aggregates and lime are mixed. Marinate treated 

aggregate in stockpiles from 24 hours to 60 days before using in asphalt concrete mix. Do not use 

aggregate marinated longer than 60 days. 

(c) Method C. Add lime to the combined cold feed aggregate as the aggregate flows from the cold 

feed bins. Mix the lime and aggregate on the conveyor belt by placing at least six paddles over the 

conveyor belt. Make the paddles protrude into the aggregate flow and direct the aggregate to fold over 

itself causing the material to migrate from one side of the conveyor belt to the other. Space the paddles 

to provide complete mixing. Provide a water spray over the conveyor belt as necessary to control dust 

and to maintain minimum moisture content.

401.10 Mixing. Measure the aggregate and asphalt into the mixer according to the JMF. Mix until particles 

are completely and uniformly coated with asphalt according to AASHTO M 156. Maintain the discharge 

temperature according to the JMF.

401.11 Hauling. Use vehicles with clean and smooth metal beds free of holes for hauling asphalt concrete 

mixes.

Coat the beds with an approved material to prevent the asphalt concrete mix from adhering to the beds. 

Do not use petroleum derivatives or other coating material that contaminates or alters the characteristics 

of the mix. Drain the bed before loading. 
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316

Equip each truck with a canvas cover or other suitable material of sufficient size to protect the asphalt 

concrete mix from the weather. If necessary to maintain temperature, use insulated truck beds and securely 

fastened covers. Provide access ports or holes for checking temperature of asphalt concrete mix in the 

truck. 

401.12 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-paving preparatory phase meeting according to 

Subsection 153.06(a) at least 3 days before the start of paving operations. Be prepared to discuss and 

provide the following:

(1) Calibration certification for the gyratory compactor. If gyratory compactor is moved, 

recalibrate;

(2) Asphalt and aggregate correction factors according to AASHTO T 308 and AASHTO T 30 on 

Form FHWA 1640, Worksheet for Ignition Furnace Binder Correction Factor AASHTO T 308. If 

RAP is included as part of the JMF, provide the asphalt and aggregate correction factors according 

to AASHTO T 30 and the FLH Addendum to AASHTO T 308 on Form FHWA 1648, Worksheet 

For Ignition Furnace Binder Correction Factor And Aggregate Gradation Correction Factor For 

Mixes Including RAP; and

(3) Plant mixing temperature.

(b) Control strip. Provide at least 7 days’ notice before starting production of an asphalt concrete 

mix.

Produce sufficient asphalt concrete mix to construct a 1000-foot-long control strip, one-lane wide, and 

at the designated lift thickness. Construct the control strip on the project at an approved location. 

Construct the control strip using asphalt concrete mix production, lay-down, and compaction 

procedures intended for the entire mix. Construct a control strip for each equipment combination and 

each plant from which production is intended.

Stop production after construction of the control strip until the asphalt concrete mix and the control 

strip are accepted. Acceptance will be based on the following:

(1) Mixture. Take at least three control strip asphalt concrete mix samples and test samples as 

shown in Table 401-10. The asphalt concrete mix is acceptable if all test results are within 

specification limits for asphalt content, VMA, and VFA; and the calculated pay factor for asphalt 

content, VMA, VFA, and gradation is 0.90 or greater. 

(2) Compaction. Compact according to Subsection 401.14. Take nuclear gauge density readings 

behind each roller pass to determine the roller pattern necessary to achieve required density. Use 

Form FHWA 1646, Asphalt Control Strip Worksheet. Document if roller was operated in vibratory 

or static mode. Provide frequency and amplitude settings if operated in vibratory mode. Provide 

documentation after completion of the control strip. 

Take nuclear gauge density readings and cut and test core samples as shown in Table 401-10. 

Density is acceptable if the core density pay factor is 0.90 or greater. Provide the CO with 

documented nuclear gauge readings correlated to core specific gravities.
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317

(3) Control strip mat defects. Control strips that exhibit physical or visual defects may be 

rejected. Defects include tearing, cracking, rutting, shoving, segregation, bleeding, excessive 

pavement roughness, and poor joints.

Repeat the control strip process until an acceptable control strip is produced. Conform to 

Subsection 106.01 for the disposition of material in rejected control strips. Accepted control strips 

may remain in place and will be accepted and measured as a part of the completed pavement. Tests 

used for the control strip will not be included in the evaluation for payment according to 

Subsection 106.05. Start full production only after the control strip is verified and accepted.

Use start-up procedures if resuming production after a termination of production due to unsatisfactory 

quality according to Subsection 106.05. 

401.13 Placing and Finishing. Do not use mixes produced from different plants unless the mixes are 

produced according to the same JMF, use material from the same sources, and are approved. 

Place HMA and WMA at temperatures according to Subsection 401.07. Measure temperature of the 

asphalt concrete mix in the hauling vehicle immediately before dumping into the spreader or measure it 

in the windrow immediately before pickup.

Suspend paving if the MTV malfunctions during paving operations. Do not resume mix placement until 

the MTV is operational.

Do not use diesel fuel or products that cause stripping as a release agent on equipment used with the 

asphalt concrete mix.

Place the asphalt concrete mix as continuously as possible. Control horizontal alignment using a reference 

line. Automatically control the grade and slope from reference lines, a ski and slope control device, or 

dual skis. Use skis having a length of at least 20 feet.

In areas where mechanical spreading and finishing are impractical, place and finish the asphalt concrete 

mix with alternate equipment to produce a uniform surface closely matching the surface obtained when 

using a mechanical paver. 

Offset the longitudinal joint of one lift at least 6 inches from the joint in the lift immediately below. Make 

the longitudinal joint in the top lift along the striped centerline of two-lane roadways or at the lane lines 

of roadways with more than two lanes. 

401.14 Compacting. Provide at least three rollers, with at least one being a pneumatic-tire roller with 

rubber tires in the front and rear. Provide one roller each for breakdown, intermediate, and finish rolling. 

Size the rollers to achieve the required results. Operate rollers according to the manufacturer’s 

recommendations.

Do not cause cracking, shoving, or undue displacement. Do not pass rollers over an unsupported edge of 

freshly laid asphalt concrete mix. Continue rolling until roller marks are eliminated, cracks are sealed, and 

the required density is obtained. For HMA, do not roll the mix after the surface cools below 175 °F.

Monitor the compaction process with nuclear density gauges calibrated to the control strip core density 

test results and evaluate according to Subsection 401.18(c). 
Section 401

318

Take nuclear gauge density readings and cut and test core samples as shown in Table 401-10. 

Compact the asphalt concrete mix with alternate equipment to obtain the required compaction along forms, 

curbs, headers, walls, and other places inaccessible to rollers.

401.15 Joints, Trimming Edges, and Cleanup. Complete pavement construction of adjacent traffic lanes 

to the same elevation within 24 hours. If elevation differences more than 3 inches between adjacent lanes 

are left overnight, sign with "Uneven Lanes" warning signs and provide a 1V:3H fillet. 

Make transverse joints vertical to the depth of the new pavement at connections to existing pavements and 

previously placed lifts. Form vertical and clean transverse joints by cutting back the previous run to expose 

the full-depth course. Protect saw cut edge from equipment and traffic. Repair damaged joints by 

sawcutting before placement of adjoining asphalt concrete pavement.

Apply an asphalt tack coat to the edge of both transverse and longitudinal joints according to Section 412. 

Dispose of material trimmed from the edges and other discarded asphalt concrete mix according to 

Subsection 203.07. 

401.16 Pavement Roughness. Measure the profile of the pavement surface according to the designated 

pavement roughness type. If no roughness type is designated, use Type IV. In addition, construct pavement 

surfaces to meet the requirements of Subsection 401.16(d). 

Provide flaggers, pilot car operations, or other temporary traffic control during profile measurement 

according to Section 635. 

(a) Profile measurement. The CO will use profile measurements to determine the Mean Roughness 

Index (MRI) values for the traveled way according to FLH T 401 and using the current version of 

Profile Viewer and Analysis (ProVAL) software. The CO will determine areas of localized roughness. 

The MRI and areas of localized roughness will be used to determine payment for the designated 

pavement roughness type and pavement areas requiring surface corrections.

The CO will identify the starting and ending points of the profile measurements. The CO will identify 

excluded areas. Cattle guards, bridges not being overlaid, and turning lanes, passing lanes, side roads, 

and ramps less than 1000 feet in length will be excluded from profile measurement, the calculation of 

MRI, and the determination of localized roughness. Measure excluded areas with a straightedge 

according to Subsection 401.16(d). 

Areas for which the ProVAL continuous report exceeds the threshold MRI value for the specified 

roughness type will be considered a defective area requiring correction. If corrections are not allowed, 

a reduction in payment will be applied according to Subsection 401.20(b). No deduction will be made 

for areas of localized roughness identified within 12.5 feet of the starting or end of a profile section or 

within 12.5 feet of excluded areas. Measure these areas with a straightedge according to 

Subsection 401.16(d). 

(b) Type I and II pavement roughness. Measure the profile of the initial pavement surface before 

construction activities disturb the existing pavement surface. The initial pavement surface is defined 

as the existing pavement surface before construction activities start.
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319

Do not proceed with work that will disturb the initial pavement surface until the CO’s analysis is 

complete.

Measure the profile of the final pavement surface before placing a surface treatment and within 21 days 

of completing roadway paving. The original overall surface MRI will be used in conjunction with the 

final overall MRI to determine an overall percent improvement for the entire traveled way.

(c) Type III pavement roughness. Measure the profile of the final pavement surface before placing 

a surface treatment and within 21 days of completing roadway paving. 

(d) Type IV straightedge measurement. Measure the pavement surface using a 10-foot metal 

straightedge at right angles and parallel to the centerline. Defective areas are deviations between the 

surface and the bottom of the straightedge more than 1⁄4 inch measured between two contacts of the 

straightedge or deviations more than 1⁄4 inch measured at the end of the straightedge. 

401.17 Defective Area Correction. Obtain approval before starting corrective work. Allow 7 days for 

review and approval of correction method proposal. 

Do not correct defective areas on the final pavement surface unless approved. Evaluate and correct 

defective areas, including localized roughness, on lower lifts by one of the following: 

(a) Milling. Replace the defective area by milling at least one-half of the pavement depth and repaving 

with the approved asphalt concrete mix. Extend defective area corrections beyond the wheel path. Mill 

the defective area according to Section 413. 

(b) Sawcutting. Replace the defective area by sawcutting and removing the defective area and 

repaving with the approved asphalt concrete mix. Saw cut and remove the defective area according to 

Section 203. Extend defective area corrections beyond the wheel path. 

(c) Grinding. Use a diamond blade machine to grind off the defective surface area. Submit the 

manufacturer and model of the equipment to be used. Identify the starting and ending station of each 

grind location, the grinding depth, and lateral extent of grinding. Optimize the endpoints of the areas 

where a grinder is to be applied using ProVAL’s Smoothness Assurance function in conjunction with 

the grinding simulation function. Submit the type of seal to be placed after grinding is completed for 

approval. Place seals according to Section 409 or 410. Limit the grinding depth to 12.5 percent of the 

design pavement thickness. If grinding more than this depth, provide a minimum 1-inch overlay. 

(d) Other. Submit a proposal for approval for other correction methods not listed above. 

After corrections are made, re-measure the pavement profile according to Subsection 401.16(a). Data from 

the re-measurement will be analyzed to determine the MRI or percent improvement, areas of localized 

roughness, and the final PFrough. If correction and re-measurement of the surface is required, the maximum 

allowable pay factor under Subsection 401.20 is 1.00.

If corrections are not allowed, no adjustment will be made to the final PFrough or localized roughness pay 

deductions. 

401.18 Acceptance. See Table 401-10 for sampling, testing, and acceptance requirements. 

Aggregate quality properties will be evaluated under Subsections 106.02 and 106.04. 
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320

Mineral filler, antistrip additives, and WMA additives will be evaluated under Subsections 106.02 and 

106.03. 

Asphalt content, VMA, and core density will be evaluated under Subsection 106.05. Pavement roughness

will be evaluated under Subsection 106.04. Asphalt binder will be evaluated under Subsections 106.03

and 106.04. Evaluations will consider the following: 

(a) Asphalt content. The upper and lower specification limits are the approved JMF target value 

±0.4 percent;

(b) VMA. The lower specification limits are shown in Table 401-1. Use the Contractor’s combined 

coarse and fine bulk specific gravity of aggregate Gsb values to calculate VMA on field produced 

asphalt concrete mix samples;

(c) Density (core). The lower specification limit is 91.0 percent of the maximum specific gravity

(density) determined according to AASHTO T 166 and AASHTO T 209. 

The percent compaction will be determined using the average maximum specific gravity (AASHTO 

T 209) from all samples tested the day the core was obtained; 

(d) Pavement roughness. The evaluation for payment will be made after defective areas are 

addressed. The pay factor is determined from Table 401-6, Table 401-7, Table 401-8, and Table 401-9; 

and 

(e) Asphalt binder. The pay factor is determined from Table 401-5. 

Construction of the HMA or WMA pavement course will be evaluated under Subsections 106.02 and 

106.04. 

Asphalt tack coat will be evaluated under Section 412. 

Measurement

401.19 Measure the Section 401 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

401.20 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 401 pay items listed in the bid schedule, except the asphalt concrete pavement contract price will 

be adjusted according to Subsections 106.05, 401.18(d) and (e). Payment will be full compensation for 

the work prescribed in this Section. See Subsection 109.05. 

Payment will be adjusted according to the following: 

(a) Asphalt concrete pavement. Payment for asphalt concrete pavement will be made at a price 

determined by multiplying the contract price by the material pay factor for each lot. The material pay 

factor is calculated as follows:

PFmaterial = 1 + [(PFVolumetric – 1) + (PFPG – 1)] 
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321

where:

PFmaterial = Material pay factor.

PFVolumetric = Pay factor for asphalt concrete pavement. PFVolumetric is the lowest single pay factor 

determined for asphalt binder content, VMA, and core density. 

PFPG = Pay factor for asphalt binder. The PFPG formula is as follows:

 

where:

PF# = For each sample, the lowest pay factor determined from any test in Table 401-5. If the 

lowest pay factor for a sample is in reject, the sample’s pay factor is zero.

n = Number of samples tested.

If either the pay factor for the asphalt binder (PFPG) or the pay factor for asphalt concrete pavement 

(PFVolumetric) is below 0.75, the lot for asphalt concrete pavement is in reject. 

(b) Pavement roughness. If the contract specifies a pavement roughness Type I, Type II, or Type III, 

a separate pay adjustment will be made for pavement roughness calculated as follows:

Type I, Type II, or Type III Pay Adjustment = (RF)(PFrough - 1.00)(L) – (LRPR)

where:

PFrough =Pay factor from Tables 401-6, 401-7, or 401-8. 

L = Total project length in lane miles.

LRPR = Localized roughness pay reduction. Each area of localized roughness more than the 

localized roughness threshold MRI specified for the designated pavement roughness type will 

receive a reduction in payment according to Table 401-9. 

RF = Roughness factor: 100,000.

For Type I and Type II pavement roughness, the localized roughness threshold computed to the nearest 

whole number is equal to the following: 

Type I Localized Roughness Threshold = Initial Overall MRI + 1.881(S25) 

Type II Localized Roughness Threshold = Initial Overall MRI + 1.282(S25) 

where:

Initial Overall MRI = MRI obtained before construction activities start.

S25 = sample standard deviation of the 25-foot fixed interval MRI values.
Section 401

322

The overall percent improvement in MRI will be determined to one decimal place for the traveled way 

according to the following formula:

 

 

For Type I pavement roughness, Table 401-6 will be used to determine the final pay factor (PFrough) 

for the traveled way to two decimal places. If the percent improvement is less than 25.0 percent and 

the final overall MRI value is less than or equal to 70.0 inches per mile, Type III-A from Table 401-8

will be used to determine the final PFrough. 

For Type II pavement roughness, Table 401-7 will be used to determine the final PFrough for the 

traveled way to two decimal places. If the percent improvement is less than 49.0 percent and the final 

overall MRI value is less than or equal to 70.0 inches per mile, Type III-A from Table 401-8 will be 

used to determine the final PFrough. 

For Type III pavement roughness, pay factors from Table 401-8 will be used in conjunction with the 

long continuous histogram printout from ProVAL’s Smoothness Assurance Analysis function and by 

utilizing a long continuous 528-foot segment length for analysis. The localized roughness threshold 

for Type III pavement roughness is 140 inches per mile. The final PFrough is equal to the sum of the 

products of the individual pay factors shown in Table 401-8 multiplied by the ratio of individual lane 

miles to the overall project lane miles and by ProVAL’s corresponding histogram percentages, divided 

by 100. The final PFrough will be determined to three decimal places.

For Type IV pavement roughness, each defective area as determined by a 10-foot metal straightedge 

will receive a reduction in payment according to Table 401-9. 
Table 401-5 

Asphalt Binder Pay Factor Table

Property Specifications(1)

Pay Factor

1.01 1.00 0.95 0.90 0.75 Reject

Tests on Original

Dynamic shear 

rheometer, kPa ≥ 1.00 ≥ 1.17 1.16 to 1.00 0.99 to 0.89 0.88 to 0.77 0.76 to 0.50 < 0.50

Tests after Rolling Thin Film Oven (RTFO)

Dynamic shear

rheometer, kPa ≥ 2.20 ≥ 2.69 2.68 to 2.20 2.19 to 1.96 1.95 to 1.43 1.42 to 1.10 < 1.10

Tests on Pressure Aging Vessel (PAV)

Dynamic shear

rheometer, kPa(2) < 5000 ≤ 4711 4712 to 5000 5001 to 5289 5290 to 5578 5579 to 6000 > 6000

Bending beam

rheometer, s, MPa ≤ 300 ≤ 247 248 to 300 301 to 338 339 to 388 389 to 449 ≥ 450

Bending beam

rheometer, m-value ≥ 0.300 ≥ 0.320 0.319 to 0.300 0.299 to 0.294 0.293 to 0.278 0.277 to 0.261 < 0.261

(1) Conform to Subsection 702.01. 

(2) If dynamic shear rheometer (PAV) value is between 5000 kPa and 6000 kPa, and the phase angle is equal to or greater than 42 degrees, the pay factor is 

1.00
Section 401

324

Table 401-6 

Type I Pavement Roughness Pay Factors

Type I-A Type I-B – 

Percent Improvement (%) Percent Improvement (%) Pay Factor (PFrough)

Greater than 50.0 Greater than 45.0 1.05

47.6 to 50.0 44.0 to 45.0 1.04

45.1 to 47.5 43.0 to 43.9 1.03

43.6 to 45.0 41.6 to 42.9 1.02

42.1 to 43.5 40.1 to 41.5 1.01

25.0 to 42.0 20.0 to 40.0 1.00

24.0 to 24.9 19.0 to 19.9 0.99

23.0 to 23.9 18.0 to 18.9 0.98

22.0 to 22.9 17.0 to 17.9 0.97

21.0 to 21.9 16.0 to 16.9 0.96

20.0 to 20.9 15.0 to 15.9 0.95

19.0 to 19.9 14.0 to 14.9 0.94

18.0 to 18.9 13.0 to 13.9 0.93

17.0 to 17.9 12.0 to 12.9 0.92

16.0 to 16.9 11.0 to 11.9 0.91

15.0 to 15.9 10.0 to 10.9 0.90

14.0 to 14.9 9.0 to 9.9 0.89

13.0 to 13.9 8.0 to 8.9 0.88

12.0 to 12.9 7.0 to 7.9 0.87

11.0 to 11.9 6.0 to 6.9 0.86

10.0 to 10.9 5.0 to 5.9 0.85

5.0 to 9.9 4.0 to 4.9 0.80

0.0 to 4.9 0.0 to 3.9 0.70

Negative Improvement Negative Improvement Correct & overlay
Section 401

325

Table 401-7 

Type II Pavement Roughness Pay Factors

Type II-A Type II-B – 

Percent Improvement (%) Percent Improvement (%) Pay Factor (PFrough)

Greater than 60.0 Greater than 50.0 1.05

58.6 to 60.0 49.0 to 50.0 1.04

57.6 to 58.5 48.0 to 48.9 1.03

56.6 to 57.5 47.0 to 47.9 1.02

55.1 to 56.5 45.0 to 46.9 1.01

49.0 to 55.0 35.0 to 44.9 1.00

48.0 to 48.9 34.0 to 34.9 0.99

47.0 to 47.9 33.0 to 33.9 0.98

46.0 to 46.9 32.0 to 32.9 0.97

45.0 to 45.9 31.0 to 31.9 0.96

44.0 to 44.9 30.0 to 30.9 0.95

43.0 to 43.9 29.0 to 29.9 0.94

42.0 to 42.9 28.0 to 28.9 0.93

41.0 to 41.9 27.0 to 27.9 0.92

40.0 to 40.9 26.0 to 26.9 0.91

38.0 to 39.9 25.0 to 25.9 0.90

36.0 to 37.9 24.0 to 24.9 0.89

35.0 to 35.9 23.0 to 23.9 0.88

34.0 to 34.9 22.0 to 22.9 0.87

33.0 to 33.9 21.0 to 21.9 0.86

31.0 to 32.9 20.0 to 20.9 0.85

25.0 to 30.9 16.0 to 19.9 0.80

10.0 to 24.9 7.5 to 15.9 0.70

Less than 10.0 Less than 7.5 Correct & overlay
Section 401

326

Table 401-8 

Type III Pavement Roughness Pay Factors

Type III-A, inch/mile Type III-B, inch/mile Pay Factor

Mean Roughness Index (MRI) Mean Roughness Index (MRI) (PFrough) 

If MRI of entire roadway is

greater than 125 in/mi

If MRI of entire roadway is

greater than 135 in/mi REJECT 

Greater than 95.0 Greater than 110.0 0.700

95.0 to 90.0 110.0 to 105.0 0.800

90.0 to 85.0 105.0 to 100.0 0.850

85.0 to 80.0 100.0 to 95.0 0.900

80.0 to 75.0 95.0 to 90.0 0.960

75.0 to 70.0 90.0 to 85.0 0.980

70.0 to 65.0 85.0 to 80.0 1.000

65.0 to 60.0 80.0 to 75.0 1.010

60.0 to 55.0 75.0 to 70.0 1.020

55.0 to 50.0 70.0 to 65.0 1.025

50.0 to 45.0 65.0 to 60.0 1.030

45.0 to 40.0 60.0 to 55.0 1.035

40.0 to 35.0 55.0 to 50.0 1.040

35.0 to 30.0 50.0 to 45.0 1.045

Less than 30.0 Less than 45.0 1.050

Table 401-9 

Localized Roughness and Straightedge Measurement Pay Reductions

Type I Type II & IV

Localized

Roughness Limit

MRI

Type III

Deduction

per

Occurrence

Deduction

per

Occurrence

Localized

Roughness

Limit

MRI, inch/mile

Deduction

per

Occurrence

$200 $300

Computed MRI value

according to Subsection: 

401.16(b) for Type I

401.16(b) for Type II

401.16(c) for Type III

140.0 to 169.9 $300

170.0 to 179.9 $450

180.0 to 189.9 $600

190.0 to 199.9 $750

200.0 to 209.9 $900

210.0 to 219.9 $1,200

220.0 to 229.9 $1,500

230.0 to 239.9 $2,000

> 240.0 $4,000
Table 401-10 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Asphalt

concrete

aggregate

(703.07) 

Measured &

tested for

conformance

(106.04 & 

105)

Aggregate

quality − Subsection

703.07

1 per

type &

source of

material

Source of

material Yes Beforeproduction

Not required

if using

Governmentfurnished

source

Asphalt binder

(702.01) 

Measured &

tested for

conformance

(106.04 & 

105)

Quality − AASHTO

M 320

1 per

type &

source of

material

Asphalt

supplier

or mixing 

plant

Yes Before

production −

Asphalt

concrete

aggregate

(703.07) 

Process

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

2 per

day per

stockpile

Crusher 

belt

(during

production)

No 24

hours

Not required

if using

a pre-crushed

commercial

source
Table 401-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

Asphalt

concrete

mixture

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11

1 per

submitted

mix design

Stockpiles Yes

30 days

before

producing

−

RAP asphalt

binder content − AASHTOT 308 " " " " −

Bulk specific

gravity of

aggregate

(coarse & fine)

−

AASHTO

T 84 &

T 85

" " " " −

VMA − AASHTO

R 35 " − " " −

VFA − " " − " " −

Air voids − " " − " " −

Tensile strength

ratio − AASHTOT 283 " − " " −
Table 401-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (control strip)

Asphalt

concrete

pavement

Statistical

(106.05) 

Gradation

AASHTO

T 30 3 minimum

Behind the

paver before

compaction

Yes 6 hours −

No. 4 I 

No. 30 I 

No. 200 I 

Other specified

sieves II

Asphalt

content(1) I AASHTO

T 308 " " " " −

VMA I AASHTO

R 35 " " " " −

VFA II " " " " " −

Density(2) I AASHTO

T 166

5 minimum In-place

after

compaction

" 24 hours

Deliver

cores to CO

after testing

is completed
Table 401-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (control strip) (continued)

Asphalt

concrete

pavement

Measured

& tested

for

conformance

(106.04) 

Mix

temperature − −

First load

& as

directed

thereafter

Hauling 

vehicle

before

dumping or

windrow

before 

pickup

No

Immediately

upon

completion

of test

−

Maximum

specific

gravity(4)

− AASHTO

T 209 3 minimum

Behind the

paver before

compaction

Yes 24 hours −

Process 

control

(153.03) 

Density − ASTM

D2950 5 minimum

At core 

location

before 

coring

No 24 hours

See

Subsection

401.12
Table 401-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Asphalt

concrete

pavement

Statistical

(106.05) 

Asphalt

content(1) I AASHTO

T 308

1 per

700 tons

Behind the

paver before

compaction

Yes 6 hours −

VMA I AASHTO

R 35 " " " " −

Density(2) I AASHTO

T 166 " 

In-place 

after

compacting

" 24 hours

Deliver

cores to CO

after testing

is completed

Measured

& tested for

conformance

(106.04) 

Placement

temperature − −

First load

& as

determined 

by the

CO 

thereafter

Hauling

vehicle

before

dumping,

or windrow

before 

pickup

No

Immediately

upon

completion

of

measurement

−

Maximum

specific

gravity(3),(4)

− AASHTO

T 209

1 per day 

minimum

Behind the

paver before

compaction

Yes 24 hours −

Asphalt

binder

(702.01) 

Measured

& tested for

conformance

(106.04) 

Quality See 

Table 401-5

AASHTO

M 320

1 per

2000 tons

of mix

In line

between

tank and

mixing plant

Yes,

2 1-quart

samples

−

Tested by

the

Government
Table 401-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Asphalt

concrete

pavement

Process 

control

(153.03) 

Gradation

at plant − AASHTOT 27 & T 11

Contractor

determined

Cold feed

or hot bins

as applicable

No 24 hours −

Moisture

content of

aggregates

− AASHTO

T 255

Contractor

determined Stockpile " " −

Gradation

at paver − AASHTOT 30

1 per

700 tons

of mix

Behind

the paver

before

compaction

" " −

Air voids −

AASHTO

T 312 &

T 166

" " " " −

VFA − AASHTO

R 35 " " " " −

Density − ASTM

D2950

1 per

500 ft

In-place after

compacting " " −
Table 401-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Product

Asphalt

concrete

pavement

Measured

& tested

for

conformance

(106.04) 

Type I & II

roughness,

before

construction

(Initial MRI)

− FLH T 401

See

Subsection

401.16

Left and 

right

wheel paths

No

Within

21days 

before 

ground 

disturbing 

work

Original

surface 

before

construction

Type I, II & III

roughness,

after

construction

(Final MRI)

− " " " " 

Within

21 days

after

completing

paving

−

Process

control

(153.03) 

Surface

tolerance −

Straightedge

measurements

Subsection

401.16(d)

Contractor

determined

See

Subsection

401.16(d)

" 24 hours −

(1) Use AASHTO T 308, Method A. Calculate the asphalt binder content by weighing the sample before and after the burn using a calibrated 

external balance.

(2) Cut two 6-inch diameter side by side cores. Obtain cores according to AASHTO R 67 as soon as the pavement has cooled sufficiently to 

allow coring, but not later than 12 hours after final rolling. Remove them with a core retriever and fill and compact the core holes with asphalt 

concrete mixture. Label the cores and protect them from damage due to handling and temperature. Submit one core for verification testing. Dry 

the other core to constant mass at 125±5 °F or vacuum dry it according to ASTM D7227 before performing the core density and measuring the 

thickness according to ASTM D3549. Use 62.245 pounds per cubic foot to convert specific gravity to density.

(3) After production paving has begun, use the average maximum specific gravity value (AASHTO T 209) for each day to adjust the percent 

compaction for the cores that represent that day’s paving.

(4) Do not use the supplemental procedure for mixtures containing porous aggregate (dry back method of AASHTO T 209).
Section 402

334

Section 402. — ASPHALT CONCRETE PAVEMENT BY HVEEM OR 

MARSHALL MIX DESIGN METHOD

Description

402.01 This work consists of constructing asphalt concrete pavement using HMA or WMA.

Material 

402.02 Conform to the following Subsections: 

Antistrip additive 702.05

Asphalt binder 702.01

Asphalt concrete aggregate 703.07

Mineral filler 725.05

Construction Requirements

402.03 Composition of Mix (Job-Mix Formula). Provide asphalt concrete mixes of aggregate, asphalt 

binder, RAP, and additives that meet the applicable aggregate gradation in Table 703-3 and design 

parameters (a), (c), and (d) or (b), (c), and (d) in Table 402-1 for the class of mix listed in the bid schedule.

Apply asphalt concrete mix design requirements for HMA to the development of the WMA mix design. 

Provide modifications to the process required for WMA technology. Submit modifications to the asphalt 

concrete mix design process according to Appendix X.2 of AASHTO R 35 for approval. 
Section 402

335

Table 402-1 

Asphalt Concrete Mix Requirements

Design Parameters

Class of Mix

A B C 

(a) Hveem (AASHTO T 246 and AASHTO T 247)

 Percent air voids(1) 3.0 to 5.0 3.0 to 5.0 3.0 to 5.0

 Stabilometer, minimum 37 35 30

 VMA, minimum, % See Table 402-2

(b) Marshall (AASHTO T 245)

 Percent air voids(1) 3.0 to 5.0 3.0 to 5.0 3.0 to 5.0

 Compaction, number of blows each end

 of test specimen 75 50 50

 Stability, pounds minimum 2000 1500 1000

 Flow, 0.01 inch 8 to 14 8 to 16 8 to 20

 VMA, minimum, % See Table 402-2

(c) Moisture Susceptibility (AASHTO T 283)(2)

 Tensile strength ratio, minimum 0.80 0.80 0.80

(d) Dust-to-binder ratio(3) 0.8 to 1.6 0.8 to 1.6 0.8 to 1.6

(1) The percent of air voids is based on AASHTO T 166, AASHTO T 209, and AASHTO T 269. 

Maximum specific gravity (density) is based on AASHTO T 209.

(2) Use 4-inch diameter specimens. AASHTO T 283 requires a freeze-thaw cycle.

(3) Dust-to-binder ratio is the percent of material including lime, bag-house fines, and other mineral 

matter added to the mixture. Calculate the ratio using the effective asphalt content calculated by 

mass of mix.

Table 402-2 

Voids in Mineral Aggregate Hveem or Marshall Mix Design

Sieve Size(1) VMA, Minimum, Percent(2),(3)

Hveem Marshall

No. 4 16.0 to 19.0 18.0 to 21.0

3⁄8 in 14.0 to 17.0 16.0 to 19.0

1⁄2 in 13.0 to 16.0 15.0 to 18.0

3⁄4 in 12.0 to 15.0 14.0 to 17.0

1 in 11.0 to 14.0 13.0 to 16.0

(1) The largest sieve size listed in the applicable specification upon which material is allowed to be 

retained.

(2) Determine VMA according to AASHTO R 35. 

(3) If mineral filler or hydrated lime is used, include in the calculation for compliance with the 

VMA.

(a) RAP. Conform to Subsection 401.03(a). 

(b) Baghouse fines. Conform to Subsection 401.03(b). 
Section 402

336

(c) Antistrip additive. Conform to Subsection 401.03(c).

(d) Submittals. Submit written JMFs and associated material with Form FHWA 1607, Worksheet For 

A Hveem Mix Design AASHTO T 246 or Form FHWA 1622, Worksheet For A Marshall Mix Design 

AASHTO T 245 for verification at least 30 days before the control strip. Include a signed statement 

prepared by the testing laboratory that certifies the proposed JMF meets the requirements and can be 

compacted in the field during production. For each proposed JMF, submit the following: 

(1) Aggregate and mineral filler. Conform to Subsection 401.03(d)(1). 

(2) Asphalt binder. Conform to Subsection 401.03(d)(2). 

(3) Antistrip additives. Conform to Subsection 401.03(d)(3). 

(4) RAP. Conform to Subsection 401.03(d)(4). 

(5) WMA technology and additive information. Conform to Subsection 401.03(d)(5). 

(e) Verification. The verification process starts when required documentation and material have been 

received. After the JMF is verified, start asphalt concrete mix production for the control strip.

(1) Aggregate gradations. Conform to Subsection 401.03(e)(1). 

(2) RAP asphalt binder content and gradation. Conform to Subsection 401.03(e)(2). 

(3) Bulk specific gravity of aggregate (Gsb). Conform to Subsection 401.03(e)(3). 

(4) Hveem stabilometer value. The Hveem stabilometer value is verified if the CO’s result is 

above the minimum specification limit in Table 402-1. 

(5) Marshall stability and flow value. The Marshall stability and flow values are verified if the 

CO’s results meet the requirements in Table 402-1. 

(6) Air voids (Va). Conform to Subsection 401.03(e)(6). 

(7) TSR. Conform to Subsection 401.03(e)(7). 

(8) VMA. The VMA result is verified if the CO’s result is within the specification limit in 

Table 402-2. 

(f) Changes and resubmissions. Conform to Subsection 401.03(f).

402.04 Mixing Plant. Conform to Subsection 401.04. 

402.05 Equipment. Conform to Subsection 401.05. 

402.06 Surface Preparation. Conform to Subsection 401.06. 

402.07 Weather Limitations. Conform to Subsection 401.07. 

402.08 Asphalt Preparation. Conform to Subsection 401.08. 
Section 402

337

402.09 Aggregate Preparation. Conform to Subsection 401.09. 

402.10 Mixing. Conform to Subsection 401.10. 

402.11 Hauling. Conform to Subsection 401.11. 

402.12 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-paving preparatory phase meeting according to 

Subsection 153.06(a) at least 3 days before the start of paving operations. Be prepared to discuss and 

provide the following:

(1) Calibration certification for the Hveem or Marshall compactor. If the Hveem or Marshall 

compactor is moved, recalibrate; and

(2) Asphalt and aggregate correction factors according to AASHTO T 308 and AASHTO T 30 

on Form FHWA 1640, Worksheet for Ignition Furnace Binder Correction Factor AASHTO T 

308. If RAP is included as part of the JMF, provide the asphalt and aggregate correction factors 

according to AASHTO T 30 and the FLH Addendum to AASHTO T 308 on Form FHWA 

1648, Worksheet For Ignition Furnace Binder Correction Factor And Aggregate Gradation 

Correction Factor For Mixes Including RAP. 

(b) Control strip. Provide at least 7 days’ notice before starting production of an asphalt concrete 

mix.

On the first day of production, produce sufficient asphalt concrete mix to construct a 1000-foot-long 

control strip, one-lane wide, and at the designated lift thickness. Construct the control strip on the 

project at an approved location. 

Construct the control strip using asphalt concrete mix production, lay-down, and compaction 

procedures intended for the entire mix. Construct a control strip for each equipment combination and 

each plant from which production is intended. 

Stop production after construction of the control strip until asphalt concrete mix and the control strip 

are accepted. Acceptance will be based on the following:

(1) Mixture. Take and test at least three control strip asphalt concrete mix samples and 

evaluate according to Subsection 402.17. The asphalt concrete mix is acceptable if all test 

results are within specification limits for gradation and asphalt content and the calculated pay 

factor for gradation and asphalt content is 0.90 or greater. 

(2) Compaction. Compact according to Subsection 401.14. Take nuclear density gauge 

readings behind each roller pass to determine the roller pattern necessary to achieve required 

density. Use Form FHWA 1646, Asphalt Control Strip Worksheet. Document if roller was 

operated in vibratory or static mode. Provide frequency and amplitude settings if operated in 

vibratory mode. Submit documentation after completion of the control strip. 

Take nuclear gauge density readings and cut core samples according to Table 402-3. Density 

is acceptable if the calculated pay factor is 0.90 or greater. Provide the CO with documented 

nuclear gauge readings correlated to core specific gravities.
Section 402

338

(3) Control strip mat defects. Control strips that exhibit physical or visual defects may be 

rejected. Defects include tearing, cracking, rutting, shoving, segregation, bleeding, excessive 

pavement roughness, and poor joints.

Repeat the control strip process until an acceptable control strip is produced. Conform to 

Subsection 106.01 for the disposition of material in rejected control strips. Accepted control strips 

may remain in place and will be accepted and measured as a part of the completed pavement. Tests 

used for the control strip will not be included in the evaluation for payment according to 

Subsection 106.05. After a control strip is verified and accepted, full production may start.

Use start-up procedures if resuming production after a termination of production due to unsatisfactory 

quality according to Subsection 106.05. 

402.13 Placing and Finishing. Conform to Subsection 401.13. 

402.14 Compacting. Conform to Subsection 401.14. 

402.15 Joints, Trimming Edges, and Cleanup. Conform to Subsection 401.15. 

402.16 Pavement Roughness. Conform to Subsection 401.16. 

402.17 Acceptance. See Table 402-3 for sampling, testing, and acceptance requirements.

Aggregate quality properties will be evaluated under Subsections 106.02 and 106.04. 

Mineral filler, antistrip additives, and WMA additives will be evaluated under Subsections 106.02 and 

106.03. 

Asphalt content, core density, and aggregate gradation will be evaluated under Subsection 106.05. 

Pavement roughness will be evaluated under Subsection 106.04. Asphalt binder will be evaluated under 

Subsections 106.03 and 106.04. Evaluations will consider the following:

(a) Asphalt content. The upper and lower specification limits are the approved JMF target value 

±0.4 percent;

(b) Density (core). The lower specification limit is 91.0 percent of the maximum specific gravity 

(density) determined according to AASHTO T 166 and AASHTO T 209. The percent compaction will 

be determined using the average maximum specific gravity (AASHTO T 209) from all samples tested 

the day the core was obtained; 

(c) Aggregate gradation. The upper and lower specification limits are the approved JMF target values 

plus or minus the allowable deviations shown in Table 703-2; 

(d) Pavement roughness. The evaluation for payment will be made after defective areas are 

addressed. Conform to Subsection 401.18(d); and 

(e) Asphalt binder. The pay factor is determined from Table 401-5. 

Construction of HMA and WMA pavement courses will be evaluated under Subsections 106.02 and 

106.04. 
Section 402

339

Measurement

402.18 Measure the Section 402 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

402.19 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 402 pay items listed in the bid schedule, except the asphalt concrete pavement contract price will 

be adjusted according to Subsections 106.05, 402.17(d) and (e). Payment will be full compensation for 

the work prescribed in this Section. See Subsection 109.05. 

Payment will be adjusted according to the following: 

(a) Asphalt concrete pavement. Payment for asphalt concrete pavement will be made at a price 

determined by multiplying the contract price by the material pay factor for each lot. The material pay 

factor is calculated as follows:

PFmaterial = 1 + [(PFVolumetric – 1) + (PFPG – 1)] 

where:

PFmaterial = Material pay factor.

PFVolumetric = Pay factor for asphalt concrete pavement. PFVolumetric is the lowest single pay factor 

determined for asphalt binder content, VMA, and core density. 

PFPG = Pay factor for asphalt binder. The PFPG formula is as follows:

where:

PF# = For each sample, the lowest pay factor determined from any test in Table 401-5. If the 

lowest pay factor for a sample is in reject, the sample’s pay factor is zero.

n = Number of samples tested.

If either the pay factor for the asphalt binder (PFPG) or the pay factor for asphalt concrete pavement 

(PFVolumetric) is below 0.75, the lot for asphalt concrete pavement is in reject.

(b) Pavement roughness. If the contract specifies a pavement roughness Type I, Type II, or Type III, 

a separate pay adjustment will be made for pavement roughness calculated as follows:

Type I, Type II, or Type III Pay Adjustment = (RF)(PFrough - 1.00)(L) – (LRPR)

where:

PFrough = Pay factor from Tables 401-6, 401-7, or 401-8. 

L = Total project length in lane miles.
Section 402

340

LRPR = Localized roughness pay reduction. Each area of localized roughness more than the 

localized roughness threshold MRI specified for the designated pavement roughness type will 

receive a reduction in payment according to Table 401-9. 

RF = Roughness factor: 100,000.

For Type I and Type II pavement roughness, the localized roughness threshold computed to the nearest 

whole number is equal to the following: 

Type I Localized Roughness Threshold = Initial Overall MRI + 1.881(S25) 

Type II Localized Roughness Threshold = Initial Overall MRI + 1.282(S25) 

where:

Initial Overall MRI = MRI obtained before construction activities start.

S25 = sample standard deviation of the 25-foot fixed interval MRI values.

The overall percent improvement in MRI will be determined to one decimal place for the traveled way 

according to the following formula:

 

 

For Type I pavement roughness, Table 401-6 will be used to determine the final pay factor (PFrough) 

for the traveled way to two decimal places. If the percent improvement is less than 25.0 percent and 

the final overall MRI value is less than or equal to 70.0 inches per mile, Type III-A from Table 401-8

will be used to determine the final PFrough. 

For Type II pavement roughness, Table 401-7 will be used to determine the final PFrough for the 

traveled way to two decimal places. If the percent improvement is less than 49.0 percent and the final 

overall MRI value is less than or equal to 70.0 inches per mile, Type III-A from Table 401-8 will be 

used to determine the final PFrough. 

For Type III pavement roughness, pay factors from Table 401-8 will be used in conjunction with the 

long continuous histogram printout from ProVAL’s Smoothness Assurance Analysis function and by 

utilizing a long continuous 528-foot segment length for analysis. The localized roughness threshold 

for Type III pavement roughness is 140 inches per mile. The final PFrough is equal to the sum of the 

products of the individual pay factors shown in Table 401-8 multiplied by the ratio of individual lane 

miles to the overall project lane miles and by ProVAL’s corresponding histogram percentages, divided 

by 100. The final PFrough will be determined to three decimal places.

For Type IV pavement roughness, each defective area as determined by a 10-foot metal straightedge 

will receive a reduction in payment according to Table 401-9. 
Table 402-3 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Asphalt

concrete

aggregate

(703.07) 

Measured &

tested for

conformance

(106.04 & 

105) 

Aggregate

quality − Subsection

703.07

1 per

type &

source

of material

Source of

material Yes Beforeproducing

Not required

if using

Governmentfurnished

source

Asphalt 

binder

(702.01) 

Measured &

tested for

conformance

(106.04) 

Quality − AASHTO

M 320

1 per

type &

source

of material

Asphalt

supplier

or

mixing 

plant

Yes Before

producing −

Asphalt

concrete

aggregate

(703.07) 

Process

control

(153.03) 

Gradation − AASHTO

T 27& T 11

2 per

day per

stockpile

Crusher 

belt

(during

production)

No 24 hours

Not required

if using

a pre-crushed

commercial

source
Table 402-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

Asphalt

concrete

mixture

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11

1 per

submitted

mix design

Stockpiles Yes

30 days

before

paving

−

RAP asphalt

binder content − AASHTOT 308 " " " " −

RAP asphalt

gradation − AASHTOT 30 " " " " 

Dry

gradation,

no binder

removed

Bulk specific

gravity of

aggregate

(coarse & fine)

− AASHTO

T 84 & T 85 " " " " −

VMA − AASHTO

R 35 " − " " −

VFA − " " − " " −

Air voids − AASHTO

T 269 " − " " −

Hveem

S-value − AASHTOT 246 & T 247 " − " " 

Required

only for

Hveem 

mix

Marshall

stability

& flow

− AASHTO

T 245 " − " " 

Required

only for

Marshall

mix

Tensile

strength ratio − AASHTOT 283 " − " " −
Table 402-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (control strip)

Asphalt

concrete

pavement

Statistical

(106.05) 

Gradation:

AASHTO

T 30 3 minimum

Behind the

paver

before

compaction

Yes 6 hours −

1⁄2 in I 

No. 4 I 

No. 30 I 

No. 200 I 

Other 

specified

sieves

II

Asphalt

content(1) I AASHTO

T 308 " " " " −

Density(2) I AASHTO

T 166 5 minimum

In-place

after

compacting

" 24 hours

Deliver

core to the

CO
Table 402-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (control strip)

Asphalt

concrete

pavement

Measured &

tested for

conformance

(106.04) 

Maximum

specific 

gravity(4)

− AASHTO

T 209

3 

minimum

Behind the

paver

before

compaction

Yes 24 hours −

Mix

temperature − −

First load

& as

directed

thereafter

Hauling

vehicle

before

dumping or

windrow

before 

pickup

No

Upon

completion

of test

−

Process

control

(153.03) 

Density − ASTM

D2950

5 

minimum

At core

location

before 

coring

No 24 hours

See

Subsection

402.12
Table 402-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Asphalt

concrete

pavement

Statistical

(106.05) 

Gradation:

AASHTO

T 30

1 per

700 tons

Behind the

paver

before

compaction

Yes 6 hours −

1⁄2 in I 

No. 4 I 

No. 30 I 

No. 200 I 

Other 

specified

sieves

II

Asphalt 

content(1) I AASHTO

T 308 " " " " −

Density(2) I AASHTO

T 166 " 

In-place

after

compacting

" 24 hours −
Table 402-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Asphalt

concrete

pavement Measured &

tested for

conformance

(106.04) 

Maximum

specific

gravity(3),(4)

− AASHTO

T 209

1 per day 

minimum

Behind

the paver

before

compaction

Yes 24 hours −

Placement

temperature − −

First load

& as

directed

thereafter

Hauling

vehicle

before

dumping,

or windrow

before

pickup

No

Upon

completion

of

measurement

−

Surface

tolerance −

Straightedge

measurements

Subsection

401.16(d)

As directed

See

Subsection

401.16(d)

No 24 hours −

Asphalt

binder

(702.01) 

Measured &

tested for

conformance

(106.04) 

Quality See 

Table 401-5

AASHTO

M 320

1 per

2000 tons

of mix

In line

between

tank &

mixing 

plan

Yes,

2 

1-quart

samples

− Tested by

Government

Asphalt

concrete

pavement

Process

control

(153.03) 

Gradation

at plant − AASHTOT 27 & T 11

Contractor

determined

Cold feed

or hot bins

as 

applicable

No 24 hours −

Moisture

content of

aggregates

− AASHTO

T 255

Contractor

determined Stockpile " " −

Density − ASTM

D2950

1 per

500 ft

In-place

after

compacting

" " −
Table 402-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Product

Asphalt

concrete

pavement

Measured &

tested for

conformance

(106.04) 

Type I

pavement

roughness,

before

construction

(Initial MRI)

− AASHTO

R 56 & R 57

See

Subsection

402.16

Left

and right

wheel

paths

No

Within 21 days 

before ground 

disturbing work

Original

surface

before

construction

Type I

pavement

roughness,

after

construction

(Final MRI)

− " " " " 

Within 21

days after

completing

paving

−

Type II

pavement

roughness,

before

construction

(Initial MRI)

− " " " " 

Within 21 days 

before ground 

disturbing work

Original

surface

before

construction

Type II

pavement

roughness,

after

construction

(Final MRI)

− " " " " 

Within 21

days after

completing

paving

−
Table 402-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Product (continued)

Asphalt

concrete

pavement

Measured &

tested for

conformance

(106.04) 

Type III

pavement

roughness

(Final MRI)

− AASHTO

R 56 & R 57

See

Subsection

402.16

Left

and right

wheel

paths

No

Within 21

days after

completing

paving

−

Measured &

tested for

conformance

(106.04) 

Surface

tolerance −

Straightedge

measurements

Subsection

401.16(d)

As directed

See

Subsection

401.16(d)

No 24 hours −

(1) Use AASHTO T 308, Method A. Calculate the asphalt binder content by weighing the sample before and after the burn using a calibrated external 

balance.

(2) Cut two 6-inch diameter side by side cores. Obtain cores as soon as the pavement has cooled sufficiently to allow coring, but not later than 12 hours 

after final rolling. Remove them with a core retriever and fill and compact the core holes with asphalt concrete mixture. Label the cores and protect them 

from damage due to handling and temperature. Submit one core for verification testing. Dry the other core to constant mass at 125±5 °F or vacuum dry it 

according to ASTM D7227 before performing the core density and measuring the thickness. Use 62.245 pounds per cubic foot to convert specific gravity 

to density.

(3) After production paving has begun, use the average maximum specific gravity value (AASHTO T 209) for each day to adjust the percent compaction 

for the cores that represent that day’s paving.

(4) Do not use the supplemental procedure for mixtures containing porous aggregate (dry back method of AASHTO T 209).
Section 403

349

Section 403. — ASPHALT CONCRETE

Description

403.01 This work consists of constructing asphalt concrete facilities using a HMA or WMA.

Construction Requirements

403.02 Composition of Mix (Job-Mix Formula). Conform to current state department of transportation

material specifications for asphalt concrete.

Submit a state department of transportation JMF approved within the past 12 months for approval at least 

30 days before production that meets the current state department of transportation requirements for the 

location and type of facility being constructed. 

For each proposed JMF, submit a production certification conforming to state department of transportation 

specifications. Submit the strength, quality, and gradation specifications for the asphalt concrete mix. 

Include copies of laboratory test reports that demonstrate aggregate, asphalt binder, additive, and mix 

properties meet state department of transportation specifications. Submit the maximum specific gravity 

(density) of the mix as determined by AASHTO T 209. 

If requested, submit a representative 100-pound loose mix sample 21 days before placement.

403.03 Production Start-Up Procedures. Conform to Subsection 153.03(b).

403.04 Equipment. Conform to Subsection 401.05. 

403.05 Surface Preparation. Conform to Subsection 401.06. 

403.06 Weather Limitations. Conform to Subsection 401.07. 

403.07 Hauling. Conform to Subsection 401.11. 

403.08 Placing and Finishing. Do not use mixes produced from different plants unless the mixes are 

produced according to the same JMF, use material from the same sources, and are approved.

Place HMA at temperatures shown in Table 401-4. Place WMA at temperatures according to 

Subsection 401.03(d)(5). Measure temperature of the asphalt concrete mix in the hauling vehicle 

immediately before dumping into the spreader or measure it in the windrow immediately before pickup.

Place the mix with a paver conforming to Subsection 401.05. Control horizontal alignment using a 

reference line. Automatically control the grade and slope from reference lines, a ski and slope control 

device, or dual skis. Use skis having a minimum length of 20 feet.

In areas where mechanical spreading and finishing are impractical, place and finish the asphalt concrete 

mix by other approved methods to produce a uniform finished surface. 

Offset the longitudinal joint according to Subsection 401.13. 
Section 403

350

403.09 Compacting. Thoroughly and uniformly compact the asphalt surface by rolling. In places 

inaccessible to rollers, use approved alternate equipment. Do not cause cracking, shoving, or undue 

displacement.

Monitor the compaction process with nuclear density gauges calibrated according to ASTM D2950 within 

6 months before use. Check the standard and reference on each day of use according to the ASTM D2950 

standardization and reference check sections. Compact to at least 91.0 percent of the maximum specific 

gravity (density) determined in Subsection 403.02. 

Do not pass rollers over an unsupported edge of freshly laid asphalt concrete mix. Continue rolling until 

roller marks are eliminated, cracks are sealed, and the required density is obtained. For HMA, do not roll 

the mix after the surface cools below 175 °F.

403.10 Joints, Trimming Edges, and Cleanup. Conform to Subsection 401.15. 

403.11 Pavement Straightedge Measurement. Measure the pavement surface using a 10-foot metal 

straightedge at right angles and parallel to the centerline. Defective areas are deviations between the 

surface and the bottom of the straightedge more than 1⁄4 inch measured between two contacts of the 

straightedge or deviations more than 1⁄4 inch measured at the end of the straightedge. 

Correct defective areas according to Subsection 401.17. Obtain approval for the method of correction. 

403.12 Acceptance. See Table 403-1 for sampling, testing, and acceptance requirements. If no asphalt 

concrete type is designated, evaluate according to Type I in Table 403-1. 

Asphalt binder will be evaluated under Subsection 106.03. 

Asphalt concrete mix properties will be evaluated under Subsections 106.03 and 106.04. 

Construction of asphalt concrete facilities will be evaluated under Subsections 106.02 and 106.04. 

Pavement straightedge measurement will be evaluated under Subsection 106.04. 

Measurement

403.13 Measure the Section 403 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

403.14 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 403 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 403-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

Asphalt 

concrete, 

Type I

Measured &

tested for 

conformance

(106.04) 

Job-mix 

formula

Subsection 

403.02 If requested

Flowing mix 

stream (bin or belt 

discharge) or 

behind the paver 

before compaction

Yes

Before 

approval of 

job-mix 

formula

Tested by 

the 

Government

Production

Asphalt

concrete,

Type I

Measured &

tested for

conformance

(106.04) 

Job-mix 

formula

Subsection 

403.02

1 per 

700 tons

Behind the paver 

before compaction Yes 24 hours −

Density(1) AASHTO

T 166 " In-place after compacting " " 

Deliver

cores to CO

after testing

is completed

Maximum 

specific 

gravity(2),(3)

AASHTO

T 209 " Behind the paver before compaction " " −

Surface

tolerance

Straightedge

measurement,

Subsection 

403.11

Continuously,

after 

compaction

Finished pavement 

surface No " −

Placement

temperature −

First load & 

as directed 

thereafter

Hauling vehicle 

before dumping, or 

windrow before 

pickup

" 

Upon 

completion of 

measurement

−

Process 

control

(153.03) 

Gradation at 

the plant

AASHTO

T 27 & T 11

Contractor 

determined

Cold feed or hot 

bins as applicable No 24 hours −

Moisture 

content of

aggregates

AASHTO

T 255 " Stockpile " " −

Density ASTM D2950 1 per 500 ft In-place after 

compacting " " −
Table 403-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Asphalt

concrete,

Type II

Measured & 

tested for

conformance

(106.04) 

Density ASTM D2950 1 per 500 ft In-place after 

compacting No 24 hours −

Surface

tolerance

Straightedge 

measurement,

Subsection 

403.11

Continuously,

after 

compaction

Finished pavement 

surface " " −

Placement

temperature −

First load & 

as directed 

thereafter

Hauling vehicle 

before dumping, or 

windrow before 

pickup

" 

Upon 

completion of 

measurement

−

(1) For asphalt concrete Type I, cut two 6-inch diameter side by side cores. Obtain cores as soon as the pavement has cooled sufficiently to allow coring, 

but not later than 12 hours after final rolling. Remove them with a core retriever and fill and compact the core holes with asphalt concrete mixture. Label 

the cores and protect them from damage due to handling and temperature. Submit one core for verification testing. Dry the other core to constant mass 

at 125±5 °F or vacuum dry it according to ASTM D7227 before performing the core density and measuring the thickness. Use 62.245 pounds per cubic 

foot to convert specific gravity to density.

(2) After production paving has begun, use the average maximum specific gravity value (AASHTO T 209) for each day to adjust the percent compaction 

for the cores that represent that day’s paving.

(3) Do not use the supplemental procedure for mixtures containing porous aggregate (dry back method of AASHTO T 209).
Section 404

353

Section 404. — THIN LIFT ASPHALT CONCRETE PAVEMENT

Description

404.01 This work consists of constructing thin lift asphalt concrete pavement using HMA or WMA. 

Material 

404.02 Conform to the following Subsections: 

Antistrip additive 702.05

Asphalt binder 702.01

Asphalt concrete aggregate 703.07

Mineral filler 725.05

Construction Requirements

404.03 Composition of Mix (Job-Mix Formula).

(a) General. Provide a thin lift asphalt concrete pavement JMF that conforms to one of the following: 

(1) Type I. At least 30 days before production, submit a state department of transportation thin lift 

asphalt concrete JMF that is used for a highway system and approved by the state department of 

transportation within the past 12 months. 

For each proposed JMF, submit a current production certification conforming to state department 

of transportation specifications. Submit the strength, quality, and gradation specifications for the 

asphalt concrete mix. Include copies of laboratory test reports that demonstrate the aggregate, 

asphalt binder, additive, and mix properties meet state department of transportation specifications.

(2) Type II. Select JMF mix design procedure (a) or (b) from Table 404-1. For the selected design 

procedure, provide an asphalt concrete mixture of aggregate, asphalt binder, RAP, and additives 

that meets the applicable aggregate gradation shown in Table 703-3 for No. 4 gradation and 

conforms to the design parameters shown in Table 404-1 for the selected mix design procedure. In 

addition, conform to the requirements of (c) from Table 404-1. 

Submit the strength, quality, and gradation specifications for the asphalt concrete mix. Include 

copies of laboratory test reports that demonstrate aggregate, asphalt binder, additive, and mix 

properties meet Federal or state department of transportation specifications.
Section 404

354

Table 404-1 

Asphalt Concrete Mix Requirements

Type II Thin Lift Asphalt Concrete Pavement

Design Parameters Specification

(a) Asphalt Concrete Pavement by Gyratory Mix Design Method (AASHTO M 323, AASHTO R 35, and 

AASHTO T 312)

Gyratory compaction level (Ninitial, Ndesign, Nmax) 6, 50, 75

Gradation (No. 4) Table 703-3

Air voids (Va), % 5

VMA, % 16 to 21(1)

VFA, % 66 to 82

Dust-to-binder ratio 0.6 to 2.0

(b) Asphalt Concrete Pavement by Marshall Mix Design Method (AASHTO T 245)

Compaction, number of blows each end of test specimen 75

Gradation (No. 4) Table 703-3

Air voids (Va), % 4

Stability, lb, minimum 2000

Flow, 0.01 in 8 to 14

VMA, % 16 to 21(1)

VFA, % 66 to 82

Dust-to-binder ratio 0.6 to 2.0

(c) Moisture Susceptibility (AASHTO T 283)

Tensile strength ratio, minimum 0.80

(1) Minimum verification value of design VMA is 16.5 percent. 

Submit the maximum specific gravity (density) of the mix as determined by AASHTO T 209. 

Limit the natural sand content of the thin lift asphalt concrete pavement mixture to no more than 

10 percent of the total weight of aggregate in the JMF.

If using WMA, apply asphalt concrete mix design requirements for HMA to the development of the 

WMA mix design. Provide modifications to the process required for WMA technology.

Submit modifications to the asphalt concrete mix design process according to AASHTO R 35, 

Appendix X.2, Special Mix Design Considerations and Practices for Warm Mix Asphalt (WMA) for 

approval.

(b) Submittals. Conform to Subsection 401.03(d). 

(c) Verification. Allow at least 30 days for verification of each JMF. The verification process starts 

when required documentation and material are received. After the JMF is verified, start asphalt 

concrete mix production for the control strip. 

(1) Type I.

(a) Aggregate gradations. The aggregate gradation is verified if the CO’s gradation on a 

combined asphalt concrete mix using the aggregate and RAP stockpile percentage 

recommendations is within the target value gradation plus or minus the tolerance for each sieve 

shown in Table 404-2. 
Section 404

355

(b) RAP asphalt binder content and gradation. The RAP asphalt binder content results are 

verified if the CO’s result for each stockpile is within ±0.75 percent by total mass using 

AASHTO T 308. Submit the RAP dry gradation, burned gradation, asphalt content, and 

specific gravity information.

(c) Theoretical maximum specific gravity of mixture (Gmm). The Gmm is verified if the CO’s 

results are within 0.024 for AASHTO T 209. 

(d) Bulk specific gravity of compacted mixture (Gmb). The Gmb is verified if the CO’s results 

are within 0.044 for AASHTO T 166. 

(e) Bulk specific gravity of aggregate (Gsb). The coarse and fine Gsb is verified if the CO’s 

results are within 0.038 for the combined AASHTO T 85 and AASHTO T 84. 

(f) VMA. The VMA result is verified if the CO’s result is 0.5 percent above the minimum 

specification limit.

(g) VFA. The VFA result is verified if the CO’s result is within the specification limit.

(h) Air voids (Va). The Va result is verified if the CO’s result at the same design asphalt binder 

content is within ±1.0 percent of the JMF design Va. 

(i) TSR. The TSR result is verified if the CO’s result is above the minimum specification limit.

(j) Stability (Marshall mix design method only). The stability result is verified if the CO’s result 

is above the minimum specification limit.

(k) Flow (Marshall mix design method only). The flow result is verified if the CO’s result is 

within the specification limits.

(2) Type II. JMF using design parameters (a) and (c) or (b) and (c) shown in Table 404-1. 

(a) Aggregate gradations. The aggregate gradation is verified if the CO’s gradation on a 

combined asphalt concrete mix using the Contractor’s aggregate and RAP stockpile percentage 

recommendations is within the Contractor’s target value gradation plus or minus the tolerance 

for each sieve shown in Table 404-2. 

(b) RAP asphalt binder content and gradation. The RAP asphalt binder content results are 

verified if the CO’s result for each stockpile is within ±0.75 percent by total mass using 

AASHTO T 308. Submit the RAP dry gradation, burned gradation, asphalt content, and 

specific gravity information.

(c) Theoretical maximum specific gravity of mixture (Gmm). The Gmm is verified if the CO’s 

results are within 0.024 for AASHTO T 209. 

(d) Bulk specific gravity of compacted mixture (Gmb). The Gmb is verified if the CO’s results 

are within 0.044 for AASHTO T 166. 

(e) Bulk specific gravity of aggregate (Gsb). The coarse and fine Gsb is verified if the CO’s 

results are within 0.038 for the combined AASHTO T 85 and AASHTO T 84. 
Section 404

356

(f) VMA. The VMA result is verified if the CO’s result is 0.5 percent above the minimum 

specification limit shown in Table 404-1 for the selected mix design procedure. 

(g) VFA. The VFA result is verified if the CO’s result is within the specification limits shown 

in Table 404-1 for the selected mix design procedure. 

(h) Air voids (Va). The Va result is verified if the CO’s result at the same design asphalt binder 

content is within ±1 percent of the target value shown in Table 404-1 for the selected mix 

design procedure. 

(i) TSR. The TSR result is verified if the CO’s result is above the minimum specification limit 

shown in Table 404-1 for the selected mix design procedure. 

(j) Stability (Marshall mix design method only). The stability result is verified if the CO’s result 

is above the minimum specification limit shown in Table 404-1 for the selected mix design 

procedure. 

(k) Flow (Marshall mix design method only). The flow result is verified if the CO’s result is 

within the specification limits shown in Table 404-1 for the selected mix design procedure. 

Table 404-2 

Aggregate Gradation Verification Tolerances

Sieve Size Tolerance,

Percent (±)

No. 4 3.0

No. 8 3.0

No. 16 3.0

No. 30 2.0

No. 50 2.0

No. 200 1.0

Other sieves 3.0

(d) Changes and resubmissions. If a JMF is rejected or the source of material is changed, submit a 

new JMF for verification. Up to 30 days may be required to evaluate a change after receipt of required 

documentation and material. Approved changes in target values will not be applied retroactively for 

payment. 

The CO will deduct JMF evaluation costs resulting from the following: 

(1) Contractor-requested changes to the approved JMF;

(2) Contractor requests for more than one JMF evaluation; and

(3) Additional testing necessary due to the failure of a submitted JMF.

404.04 Mixing Plant. Conform to Subsection 401.04. 

404.05 Equipment. Conform to Subsection 401.05. 

404.06 Surface Preparation. Conform to Subsection 401.06. 
Section 404

357

404.07 Weather Limitations. Place asphalt concrete mix on a dry, unfrozen surface when the air 

temperature in the shade is above 60 °F and rising. For HMA, conform to Table 404-3. For WMA, adjust 

Table 404-3 minimum lay-down temperatures according to the manufacturer’s recommendations.

Table 404-3 

Thin Lift Asphalt Concrete Pavement Placement Temperature

Road Surface Temperature, °F Minimum Lay-Down Temperature, °F(1)

< 59.9 (2) 

60 to 69.9 295

70 to 79.9 285

80 to 89.9 280

≥ 90 270

(1) Do not heat the asphalt concrete mix above the temperature specified in the approved asphalt 

concrete mix design.

(2) Do not pave.

404.08 Asphalt Preparation. Conform to Subsection 401.08. 

404.09 Aggregate Preparation. Conform to Subsection 401.09. 

404.10 Mixing. Conform to Subsection 401.10. 

404.11 Hauling. Conform to Subsection 401.11. 

404.12 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-paving preparatory phase meeting according to 

Subsection 153.06(a) at least 3 days before the start of paving operations. Be prepared to discuss the 

following:

(1) Calibration certification for the appropriate laboratory equipment based on the approved 

JMF mix design procedure. 

(2) Asphalt and aggregate correction factors according to AASHTO T 308 and AASHTO T 30 

on Form FHWA 1640, Worksheet for Ignition Furnace Binder Correction Factor AASHTO T 

308. If RAP is included as part of the JMF, provide the asphalt and aggregate correction factors 

according to AASHTO T 30 and the FLH Addendum to AASHTO T 308 on Form FHWA 1648, 

Worksheet for Ignition Furnace Binder Correction Factor and Aggregate Gradation Correction 

Factor for Mixes Including RAP. 

(b) Control strip. Provide 7 days’ notice before starting production of an asphalt concrete mix.

On the first day of production, produce sufficient asphalt concrete mix to construct a 1000-foot-long 

control strip, one-lane wide, and at the designated lift thickness. Construct the control strip on the 

project at an approved location. 

Construct the control strip using asphalt concrete mix production, lay-down, and compaction 

procedures intended for the entire mix. Stop production after construction of the control strip until the 

asphalt concrete mix and the control strip are evaluated for acceptance.
Section 404

358

(1) Mixture. Take at least three control strip asphalt concrete mix samples from the paver hopper 

and test according to Subsection 404.17. 

Asphalt concrete pavement mixtures will be evaluated based on the following: 

(a) Gyratory mix design method (AASHTO M 323, AASHTO R 35, and AASHTO T 312). The 

asphalt concrete mix is acceptable if all test results are within specification limits for asphalt 

content and VMA, and the calculated pay factor for asphalt content, VMA, and gradation is 

0.90 or greater. 

(b) Marshall mix design method (AASHTO T 245). The asphalt concrete mix is acceptable if 

all test results are within specification limits for asphalt content and gradation, and the 

calculated pay factor for asphalt content and gradation is 0.90 or greater. 

(2) Compaction. Compact according to Subsection 404.14. Provide thin-lift nuclear density 

gauges calibrated according to the ASTM D2950 calibration section and within 6 months before 

use. Check the standard and reference on each day of use according to the ASTM D2950 

standardization and reference check sections.

Take nuclear gauge density readings behind each roller pass to determine the roller pattern 

necessary to achieve required density. Provide documentation of passes for each roller used in the 

control strip. Identify breakdown and finish roller in the documentation. Provide this 

documentation to the CO after completion of the control strip. 

Take nuclear gauge density readings at 10 randomly selected locations as directed. Take 5 of the 

10 readings at the location designated by the CO for asphalt pavement cores. Take reading over 

the core location before the core is taken from pavement. Take other 5 readings at random locations 

on the test strip mat at locations designated by the CO. 

Cut and test 5 core samples at randomly selected locations as directed and as shown in Table 404-4

to verify nuclear density gauge readings. A correction factor will be applied to control strip and 

production density results as shown in Table 404-4, Footnote (4), if applicable. Provide the CO 

with documented nuclear gauge readings correlated to core densities. Density is acceptable if the 

nuclear gauge density pay factor of the 10 randomly selected locations is 0.90 or greater. 

(3) Control strip mat defects. Control strips that exhibit physical or visual defects will be 

rejected. Defects include tearing, cracking, checking, rutting, shoving, segregation, bleeding, 

excessive pavement roughness, or poor joints. 

Repeat the control strip process until an acceptable control strip is produced. Conform to 

Subsection 106.01 for the disposition of material in rejected control strips. Accepted control strips may 

remain in place and will be accepted and measured as a part of the completed pavement. Tests used for 

the control strip will not be included with production paving results in the evaluation for payment 

according to Subsection 106.05. After a control strip is verified and accepted, full production may start.

Use start-up procedures if resuming production after a termination of production due to unsatisfactory 

quality according to Subsection 106.05. 

404.13 Placing and Finishing. Conform to Subsection 401.13. 
Section 404

359

404.14 Compacting. Provide one roller each for breakdown and finish rolling. Size the rollers to achieve 

the required results. Operate rollers in static mode according to the manufacturer’s recommendations. Do 

not use diesel fuel as a release agent with rollers used to compact asphalt concrete mix.

Monitor the compaction process with nuclear density gauges calibrated to the control strip density test 

results. Compact to the requirements of Subsection 404.17(b). 

Compact the asphalt concrete mix with alternate equipment to obtain the required compaction along forms, 

curbs, headers, walls, and other places inaccessible to rollers.

Do not cause cracking, shoving, or undue displacement. Continue compaction until surface marks are 

eliminated and cracks are sealed.

404.15 Joints, Trimming Edges, and Cleanup. Conform to Subsection 401.15. 

404.16 Pavement Straightedge Measurement. Measure the pavement surface using a 10-foot metal 

straightedge at right angles and parallel to the centerline. Defective areas are deviations between the 

surface and the bottom of the straightedge more than 1⁄4 inch measured between two contacts of the 

straightedge or deviations more than 1⁄4 inch measured at the end of the straightedge. 

Correct defective areas according to Subsection 401.17. Obtain approval for the method of correction. 

404.17 Acceptance. See Table 404-4 for sampling, testing, and acceptance requirements.

Aggregate quality properties will be evaluated under Subsections 106.02 and 106.04. 

Mineral filler, antistrip additives, and WMA additives will be evaluated under Subsections 106.02 and 

106.03. 

Asphalt content, density, VMA for asphalt concrete pavement by gyratory mix design method, and 

gradation for asphalt concrete pavement by Marshall mix design will be evaluated under 

Subsection 106.05. Pavement roughness will be evaluated under Subsection 106.04. Asphalt binder will 

be evaluated under Subsections 106.03 and 106.04. 

(a) Asphalt content. The upper and lower specification limits are the approved JMF target value 

±0.4 percent.

(b) Density. The lower specification limit is 90.0 percent of the maximum specific gravity (density) 

determined according to ASTM D2950 and AASHTO T 209. The percent compaction will be 

determined using the average maximum specific gravity (AASHTO T 209) from all samples tested 

each day.

(c) Pavement roughness. The evaluation for payment will be made after defective areas are 

addressed. Conform to Subsection 401.17. 

(d) Asphalt binder. The pay factor is determined from Table 401-5. 

(e) VMA for asphalt concrete pavement by gyratory mix design method. 
Section 404

360

(1) Type I. The lower specification limit is the minimum VMA as found in the state department 

of transportation specifications for the thin lift asphalt concrete pavement used for the approved 

JMF. After the JMF has been verified according to Subsection 404.03, use the Contractor’s 

combined coarse and fine bulk specific gravity of aggregate Gsb value from the approved JMF to 

calculate VMA on field produced asphalt concrete mix samples.

(2) Type II. The lower specification limit is the value shown in Table 404-1. After the JMF has 

been verified according to Subsection 404.03, use the Contractor’s combined coarse and fine bulk 

specific gravity of aggregate Gsb value from the approved JMF to calculate VMA on field produced 

asphalt concrete mix samples.

(f) Gradation for asphalt concrete pavement by Marshall mix design method. The upper and 

lower specification limits are the approved JMF target values plus or minus the allowable deviations 

shown in Table 703-2.

Construction of the HMA or WMA pavement course and the in-place mat condition will be evaluated 

under Subsections 106.02 and 106.04. Areas of the asphalt pavement course which exhibit physical or 

visual defects or distresses as described in Subsection 404.12(b)(3) may require removal and replacement.

Measurement

404.18 Measure the Section 404 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

404.19 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 404 pay items listed in the bid schedule, except the asphalt concrete pavement contract price will 

be adjusted according to Subsection 106.05 and Table 401-7. Payment will be full compensation for the 

work prescribed in this Section. See Subsection 109.05. 

Payment for thin lift asphalt concrete pavement work will be made at a price determined by multiplying 

the contract price by the material pay factor. The material pay factor is calculated as follows:

PFPG = Pay factor for asphalt binder. 

The PFPG formula is as follows:

PPPPPPPP =

(PPPP1 + PPPP2 + PPPP3 + ... . PPPPnn)

nn

where:

PF# = For each sample, the lowest pay factor determined from any test in Table 401-7. If the 

lowest pay factor for a sample is in reject, the sample’s pay factor is zero.

n = Number of samples tested.

PFmaterial = 1 + [(PFmix – 1) + (PFPG – 1)] 
Section 404

361

where:

PFmateria l = Material pay factor.

PFmix = Pay factor for asphalt concrete pavement. PFmix is the lowest single pay factor determined 

for:

(a) Gyratory mix design method Type I or II. Asphalt binder content, VMA, and density.

(b) Marshall mix design method Type I or II. Asphalt binder content, aggregate gradation, and 

density. 

If either the pay factor for the asphalt binder (PFPG) or the pay factor for asphalt concrete pavement (PFmix) 

is below 0.75, the lot for asphalt concrete pavement is in reject. 
Table 404-4 

Sampling, Testing, and Acceptance Requirements

Material or 

Product 

(Subsection)

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Source

Asphalt

concrete

aggregate

(703.07) 

Measured &

tested for

conformance

(106.04 & 105)

Aggregate

quality − Subsection

703.07

1 per type &

source

of material

Source of

material Yes Beforeproducing

Not required

if using

Governmentfurnished 

source

Asphalt binder

(702.01) 

Measured &

tested for

conformance

(106.04)

Quality − AASHTO

M 320 " 

Asphalt

supplier or

mixing plant

" " −

Asphalt

concrete

aggregate

(703.07) 

Process

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

2 per

day per

stockpile

Crusher belt

(during

production)

No 24 hours

Not required

if using a 

pre-crushed

commercial

source
Table 404-4 (continued)

Sampling, Testing, and Acceptance Requirements

Material or 

Product 

(Subsection)

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Mix Design

Asphalt 

concrete 

mixture

Measured & 

tested for 

conformance 

(106.04) 

Gradation − AASHTO T 27 

& T 11

1 per 

submitted 

mix design

Stockpiles Yes

30 days

before 

paving

−

RAP asphalt 

binder content − AASHTO T 308 " " " " −

RAP asphalt 

Gradation − AASHTO T 30 " " " " 

Dry 

gradation, no 

binder 

removed

Bulk specific 

gravity of 

aggregate 

(coarse & fine)

− AASHTO T 84 

& T 85 " “ " " −

VMA − AASHTO R 35 " − " " −

VFA − " " − " " −

Air voids − AASHTO T 

269 " − " " −

Marshall 

stability & 

flow

− AASHTO T 

245 " − " " 

Only 

required for 

mixtures 

designed by 

Marshall

mix design 

method

Tensile 

strength ratio − AASHTO T 283 " − " " −
Table 404-4 (continued)

Sampling, Testing, and Acceptance Requirements

Material or 

Product 

(Subsection)

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling Split Sample Reporting Time Remarks

Production Start-up (control strip)

Asphalt 

concrete 

pavement

Statistical 

(106.05) 

Gradation

AASHTO T 30 3 minimum Paver 

hopper Yes 6 hours −

No. 4 II

No. 8 II

No. 16 II

No. 30 II

No. 50 II

No. 200 II

Other specified 

sieves II

Asphalt 

content(1) II AASHTO T 

308 " " " " −

VMA II AASHTO R 35 " " " " 

Only required 

for mixtures 

designed by 

Gyratory mix 

design 

method

Density(2),(4),(5) II ASTM D2950 10 minimum

In-place 

after 

compacting

" 24 hours

Locations 

randomly 

selected and 

witnessed by 

CO

Density(2),(6) II AASHTO T 

166 5 minimum

In-place 

after 

compacting

" 24 hours

Locations 

randomly

selected and 

witnessed by 

CO
Table 404-4 (continued)

Sampling, Testing, and Acceptance Requirements

Material or 

Product 

(Subsection)

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling Split Sample Reporting Time Remarks

Production Start-up (control strip) (continued)

Asphalt 

concrete 

pavement

Measured & 

tested for 

conformance 

(106.04) 

Maximum 

specific 

gravity(3)

− AASHTO T 

209 3 minimum Paver hopper Yes 24 hours −

Mix temperature − −

First load & 

as directed 

thereafter

Hauling 

vehicle 

before 

dumping or 

windrow 

before 

pickup

No

Upon 

completion 

of test

−

Process control

(153.03) Density − ASTM D2950 5 minimum − No 24 hours −
Table 404-4 (continued)

Sampling, Testing, and Acceptance Requirements

Material or 

Product 

(Subsection)

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Production

Asphalt 

concrete 

pavement

Measured & 

tested for 

conformance 

(106.04) 

Placement 

temperature − −

First load & as

directed

thereafter

Hauling 

vehicle 

before 

dumping, 

or windrow 

before 

pickup

" 

Upon 

completion of 

measurement

−

Maximum 

specific 

gravity(3)

− AASHTO 

T 209

1 per 

7000 yd2 but 

not less than 1 

per day

Paver 

hopper Yes 24 hours

Part of sample 

taken from 

paver hopper 

for gradation 

and AC content

Surface 

tolerance −

Straightedge 

measurement, 

Subsection 

404.16

Continuously, 

after 

compaction

Finished 

pavement 

surface

No − −

Process control 

(153.03) 

Gradation at 

the plant − AASHTO T 27 & T 11

Contractor 

determined

Cold feed 

or hot bins

as 

applicable

" 24 hours −

Moisture 

content of 

aggregates

− AASHTO 

T 255 " Stockpile " " −

Density − ASTM D2950 1 per 500 ft

In-place 

after 

compacting

" " −
Table 404-4 (continued)

Sampling, Testing, and Acceptance Requirements

Material or 

Product 

(Subsection)

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Production (continued)

Asphalt 

concrete 

pavement

Statistical 

(106.05) 

Gradation

AASHTO 

T 30

1 per

7000 yd2 but 

not less than 

1 per day

Paver hopper Yes 6 hours

Only 

required for 

mixtures 

designed by 

Marshall 

mix design 

method

No. 4 II

No. 8 II

No. 16 II

No. 30 II

No. 50 II

No. 200 II

Other specified 

sieves II

Asphalt 

content(1) II AASHTO 

T 308 " " " " −

VMA II AASHTO R 35 " " " " 

Only 

required for 

mixtures 

designed by 

Gyratory 

mix design 

method

Density(7),(8) II ASTM D2950 10 per 

7000 yd2

In-place 

after 

compacting

" Immediate

Testing 

witnessed by 

CO
Table 404-4 (continued)

Sampling, Testing, and Acceptance Requirements

Material or Product 

(Subsection)

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Finished Product

Asphalt concrete 

mixture pavement 

surface

Measured &

tested for 

conformance 

(106.04) 

Type IV straightedge

(surface tolerance) – 

Straightedge 

measurement, 

Subsection 404.16

– Subsection

404.16 – 24 hours – 

(1) Use AASHTO T 308, Method A. Calculate the asphalt binder content by weighing the sample before and after the burn using a calibrated external balance.

(2) Take nuclear gauge density readings according to ASTM D2950. Set nuclear gauge readings to 1 minute and the layer thickness to 1 inch. Take 5 of the 10 readings 

at the location designated by CO for asphalt pavement cores. Take reading over the core location before the core is taken. Take other 5 readings at random locations on 

the test strip mat at locations designated by CO. For calculation of percent compaction (percent of maximum density), use the average of the three loose mix samples 

taken during the test strip. 

(3) Cut two 6-inch diameter side by side cores. Remove them with a core retriever and fill and compact the core holes with the approved thin lift asphalt concrete mixture. 

Label the cores and protect them from damage due to handling and temperature. Submit one core for verification testing. Dry the other core to constant mass at 125±5 °F 

or vacuum dry it according to ASTM D7227 before performing the core density and measuring the thickness. Use 62.245 pounds per cubic foot to convert specific gravity 

to density. Use core results to verify control strip nuclear density gauge readings.

(4) Calculate theoretical maximum specific gravity according to AASHTO T 209. Use 62.245 pounds per cubic foot to convert specific gravity to density. Compare the 

core density to the corresponding nuclear gauge reading. Subtract corresponding nuclear density gauge reading from core density value. Do this for all 5 asphalt pavement 

core nuclear density gauge reading pairs. Determine the average correction factor by averaging the differences of the 5 pairs. This will be the correction factor applied to 

the nuclear density gauge readings for the test strip and during production.

(5) Use the developed correction factor and apply it to the 10 nuclear density readings taken for the test strip. Use the corrected density readings to determine the pay 

factor for density for the test strip. 

(6) Do not use the supplemental procedure for mixtures containing porous aggregate (dry back method of AASHTO T 209).

(7) After production paving has begun, use the average maximum specific gravity value (AASHTO T 209) for each day to adjust the percent compaction for the in- place 

density readings taken by ASTM D2950 that represent that day’s paving

(8) The average in-place density of the 10 locations will be considered the in-place density of that 7000-square yard lot of thin lift asphalt concrete pavement and will be 

used for acceptance purposes. Report as percent compaction (percent of maximum density)
Section 405

369

Section 405. — OPEN-GRADED ASPHALT FRICTION COURSE

Description

405.01 This work consists of constructing an open-graded asphalt friction course (OGFC).

Material 

405.02 Conform to the following Subsections: 

Antistrip additive 702.05

Asphalt binder 702.01

Mineral filler 725.05

Open-graded asphalt friction course aggregate 703.08

Construction Requirements

405.03 Composition of Mix (Job-Mix Formula). Provide OGFC mixes of aggregate and asphalt binder 

designed according to ASTM D7064 or other approved methods that meet the applicable requirements 

shown in Table 405-1. Fabricate gyratory compacted specimens 6 inches in diameter and 4 inches nominal 

height. The Cantabro abrasion test is not required. 

Table 405-1 

OGFC Mix Requirements

Design Parameter Requirement

Air voids, ASTM D3203 or D6752 18% minimum

Draindown, ASTM D6390 0.3% maximum,

by mixture mass

Moisture susceptibility,

AASHTO T 283, except as modified by 

ASTM D7064

80% minimum

(a) Submittals. Submit a written JMF, mix design reports, applicable charts, application temperature 

range, and design data for verification at least 30 days before production. Include a signed statement 

prepared by the testing laboratory that certifies the proposed JMF meets requirements. For the 

proposed JMF, submit the following: 

(1) Aggregate and mineral filler.

(a) Target values: 

(1) Target value for percent passing each specified sieve size for the aggregate blend and

(2) Set target values within the gradation ranges shown in Table 703-4 for the required 

grading. Allowable deviations are shown in Table 703-2. 

(b) Source and percentage of each stockpile to be used;

(c) Average gradation of each stockpile;
Section 405

370

(d) Representative samples from each stockpile. Use split samples of material taken at the same 

time samples are taken for testing by the Contractor’s laboratory.

(1) 200 pounds of aggregates proportioned by each stockpile according to the JMF and

(2) 2 pounds of mineral filler, if proposed for the JMF.

(e) Results of aggregate quality tests performed within 1 year of use. 

(2) Asphalt binder. Conform to Subsection 401.03(d)(2). 

(3) Antistrip additives. Conform to Subsection 401.03(d)(3). 

(b) Verification. The verification process starts after required documentation and material are 

received. Do not start OGFC production until the JMF is verified. 

(1) Aggregate gradations. The Contractor’s aggregate gradation is verified if the CO’s gradation 

on a combined OGFC mix using the Contractor’s aggregate stockpile percentage recommendations 

is within the Contractor’s target value gradation plus or minus the tolerance shown in Table 405-2. 

Table 405-2 

Aggregate Gradation Verification Tolerances

Sieve Size Tolerance,

Percent (±)

No. 4 3.0

No. 8 3.0

No. 200 1.0

(2) Moisture susceptibility. The Contractor’s retained tensile strength result determined by 

AASHTO T 283, except as modified by ASTM D7064, is verified if the CO’s result is 80 percent 

minimum.

(c) Changes and resubmissions. If a JMF is rejected or the source of material is changed, submit a 

new JMF for verification. Up to 14 days may be required to evaluate a change after receipt of required 

documentation and material. Approved changes in target values will not be applied retroactively for 

payment. 

The CO will deduct JMF evaluation costs resulting from the following:

(1) Contractor-requested changes to the approved JMF; and

(2) Additional testing necessary due to the failure of a submitted JMF.

405.04 Mixing Plant. Conform to Subsection 401.04. 

405.05 Pavers. Conform to Subsection 401.05(a).

405.06 Surface Preparation. Conform to Subsection 401.06. 
Section 405

371

405.07 Weather Limitations. Place the OGFC mix on a dry asphalt surface when the air temperature in 

the shade is above 55 °F and the road surface temperature is above 60 °F. Stop placement if either 

temperature falls below these minimums.

405.08 Preparing and Mixing Material. Prepare, mix, and control material according to 

Subsections 401.08 through 401.10, except do not heat the aggregate introduced into the mixer above the 

optimum mixing temperature established in the JMF.

405.09 Hauling, Placing, and Finishing. Haul, place, and finish the mix according to Subsections 401.11

and 401.13. Place the mix within the approved temperature range. Minimize asphalt binder drainage by 

discharging the mix into the paver within 11⁄2 hours of loading the truck. If surge bins are used, start this 

11⁄2-hour limit at the time the mix is deposited into the surge bin.

405.10 Compacting. Roll the OGFC mix before the mix temperature drops below 200 °F or the 

temperature recommended by the asphalt binder manufacturer. Use a steel-wheeled roller for compacting 

the mix. Do not shove, distort, or strip the mix beneath the roller. Roll the mix parallel to the centerline, 

commencing at the outside edge and progressing towards the center. On superelevated curves, start the 

rolling on the low side and progress to the high side. Limit rolling to that necessary to consolidate the 

OGFC and bond it to the underlying surface. 

405.11 Joints and Cleanup. Use butt joints for longitudinal and transverse joints. Protect the completed 

OGFC from traffic until it has sufficiently hardened to resist abrasion, pickup, and raveling.

Dispose of material trimmed from the edges and other discarded asphalt concrete mix according to 

Subsection 203.07. 

405.12 Straightedge Measurement. Conform to Subsection 403.11. 

405.13 Acceptance. See Table 405-3 for sampling, testing, and acceptance requirements.

Aggregate quality properties will be evaluated under Subsections 106.02 and 106.04. 

Mineral filler and antistrip additives will be evaluated under Subsections 106.02 and 106.03. 

Asphalt binder will be evaluated under Subsections 106.03 and 106.04. 

Asphalt content and aggregate gradation will be evaluated under Subsection 106.05. Evaluations will 

consider the following:

(a) Asphalt content. The upper and lower specification limits are the approved JMF target value 

±0.4 percent.

(b) Aggregate gradation. The upper and lower specification limits are the approved JMF target 

values plus or minus the allowable deviations shown in Table 703-2. 

Construction of open-graded asphalt friction course will be evaluated under Subsections 106.02 and 

106.04. 
Section 405

372

Measurement

405.14 Measure the Section 405 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

405.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 405 pay items listed in the bid schedule, except the OGFC contract price will be adjusted 

according to Subsection 106.05. Payment will be full compensation for the work prescribed in this 

Section. See Subsection 109.05. 

Payment for OGFC will be made at a price determined by multiplying the contract price by the material 

pay factor. The material pay factor is the lowest single pay factor determined for asphalt content or any 

individual sieve of the aggregate gradation. 
Table 405-3 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

OGFC 

aggregate

(703.08) 

Measured &

tested for

conformance

(106.04 & 

105)

Quality − Subsection

703.08

1 per

type &

source of

material

Source of

material Yes Beforeproduction

Not required

if using

Governmentfurnished 

source

Asphalt 

binder

(702.01) 

" Quality − AASHTO

M 320 " 

Asphalt 

supplier

or mixing 

plant

" " −

Mix Design

OGFC 

asphalt

concrete 

mixture

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11

1 per

submitted

mix design

Stockpiles Yes

30 days

before

producing

−

Air voids −

ASTM

D3203 or

D6752

" − " " −

Draindown − ASTM

D6390 " − " " −

Tensile

strength

ratio

− AASHTO

T 283 " − " " 

Complete

AASHTO

T 283,

except as

modified by

ASTM 

D7064
Table 405-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

OGFC

Statistical

(106.05) 

Asphalt

content I AASHTOT 308

1 per

300 tons

Point of

discharge

of the

mixing unit

Yes 24 hours −

Gradation

(at paver)

AASHTO

T 30 " " " " −

No. 4 I 

No. 200 I 

Other specified

sieves II

Measured &

tested for

conformance

(106.04) 

Placement

& 

compaction

temperature

− −

First load

& as

directed

thereafter

Hauling 

vehicle 

before 

dumping, or 

windrow 

before pickup 

and pavement 

surface 

during rolling

No

Upon

completion

of

measurement

−

Asphalt

binder

(702.01) 

" Quality − Subsection

702.01

1 per

1000 tons

of mix

In line 

between tank

& mixing 

plant

Yes,

2 1-quart

samples

− Test by

Government
Table 405-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

OGFC

Process 

control

(153.03) 

Gradation

at plant − AASHTOT 27 & T 11

Contractor

determined

Cold feed 

or hot 

bins as 

applicable

No 24 hours −

Moisture

content of

aggregates

− AASHTO

T 255 " Stockpile " " −

Finished Product

OGFC

Measured &

tested for

conformance

(106.04) 

Surface

tolerance −

Straightedge

measurements,

Subsection

403.11

Continuously, 

after

compaction

Finished

pavement

surface

No 24 hours −
Section 406

376

Section 406. — FOG SEAL

Description

406.01 This work consists of applying an emulsified asphalt fog seal.

Material 

406.02 Conform to the following Subsections: 

Blotter 703.12

Emulsified asphalt 702.02

Water for construction 725.01(c)

Construction Requirements

406.03 Equipment. Provide an asphalt distributor with the following:

(a) Heater for uniformly heating the asphalt;

(b) Full circulation spray bar adjustable to 15-foot width;

(c) Positive controls including tachometer, pressure gauge, volume measuring device, or calibrated 

tank to uniformly deposit asphalt over the full width within 0.02 gallons per square yard of the required 

rate; and

(d) Thermometer for measuring asphalt temperature in the tank.

406.04 Surface Preparation. 

(a) Clean the existing surface of loose material, dirt, and other deleterious material before placing the 

fog seal. Remove or protect raised pavement markers, pavement markings, reflectorized tape, and 

other material that interferes with the work. Protect service entrances (such as manholes, valve boxes, 

and drop inlets). Protect concrete work, rock walls, and other objects adjacent to the work. 

(b) Dry the surface before placing the fog seal.

406.05 Weather Limitations. Apply fog seals only when the following apply: 

(a) Ambient air temperature is above 50 °F;

(b) Surface temperature is above 50 °F;

(c) Weather is not foggy; 

(d) Precipitation or temperatures below 40 °F are not anticipated for at least 24 hours after application; 

and 

(e) Sustained winds are less than or equal to 10 miles per hour. 
Section 406

377

406.06 Asphalt Application. Dilute the emulsion one part water to one part emulsified asphalt.

Apply the emulsion uniformly according to Subsection 407.09. Submit a proposed application rate for 

approval. Refer to AASHTO R 105 for guidance. 

At locations where the fog seal cannot be applied with an asphalt distributor spray bar, apply the fog seal 

uniformly using a hand spray attachment or by another approved method. 

Do not allow traffic on the fog seal until it is completely cured or substantially tack free. 

Cover unabsorbed asphalt with blotter to protect traffic or minimize precipitation damage. Remove excess 

blotter after the asphalt is absorbed. Dispose of material according to Subsection 203.07. 

406.07 Acceptance. See Table 406-1 for sampling, testing, and acceptance requirements.

Blotter will be evaluated under Subsection 106.03. 

Emulsified asphalt will be evaluated under Subsections 106.02 and 106.03. Provide a production 

certification with each load of emulsified asphalt.

Construction of fog seals will be evaluated under Subsections 106.02 and 106.04. 

Measurement

406.08 Measure the Section 406 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Measure fog seal including water added for dilution. Show a breakdown of total emulsion and water added 

on the load invoices provided to the CO.

Do not measure fog seal placed on newly patched areas during chip seal work. 

Payment

406.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 406 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 406-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Emulsified

asphalt

(702.02) 

Process

control

(153.03) 

Placement

temperature − −

1 per

distributor

truck 

minimum

Distributor

truck No

Before

incorporating

into work

−
Section 407

379

Section 407. — CHIP SEAL

Description

407.01 This work consists of applying a single or double course chip seal. 

Material 

407.02 Conform to the following Subsections: 

Asphalt binder 702.01

Blotter 703.12

Chip seal aggregate 703.09

Emulsified asphalt 702.02

Construction Requirements

407.03 Qualifications. At least 14 days before starting chip seal work, submit a résumé for the foreperson 

describing experience on at least five chip seal projects of similar complexity for approval.

407.04 Composition. Submit the following for approval at least 30 days before placement:

(a) Aggregate samples. 80 pounds from the material produced for the project, the gradation range 

represented, and the proposed target value for each sieve size;

(b) Asphalt sample. 1-gallon sample with test results from the manufacturer according to 

AASHTO M 316; 

(c) Spread rates. The proposed spread rate for the asphalt and aggregate; and

(d) Density. The density of the aggregate according to AASHTO T 19, shoveling procedure. 

407.05 Equipment. Provide equipment conforming to the following:

(a) Asphalt distributor. Conform to Subsection 406.03. Maintain two-way radio communication 

with the aggregate spreader.

(b) Sweeper. Provide two sweepers conforming to Subsection 409.05(d).

(c) Pneumatic-tire rollers.

(1) Three rollers each with a minimum compacting width of 5 feet or two rollers each with a 

minimum compacting width of 6.5 feet; and

(2) Gross mass adjustable within the range of 200 to 360 pounds per inch of compaction width. 

(d) Aggregate spreader. Controls to uniformly deposit aggregate over the full asphalt width. 
Section 407

380

407.06 Surface Preparation. Conform to Subsection 406.04(a). Prepare the surface as follows:

(a) Newly asphalt patched areas. Fog seal according to Section 406. 

(b) Existing asphalt surfaces including recycled asphalt pavements. Dry the surface.

(c) Aggregate base course surfaces.

(1) If using an emulsified asphalt, make the surface damp.

(2) If using an asphalt binder, dry the surface. 

407.07 Weather Limitations. Apply chip seals only when the following apply: 

(a) Ambient air temperature is above 65 °F;

(b) Surface temperature in the shade is above 60 °F;

(c) Surface temperature in the sun is below 150 °F;

(d) Weather is not foggy; 

(e) Precipitation or temperatures below 40 °F are not anticipated for at least 24 hours after application;

(f) Sustained winds are less than or equal to 10 miles per hour; and 

(g) Application is completed at least 2 hours before sunset. 

407.08 Production Start-Up Procedures. 

(a) Preparatory phase meeting. Conduct a pre-chip seal preparatory phase meeting according to 

Subsection 153.06(a) at least 3 days before the start of chip seal operations. 

(b) Control strip. On the first day of each chip seal layer placement, construct up to three 200- to 

500-foot control strips that are one-lane wide according to Subsections 407.09 and 407.10. Coordinate 

the control strip locations with the CO. Start the first control strip at the proposed application rates. 

Vary the asphalt material or surface aggregate application rate for each control strip. Construct the 

control strip using the material, lay-down procedures, and compaction procedures intended for the 

entire project.

Repeat the control strip process until an acceptable control strip is produced. Cease production until 

the material and the control strip are evaluated and accepted. The CO will indicate which strip will 

serve as the accepted project control strip.

Accepted control strips may remain in place and will be accepted as a part of the completed project. 

Correct rejected control strips.

Use these start-up procedures if changing construction procedures, if resuming production after a 

termination of production due to unsatisfactory quality according to Subsection 106.04, or the starting of 

a new construction season.
Section 407

381

407.09 Asphalt Application. Calibrate asphalt distributors before the start of the project and if directed. 

Calibrate the spray bar height, check nozzle angle, and verify longitudinal and transverse application rates 

according to ASTM D2995. 

Spread building paper on the pavement surface at the start and end of each asphalt application so 

distributor flow is started and stopped on the paper. 

Apply asphalt uniformly at the optimum application rate determined from the control strip. Do not apply 

more asphalt than can immediately be covered with aggregate. Correct skipped areas or deficiencies.

Submit documentation of calibrations and application rates at the end of each day’s production. 

Remove and dispose of material spills and associated debris at the end of each shift according to

Subsections 203.05 and 203.07. 

407.10 Aggregate Application. If emulsified asphalt is used, verify the aggregate stockpile moisture daily 

and use moist surfaced aggregate.

If asphalt binder is used, dry the aggregate. Precoat the aggregate uniformly with 2 to 3 percent of residual 

asphalt by mass of aggregate. Maintain the flow qualities of the precoated aggregate to allow uniform 

spreading with the aggregate spreader. 

Calibrate aggregate spreaders before the start of project if directed. Calibrate the longitudinal and 

transverse spread rates.

Apply aggregate uniformly at the optimum application rate determined from the accepted control strip. 

Apply the aggregate immediately after the asphalt material is applied. Operate the aggregate spreader so 

asphalt is covered with the aggregate before wheels pass over it. For part-width construction, leave an 

uncovered 6-inch-wide asphalt strip to allow an overlap of asphalt material.

Cover excess asphalt with blotter.

Correct excesses and deficiencies by adding or removing aggregate to achieve a uniform texture before 

the asphalt cures.

Operate rollers at a maximum speed of 5 miles per hour. Do not allow the aggregate to be displaced by 

pickup or sticking of material to the tire surface. Roll the surface to bond the aggregate uniformly and 

thoroughly over the full width. Complete rolling within 1 hour after asphalt is applied to the surface. 

Perform three passes with the rollers. Do not allow traffic to travel over aggregate until rolling is 

completed and if used, the fog seal has cured. 

Submit documentation for calibrations and application rates at the end of each day’s production. 

Use a pilot car according to Section 635 to limit traffic speeds to 10 miles per hour for at least the first 

45 minutes after rolling. Limit speeds to 20 miles per hour for the next 24 hours. 

Vacuum sweep the surface when the air temperature is below 90 °F. Do not displace embedded material. 

Lightly vacuum sweep the roadway surface within 24 hours of aggregate application. Vacuum sweep the 

roadway surface within 48 hours after aggregate application to remove excess aggregate from the roadway 
Section 407

382

surface unless otherwise approved. Hand broom in select locations if directed. Dispose of material 

according to Subsection 203.07. 

407.11 Placing and Finishing. Apply the asphalt and aggregate according to Subsections 407.09 and 

407.10, and Table 407-1. The application rates in these tables are for estimating purposes only. Determine 

the exact rates based on accepted control strips.

Within 7 days of completing the chip seal, apply a fog seal according to Section 406. 

Table 407-1 

Approximate Quantities of Material for Single Course Chip Seal

Type

Nominal 

Maximum 

Size of 

Aggregate

Aggregate

Gradation(1)

Estimated 

Quantity of 

Aggregate,

pounds per 

square yard(2)

Estimated 

Quantity of 

Asphalt 

Binder, gallons 

per square 

yard

Estimated 

Quantity of 

Emulsified 

Asphalt, 

gallons per 

square yard

1A 3⁄4 in A 44 to 53 0.31 to 0.42 0.48 to 0.65

1B 1⁄2 in B 29 to 33 0.25 to 0.34 0.39 to 0.53

1C 3⁄8 in C 24 to 28 0.18 to 0.28 0.27 to 0.43

1D No. 4 D 18 to 24 0.14 to 0.19 0.27 to 0.43

(1) See Table 703-5 for aggregate gradations.

(2) Aggregate masses are for aggregates having a bulk specific gravity of 2.65, as determined by AASHTO T 84 and 

AASHTO T 85. Make proportionate corrections if the aggregate provided has a bulk specific gravity above 2.75 or 

below 2.55.

407.12 Double Course Chip Seal. Apply each asphalt and aggregate layer according to 

Subsections 407.09 and 407.10, and Table 407-2. Table 407-2 application rates are for estimating 

purposes only. Determine the exact rates based on accepted control strips.

If using emulsified asphalt, wait at least 24 hours between applications. If using asphalt binder, no wait is 

required between applications. Lightly vacuum sweep the first layer to remove loose material. 

Within 7 days of completing the double course chip seal, apply a fog seal according to Section 406. 
Section 407

383

Table 407-2 

Approximate Quantities of Material for Double Course Chip Seal

Type

(Thickness)

Nominal

Maximum

Size of

Aggregate

Aggregate

Gradation(1)

Estimated

Quantity of

Aggregate, 

pounds per 

square yard(2)

Estimated

Quantity of

Asphalt

Binder,

gallons per 

square yard

Estimated

Quantity of

Emulsified

Asphalt,

gallons per 

square yard

2A (7⁄8 inch)

1st Application 3⁄4 in A 44 to 53 0.29 to 0.41 0.43 to 0.60

2nd Application 3⁄8 in C 24 to 29 0.41 to 0.46 0.60 to 0.70

2B (3⁄4 inch)

1st Application 1⁄2 in B 33 to 44 0.27 to 0.31 0.39 to 0.48

2nd Application 3⁄8 in C 22 to 26 0.29 to 0.38 0.45 to 0.58

2C (1⁄2 inch)

1st Application 3⁄8 in C 29 to 39 0.17 to 0.27 0.27 to 0.39

2nd Application No. 4 D 13 to 18 0.27 to 0.31 0.39 to 0.48

(1) See Table 703-5 for aggregate gradations.

(2) Aggregate masses are for aggregates having a bulk specific gravity of 2.65, as determined by AASHTO T 84 and 

AASHTO T 85. Make proportionate corrections if the aggregate provided has a bulk specific gravity above 2.75 or 

below 2.55.

407.13 Acceptance. See Table 407-3 for sampling, testing, and acceptance requirements.

Emulsified asphalt and asphalt binder will be evaluated under Subsections 106.03 and 106.04. Provide a 

production certification with each load of emulsified asphalt or asphalt binder. 

Chip seal aggregate gradation will be evaluated under Subsection 106.05. 

The upper and lower specification limits are equal to the calculated mean of all test results plus or minus 

the allowable deviations shown in Tables 703-5 and 703-2, except as follows:

(a) If the calculated mean value for a tested sieve exceeds the maximum gradation range value shown 

in Table 703-5, then the upper specification is equal to the maximum gradation value in Table 703-5

plus or minus the allowable deviation in Table 703-2. 

(b) If the calculated mean value for a tested sieve is less than the minimum gradation range value 

shown in Table 703-5, then the lower specification is equal to the minimum gradation value in 

Table 703-5 plus or minus the allowable deviation in Table 703-2. 

Construction of asphalt chip seals will be evaluated under Subsections 106.02 and 106.04. 

Fog seal will be evaluated under Section 406. 
Section 407

384

Measurement

407.14 Measure the Section 407 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

407.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 407 pay items listed in the bid schedule, except the chip seal contract price will be adjusted 

according to Subsection 106.05. Payment will be full compensation for the work prescribed in this 

Section. See Subsection 109.05. 

Payment for the chip seal will be made at a price determined by multiplying the contract price by the 

material pay factor. The material pay factor is the lowest single pay factor determined for each specified 

sieve of the aggregate gradation for each aggregate gradation provided. 

If two gradations are provided for a double chip seal the material pay factor is weighted for the quantity 

of each aggregate gradation spread as a percent of the total. The material pay factor is calculated as 

follows:

  

 

where:

PFMaterial = Material pay factor.

PF1st = Pay factor for first aggregate gradation. PF1st is the lowest single pay factor determined for 

each specified sieve. 

PF2nd = Pay factor for second aggregate gradation. PF2nd is the lowest single pay factor determined for 

each specified sieve. 

SR1st = Spread rate for the first aggregate per square yard.

SR2nd = Spread rate for the second aggregate per square yard. 
Table 407-3 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)(3)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Chip seal

aggregate(1)

(703.09) 

Measured & 

tested for 

conformance

(106.04 & 105) 

Quality − Subsection

703.09

1 per

material type

Source of

material Yes Beforeproducing −

Process

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

2 per day per 

stockpile

Crusher belt

(during

production)

No 24 hours

Not required 

if using a precrushed 

commercial 

source

Blotter

(703.12) " " − Subsection

703.12 " " " " −

Asphalt binder(2)

(702.01) or 

emulsified 

asphalt(2) (702.02) 

Measured &

tested for

conformance

(106.04) 

Quality − Section

702

1 per

material type

Point of

shipment

or

delivery

Yes(5)

Before

incorporating

into work

−
Table 407-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)(3)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Chip seal

aggregate(1)

(703.09) 

Statistical(3)

(106.05) 

Gradation

(See Table

703-5 for

applicable

sieves)

I AASHTO

T 27 & T 11

(3) 

Production

belt or

spreader

discharge(4)

Yes 24 hours −

Process control

(153.03) 

Moisture on

surface of

aggregates

−

Visual

inspection

(407.10) 

Contractor

determined

Stockpile

or spreader

discharge

No

Before

incorporating

into work

−

Asphalt

binder(2)

(702.01)

or

emulsified

asphalt(2)

(702.02) 

Measured &

tested for

conformance

(106.04) 

Quality − Section

702

1 per

tanker truck

including

trailer

Tanker

or

Distributor

Yes(5) − Tested by

Government

Process control

(153.03) 

Placement

temperature − −

1 per

distributor

truck 

minimum

Distributor

truck No

Before

incorporating

into work

−

(1) Applies to each aggregate grade provided.

(2) Applies to each asphalt material provided.

(3) For plan quantities less than 40,000 square yards, material will be accepted according to Subsection 106.03. For plan quantities equal to or greater than 40,000 square 

yards, material will be accepted according to Subsection 106.05. For plan quantities between 40,000 and 240,000 square yards, the sampling frequency will be determined 

by dividing the plan quantity by eight. If plan quantity exceeds 240,000 square yards, the sampling frequency will be one every 30,000 square yards.

(4) Select one point of sampling. Use the same point of sampling throughout project or lot.

(5) Two 1-quart samples for asphalt binder. One 1-gallon sample for emulsified asphalt.
Section 408

387

Section 408. — ULTRATHIN BONDED WEARING COURSE

Description

408.01 This work consists of placing an ultrathin bonded wearing course (UTBWC). 

Material

408.02 Conform to the following Subsections: 

Antistrip additive 702.05

Asphalt binder 702.01

Polymer-modified emulsified asphalt membrane 702.02(e)

Ultrathin bonded wearing aggregate 703.18

Construction Requirements

408.03 Composition of Mix (Job-Mix Formula). Provide mixes of aggregate, asphalt binder, and 

antistrip additive that meet the aggregate gradation shown in Table 703-10 and design parameters shown 

in Table 408-1 at the proposed optimum binder content (OBC). Include additional design trial points that 

bracket the OBC with at least one point at 0.4 percent above and below the OBC. Test draindown and 

determine film thickness on these trial points. Do not propose an OBC less the 5.0 percent by total weight 

of mix.

Table 408-1 

Ultrathin Bonded Wearing Course Requirements

Design Parameters Test Method Requirement

Film thickness, μm Asphalt Institute MS-2 

Table 8.1(1) 12.0 minimum

Drain down, % AASHTO T 305(2) 0.10 maximum

Moisture susceptibility AASHTO T 283(3) 0.70 minimum

(1) Film thickness is calculated based on effective asphalt content and determined as follows:

PPTT = � PPbbMM

UUSS × GGbb × 1000� × 106

where:

FT = Film Thickness in μm

Pbe = Effective asphalt content by total weight of mix according to Asphalt Institute, MS-2 Asphalt Mix 

Design Methods, 7th edition 

SA = Estimated surface area of the aggregate blend in m2

/kg according to MS-2 Asphalt Mix Design 

Methods, 7th edition, Table 8.1

Gb = Specific gravity of asphalt binder

(2) Combine aggregate and asphalt binder at supplier’s recommended mixing temperature. Return to the basket 

any coated aggregate that falls through the wire basket during loading and do not consider it as draindown.

(3) Make 4-inch diameter specimens with a compacted height of 2.5±0.05 inches. Compact specimens using 

methods according to AASHTO T 283. Use mixture and compaction temperatures recommended by the binder 

supplier.

(a) Recycled asphalt pavement use. Do not use RAP in the JMF. 
Section 408

388

(b) Submittals. Submit JMF at least 21 days before the control strip. Include the location of 

commercial mixing plants to be used and a separate JMF for each plant. Include a signed statement 

prepared by the testing laboratory that certifies the proposed JMF meets the requirements of the 

contract and can be placed in the field during production to meet contract requirements. For each JMF, 

submit the following:

(1) Aggregate. 

(a) Designate target values within the gradation band specified for the aggregate grading 

shown in Table 703-10;

(b) Percent passing each sieve size for the aggregate blend;

(c) Source and percentage of each aggregate stockpile to be used;

(d) Average gradation of each aggregate stockpile from process control tests; and

(e) Results of aggregate quality tests. Include Los Angeles abrasion, sodium sulfate soundness, 

fractured faces, flat and elongated particles, sand equivalent, and specific gravity results from 

tests performed within 1 year of aggregate use.

(2) Asphalt binder.

(a) Target asphalt binder content by total weight of mixture;

(b) Recent test results from the supplier for the asphalt binder including a 

temperature-viscosity curve; and

(c) Laboratory mixing temperature range and laboratory compaction temperature range for the 

performance grade asphalt to be used in the mix. 

(3) Antistrip additives. If part of the JMF:

(a) Name of product; 

(b) Manufacturer; and

(c) Dosage rate.

(c) Changes and resubmissions. If a JMF is rejected or a material source is changed, submit a new 

JMF for approval. Allow 14 days for approval.

Do not start mix production until the JMF is approved. 

408.04 Mixing Plant. Conform to Subsection 401.04. 

408.05 Equipment. 

(a) Pavers. Use pavers that are designed and built for applying the UTBWC. Provide a paver with the 

following:
Section 408

389

(1) Self-propelled integrated distributor-paver with a receiving hopper, feed conveyor, insulated 

emulsion storage tank, spray bar, variable-width heated vibratory tamper bar screed, electronic 

device to determine rate of emulsion application, and variable width adjustment.

(2) Capable of applying polymer-modified emulsified asphalt membrane using a metered 

mechanical pressure spray bar at a temperature from 120 to 180 oF. Capable of continuously 

monitoring the rate of spray and providing a uniform rate across the width of the paver.

(3) Capable of applying the UTBWC mix within 5 seconds of applying the polymer-modified 

emulsion. 

(4) Capable of spreading and finishing the UTBWC mix to the required cross-section, grade, and 

at least 12 inches more than the required width and producing a uniformly finished surface without 

segregation, tearing, shoving, gouging, and other blemishes. 

(5) Equipped with automatic screed controls with sensors that can sense grade from an outside 

reference line, sensing the transverse slope of the screed, and providing the automatic signals that 

operate the screed to maintain grade and transverse slope.

(6) Heated, vibratory, full-width feed auger screed extension.

(7) Operable at forward speeds consistent with satisfactory mix lay down.

(b) MTV. Conform to Subsection 401.05(b).

408.06 Surface Preparation. Thoroughly clean the existing surface of all loose material, dirt, and other 

deleterious substances by approved methods. Remove pavement markings. If needed, use pressurized 

water and vacuum systems to ensure a clean surface. 

Protect stone masonry, manhole covers, drains, grates, catch basins, other utility structures, curb and 

gutter, sidewalks, and walls with plastic or building felt. Clearly mark protected and covered features that 

will be re-exposed. 

Do not start placement of the UTBWC until patching according to Section 418 and crack filling according 

to Section 414 has been completed.

408.07 Weather Limitations. Place the UTBWC on a dry, unfrozen surface when the ambient air 

temperature in the shade is above 50 oF and rising and the pavement surface temperature is above 50 oF. 

Do not place UTBWC when temperatures below 32 °F are anticipated within 36 hours after application. 

408.08 Preparing and Mixing Material. Conform to Subsections 401.08, 401.09, and 401.10. 

408.09 Hauling. Conform to Subsection 401.11. 

408.10 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-paving preparatory phase meeting according to 

Subsection 153.06(a) at least 3 days before the start of paving operations. Be prepared to discuss and 

provide the following:

(1) Proposed schedule of paving operations; 
Section 408

390

(2) List of all equipment (compaction, laydown, haul), and personnel used in the production and 

construction of the work; 

(3) Proposed traffic control plan for paving operations including provisions for pavement dropoffs and moving operations; 

(4) Procedures for constructing the control strip including placing, rolling, finishing, and 

roughness procedures; 

(5) AASHTO T 308 asphalt binder and aggregate correction factors on Form FHWA 1640, 

Worksheet for Ignition Furnace Binder Correction Factor for each JMF;

(6) Proposed polymer-modified emulsified asphalt membrane application rate; and

(7) Proposed placement sequence and joint locations.

(b) Control strip. Provide at least 7 days’ notice before starting production of an asphalt concrete 

mix.

Produce and place approximately 200 tons of mix to construct a control strip, one-lane wide, and at 

the designated lift thickness on the first day of production. Construct the control strip on the project at 

an approved location. 

Construct the control strip using mix production, lay-down, and compaction procedures intended for 

the entire mix. Construct a control strip for each equipment combination and each plant from which 

production is intended. Stop production after construction of the control strip until the asphalt concrete 

mix and the control strip are evaluated and accepted.

Review the conditions of the existing pavement and propose a polymer-modified emulsified asphalt 

membrane application rate for approval 7 days before completing the control strip. It is estimated that 

the target application rate will be from 0.15 to 0.20 gallons per square yard. Evaluate and determine 

the application rate during the control strip. In coordination with the CO, adjust the application rate 

based on existing conditions and recommendations from the supplier. 

Take and test at least three control strip UTBWC mix samples and evaluate according to 

Subsection 408.15 and Table 408-2. 

Repeat the control strip process until an acceptable control strip is produced. Conform to 

Subsection 106.01 for the disposition of material in rejected control strips. Accepted control strips 

may remain in place and will be accepted and measured as a part of the completed pavement. After a 

control strip is accepted, full production may start. 

Use start-up procedures if resuming production after a termination of production due to unsatisfactory 

quality. 

408.11 Placing and Finishing. Do not use mixes produced from different plants unless the mixes are 

produced according to the same JMF, use material from the same sources, and are approved.
Section 408

391

Apply the polymer-modified emulsified asphalt membrane at the rate approved in the control strip 

according to Subsection 407.08 and this Section. Apply the target application rate within a tolerance of 

±0.02 gallons per square yard. 

Do not allow wheels or other parts of the paving machine to come in contact with the polymer-modified 

emulsion membrane before the UTBWC mix is applied. Use a metered mechanical pressure spray bar at 

a temperature of 140 to 180 °F. Continuously monitor the rate of spray and provide a uniform application 

across the entire pavement width. Confirm the application rate of the polymer-modified emulsified asphalt 

membrane at least every 4 hours of production time by dividing the volume of polymer-modified 

emulsified asphalt membrane used by the area of paving for that timeframe.

Place the UTBWC mix at the temperature recommended in the JMF. Measure temperature of the mix in 

the hauling vehicle immediately before dumping into the MTV or measure it in the windrow immediately 

before pickup. 

Place the UTBWC mix with a paver conforming to Subsection 408.05. Control horizontal alignment using 

a reference line. Automatically control the grade and slope from reference lines, a ski and slope control 

device, or dual skis. Use skis having a minimum length of 20 feet.

Place the UTBWC to the thickness shown in the plans. Measure thickness with a depth probe transversely 

across the mat in wheel paths and near centerline at least once every 500 feet. Submit certified weight 

tickets for the materials supplied.

Place the UTBWC mix as continuously as possible. Do not overlap or hot lap the asphalt. Pave through 

lanes after paving adjacent shoulders, tapers, driveways, road connections, turn pockets, and transitions. 

For UTBWC mix placed on the areas adjacent to through lanes, cut the hot asphalt as necessary to form 

neat, straight, vertical joints along the lane lines. 

If polymer-modified emulsion membrane is spilled into the hopper of the paver, remove and dispose of 

the contaminated material according to Subsections 203.05 and 203.07. 

In areas where mechanical spreading and finishing are impractical, place and finish the mix with alternate 

equipment to produce a uniform surface closely matching the surface obtained when using a mechanical 

paver. 

Use an MTV on mainline construction if placing UTBWC mix. Suspend paving if the MTV malfunctions 

during paving operations. Do not resume mix placement until the MTV is operational. 

408.12 Rolling. Provide at least two steel double drum asphalt rollers with a weight of at least 11 tons. 

Provide well maintained rollers with functioning water system and scrapers to prevent adhesion of the 

fresh mix onto the roller drums. A release agent (added to the water system) may be required to prevent 

adhesion of the fresh mix to the roller drums. Do not use diesel fuel as a release agent. Operate rollers 

according to the manufacturer’s recommendations.

Immediately after placing the UTBWC mix, make at least two passes with a double drum asphalt roller 

operated in the static mode. Complete compaction before the UTBWC mix temperature falls below 185 oF. 

Do not allow the roller to remain stationary on the freshly placed UTBWC mix. Do not cause cracking, 

shoving, or undue displacement. 
Section 408

392

408.13 Joints, Trimming Edges, and Cleanup. Use butt joints for longitudinal and transverse joints. At 

connections to existing pavements and previously placed lifts, make the transverse joints vertical to the 

depth of the new pavement. Form transverse joints by cutting back the previous run to expose the 

full-depth course.

Dispose of material trimmed from the edges and any other discarded asphalt mix according to 

Subsection 203.07. 

Protect the completed UTBWC from traffic until it has sufficiently hardened to resist abrasion, shoving, 

pickup, and raveling.

408.14 Pavement Straightedge Measurement. Use a 10-foot metal straightedge to measure at right 

angles and parallel to the centerline. Defective areas are surface deviations more than 0.25 inch, measured 

between any two contacts of the straightedge. 

Correct defective areas. Obtain approval for the proposed method of correction. 

408.15 Acceptance. See Table 408-2 for sampling and testing requirements and the acceptance quality 

characteristic category.

Antistrip additives will be evaluated under Subsections 106.02 and 106.03. 

Asphalt binder and polymer-modified emulsified asphalt membranes will be evaluated under 

Subsections 106.03 and 106.04. 

Construction of the UTBWC will be evaluated under Subsections 106.02 and 106.04. 

Aggregate gradation and aggregate properties will be evaluated under Subsections 106.03 and 106.04. 

Asphalt content will be evaluated under Subsection 106.04. The tolerance from the target for asphalt 

binder is ±0.5 percent.

Asphalt pavement crack filling will be evaluated under Section 418. 

Asphalt pavement patching will be evaluated under Section 414. 

Measurement

408.16 Measure the Section 408 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

408.17 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 408 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 408-2 

Sampling, Testing, and Acceptance Requirements

Material 

or Product

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Source

Aggregate 

quality

Measured & 

tested for 

conformance

(106.04 & 

105) 

Quality − Subsection 

703.18

1 per type 

& source of 

material

Source of 

materials Yes Before production −

Asphalt 

binder

Measured & 

tested for 

conformance

(106.04 & 

105) 

Quality − AASHTO

M 320

1 per type 

& source of 

material

Asphalt 

supplier or 

mixing 

plant

Yes Before 

production −

Polymermodified 

emulsified 

asphalt 

membrane

Measured & 

tested for 

conformance

(106.04 & 

105) 

Quality − Subsection 

702.02(e)

1 per type 

& source of 

material

Membrane 

supplier Yes Before production −

Mix Design

UTBWC

(mix 

design)

Measured & 

tested for 

conformance

(106.04) 

Gradation(2) −

AASHTO 

T 11 & 

T 27

1 per each 

submitted 

mix design

Stockpiles If 

requested

21 days 

before 

paving

−

Film thickness − See Table 

408-1 " − " " −

Draindown − AASHTO 

T 305(3) " − " " −

Moisture 

susceptibility − AASHTO T 283(3) " − " " −
Table 408-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material 

or Product

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Production Start-up (control strip)

UTBWC

Measured & 

tested for 

conformance

(106.04) 

Gradation(2) − AASHTO 

T 30 3 minimum

Truck or 

paver 

hopper

Yes 24 hours −

Asphalt 

content(1) − AASHTO

T 308 " " " " −

Mix 

temperature − −

Each load 

& as 

directed

Hauling 

vehicle 

before 

dumping 

or 

windrow 

before 

pickup

− As directed −
Table 408-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or 

Product

Type of 

Acceptance 

(Subsection)

Characteristic Category Test Methods 

Specifications

Sampling 

Frequency

Point of 

Sampling

Split 

Sample

Reporting 

Time Remarks

Production

UTBWC

Measured & 

tested for 

conformance

(106.04) 

Gradation(2) − AASHTO T 30 1 per 300 

tons

Truck or 

paver 

hopper

Yes 24 hours −

Asphalt 

content(1) − AASHTO 

T 308 " " " " −

Mix 

temperature − −

Each load 

& as 

directed

Hauling 

vehicle 

before 

dumping or 

windrow 

before 

pickup

−

Upon 

completion of 

measurement

−

Polymermodified 

emulsion

membrane

" Quality − Subsection 

702.02(e)

1 per 700 

tons of mix

Tanker or 

point of 

delivery

Yes − −

Asphalt 

binder " Quality − Subsection 

702.01

1 per 700 

tons of mix

In line 

between 

tank & 

mixing 

plant

Yes, tested 

by 

Government

Tested by 

Government −

(1) Use AASHTO T 308, Method A. Calculate the asphalt binder content by weighing the sample before and after the burn using a calibrated external balance. 

Modify AASHTO T 308, parts 8.2 and 10.2 to allow the use of AASHTO T 255, Total Evaporable Moisture Content of Aggregate by Drying.

(2) Use only sieves indicated for the specified gradation.

(3) As modified by Table 408-1.
Section 409

396

Section 409. — MICRO SURFACING

Description

409.01 This work consists of applying a polymer-modified micro surfacing mix on a pavement surface.

Material 

409.02 Conform to the following Subsections: 

Micro surfacing aggregate 703.10(b)

Mineral filler 725.05

Polymer-modified emulsified asphalt for micro surfacing 702.02(b)

Water for construction 725.01(c)

Construction Requirements

409.03 Qualifications. At least 14 days before starting micro surfacing work, submit a résumé for the 

foreperson describing experience on at least five micro surfacing projects of similar complexity for 

approval. 

409.04 Composition of Mix (Job-Mix Formula). Submit a written JMF for micro surfacing which 

complies with ISSA A143, Recommended Performance Guidelines for Micro Surfacing for approval at 

least 14 days before production. Include the following: 

(a) Aggregate gradation values. Percent passing for each sieve size for the aggregate blend;

(b) Emulsified asphalt content. Residual asphalt content, as a percent by mass of dry aggregate;

(c) Polymer-modifier. Type and quantity of polymer-modifier solids based on the residual asphalt 

content; 

(d) Aggregate samples. 80-pound sample of each aggregate; 

(e) Polymer-modified emulsified asphalt sample. 1-gallon sample with a production certification 

conforming to Subsection 106.03(b); 

(f) Mineral filler samples. 10-pound sample of each proposed mineral filler; and 

(g) Proposed application rate. Use ISSA A143 for guidance. 

409.05 Equipment. 

(a) Mixing and proportioning equipment. Conform to ISSA A143. 

(b) Spreading equipment. Conform to ISSA A143. 

(c) Secondary strike-off. Conform to ISSA A143. 
Section 409

397

(d) Sweeper. Provide a sweeper conforming to the following:

(1) Self-propelled; 

(2) Vertical broom pressure control; and

(3) Vacuum capability.

(e) Pneumatic-tire rollers. Provide rollers conforming to the following:

(1) Self-propelled; 

(2) 10-ton gross mass with a tire pressure of 50 pounds per square inch; and

(3) Water-spray system.

(f) Auxiliary equipment. Provide hand squeegees, shovels, and other equipment necessary to perform 

the work. Provide power brooms, air compressors, water flushing equipment, and hand brooms to 

clean the pavement surface.

Other equipment of proven performance may be used in addition to or instead of this equipment if 

approved. 

409.06 Surface Preparation. Conform to Subsection 406.04(a).

409.07 Weather Limitations. Apply only when the following apply: 

(a) Ambient air temperature is above 45 °F;

(b) Surface temperature in the shade is above 45 °F;

(c) Weather is not foggy or overcast; and

(d) Precipitation or temperatures below 32 °F are not anticipated for at least 24 hours after application.

409.08 Calibration. Calibrate mixing equipment according to ISSA A143. Submit calibration results 

before starting production. 

409.09 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-surfacing preparatory phase meeting according to 

Subsection 153.06(a) at least 3 days before the start of surfacing operations. 

(b) Control strip. On the first day of placement, construct one 300-foot-long control strip, one lane 

wide. Construct control strip on the project at an approved location. Construct the control strip using 

material, lay-down, and rolling procedures intended for the entire project. Start the control strip at the 

proposed application rate. Adjust the application rate for the surface conditions, if needed. 

Cease production after construction of the control strip until the material and the control strip are 

evaluated and accepted. Repeat the control strip process until an acceptable control strip is produced.
Section 409

398

Acceptable control strips may remain in place and will be accepted as a part of the completed surface 

treatment. Correct rejected control strips.

Use these start-up procedures if changing construction procedures, if resuming production after a 

termination of production due to unsatisfactory quality according to Subsection 106.04, or the starting of 

a new construction season.

409.10 Application. Fog the surface with water in front of the spreader.

Blend the additives with the aggregate. Pre-wet the aggregate in the pugmill before mixing with the 

polymer-modified emulsified asphalt.

Mix the surfacing material for no more than 4 minutes. Ensure the mix is of uniform consistency as it 

leaves the mixer and conforms to the approved JMF. Apply micro surfacing material at the application 

rate determined from the control strip. Adjust mineral filler and polymer-modified emulsified asphalt 

content during construction if approved to adjust for variations in field conditions. 

Clean the spreader box before the start of each work shift.

Carry sufficient mix in the spreader to completely cover the surface. Spread the mix with a spreader box. 

In areas not accessible to the spreader, use hand squeegees to provide uniform coverage and match the 

finish of spreader.

Remove streaks and transverse ripples as defined by ISSA A143 from the finished surface.

Provide straight lines along curbs and shoulders and do not allow runoff onto these areas. Provide straight 

and neat starting and ending joints by masking surfaces. Mask surfaces to provide straight and neat 

longitudinal or transverse joints at required locations (such as intersections and irregular shaped areas). 

For transverse joints, use a butt joint. Use building paper placed over previously placed micro surfacing 

or other suitable methods to avoid double placement of micro surfacing. Remove ridges or bumps in the 

finished surface.

For longitudinal joints, place joints on lane lines. Use half passes and odd-width passes only in turnouts 

and parking areas. Do not use half passes for the last pass in paved areas. Overlap longitudinal joints no 

more than 3 inches. Limit the elevation difference at joints to less than 1⁄4 inch.

Start rolling after the mixture has cured to the point where it will not pick up on the roller tires. Roll 

parking areas and turnouts with at least two full-coverage passes with the roller. Rolling the mainline 

roadway is not required.

Allow treated areas to cure before opening to traffic. Cure is complete when clear water can be pressed 

out of the placed mix with a white piece of paper without discoloring the paper. Do not allow traffic in 

parking areas or pullouts for at least 48 hours after completing application.

Remove and dispose of material spills and associated debris at the end of each shift according to

Subsections 203.05 and 203.07. 
Section 409

399

Two weeks to one month after completion of micro surfacing application and before placing permanent 

pavement markings, sweep the entire treated surface. Dispose of swept material according to 

Subsection 203.07. 

409.11 Acceptance. See Table 409-1 for sampling, testing, and acceptance requirements.

Micro surfacing aggregate will be evaluated under Subsections 106.02 and 106.04. 

Mineral filler will be evaluated under Subsections 106.02 and 106.03. 

Polymer-modified emulsified asphalt will be evaluated under Subsections 106.03 and 106.04. Provide a 

production certification with each load of polymer-modified emulsified asphalt.

Construction of the micro surfacing will be evaluated under Subsections 106.02 and 106.04. 

Measurement

409.12 Measure the Section 409 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

409.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 409 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 409-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Micro

surfacing

aggregate for

surface

mixture(1)

Measured &

tested for

conformance

(106.04 & 

105) 

Quality − Subsection

703.10

1 per

material

type

Source of

material Yes Beforeproducing −

Process

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

2 per

day per

stockpile

Crusher

belt

(during

production)

No 24 hours

Not required

if using

a pre-crushed

commercial

source

Polymermodified

emulsified

asphalt(2)

Measured &

tested for

conformance

(106.04) 

Quality − Subsection

702.02(b)

1 per

material

type

Emulsified 

asphalt 

supplier

Yes,

2 1-quart

samples

Before

incorporating

into work

−
Table 409-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Micro

surfacing

aggregate for

surface

mixture(1)

Measured &

tested for

conformance

(106.04) 

Gradation

(See

Table 703-6

for applicable

sieves)

− AASHTO

T 27 & T 11

1 per

10,000 yd2 Stockpile Yes 24 hours −

Polymermodified

emulsified

asphalt(2)

Measured &

tested for

conformance

(106.04) 

Quality − Subsection

702.02(b)

1 per

day

Mixing 

equipment

or point of

delivery

Yes,

2 1-quart

samples

− Tested by 

Government

Process

control

(153.03) 

Placement

temperature − −

Daily at 

start-up & 

Contractor 

determined 

thereafter

Mixing 

equipment No

Before

incorporating

into work

−

(1) Applies to each aggregate grade provided.

(2) Applies to each asphalt material provided.
Section 410

402

Section 410. — SLURRY SEAL

Description

410.01 This work consists of applying an emulsified asphalt slurry seal mix on a pavement surface.

Material 

410.02 Conform to the following Subsections: 

Emulsified asphalt 702.02

Mineral filler 725.05

Slurry seal aggregate 703.10(a)

Water for construction 725.01(c)

Construction Requirements

410.03 Qualifications. Submit a résumé for the foreperson describing experience on at least five slurry 

seal projects of similar complexity for approval at least 14 days before starting slurry seal work.

410.04 Composition of Mix (Job-Mix Formula). Submit a written JMF for asphalt slurry seal that 

conforms to ISSA A105, Recommended Performance Guideline for Emulsified Asphalt Slurry Seal for 

approval at least 30 days before production. Include the following:

(a) Aggregate gradation values. Percent passing for each sieve size for the aggregate blend;

(b) Emulsified asphalt content. Residual asphalt content, as a percent by mass of dry aggregate;

(c) Aggregate samples. 80-pound sample of each aggregate; 

(d) Emulsified asphalt sample. 1-gallon sample with a production certification conforming to 

Subsection 106.03(b); and

(e) Mineral filler samples. 10-pound sample of each proposed mineral filler. 

410.05 Equipment. 

(a) Mixing and proportioning equipment. Conform to ISSA A105. 

(b) Spreading equipment. Conform to ISSA A105. 

(c) Sweeper. Conform to Subsection 409.05(d).

(d) Pneumatic-tire rollers. Conform to Subsection 409.05(e).

(e) Auxiliary equipment. Conform to Subsection 409.05(f).

Other equipment of proven performance may be used in addition to or instead of this equipment if 

approved. 
Section 410

403

410.06 Surface Preparation. Conform to Subsection 406.04(a).

410.07 Weather Limitations. Conform to Subsection 409.07. 

410.08 Calibration. Calibrate each mixing unit according to ISSA A105. Submit calibration results before 

starting production. 

410.09 Production Start-Up Procedures. Conform to Subsection 409.09. 

410.10 Application. Mix the material according to ISSA A105. Fog the surface with water in front of the 

spreader.

Blend the additives with the aggregate. Pre-wet the aggregate in the pugmill before mixing with the 

emulsified asphalt.

Mix the surfacing material no more than 4 minutes. Ensure the mix is of uniform consistency as it leaves 

the mixer and conforms to the approved JMF. Apply surfacing material at the application rate determined 

from the control strip. Adjust mineral filler and emulsified asphalt content during construction if approved 

to adjust for variations in field conditions.

Clean the spreader box before the start of each work shift.

Carry sufficient mix in the spreader to completely cover the surface. Spread the mix with a spreader box. 

In areas not accessible to the spreader box, use hand squeegees to provide uniform coverage and match 

the finish of spreader.

Remove streaks and transverse ripples as defined by ISSA A105 from the finished surface.

Provide straight lines along curbs and shoulders and do not allow runoff on these areas. Provide straight 

and neat starting and ending joints by masking surfaces. Mask surfaces to provide straight and neat 

longitudinal or transverse joints at required locations (such as intersections and irregular shaped areas).

For transverse joints, use a butt joint. Use building paper placed over previously placed slurry seal or other 

suitable methods to avoid double placement of slurry seal. Remove ridges or bumps in the finished surface.

For longitudinal joints, place joints on lane lines. Use half passes and odd-width passes only in turnouts 

and parking areas. Do not use half passes for the last pass in paved areas. Overlap longitudinal joints no 

more than 3 inches. Limit the elevation difference at joints to less than 1⁄4 inch.

Start rolling after the mixture has cured to the point where it will not pick up on the roller tires. Roll 

parking areas and turnouts with at least two full-coverage passes with the roller. Rolling the mainline 

roadway is not required. 

Allow treated areas to cure before opening to traffic. Cure is complete when clear water can be pressed 

out of the mix with a white piece of paper without discoloring the paper. Do not allow traffic in parking 

areas or pullouts for at least 48 hours after completing application. 

Remove and dispose of material spills and associated debris at the end of each shift according to

Subsections 203.05 and 203.07. 
Section 410

404

Two weeks to one month after completion of slurry seal application and before placing permanent 

pavement markings, sweep the entire treated surface. Dispose of swept material according to 

Subsection 203.07. 

410.11 Acceptance. See Table 410-1 for sampling, testing, and acceptance requirements.

Emulsified asphalt will be evaluated under Subsections 106.03 and 106.04. Provide a production 

certification with each load of emulsified asphalt.

Mineral filler will be evaluated under Subsections 106.02 and 106.03. 

Slurry seal aggregate will be evaluated under Subsections 106.02 and 106.04. 

Construction of the slurry seal will be evaluated under Subsections 106.02 and 106.04. 

Measurement

410.12 Measure the Section 410 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

410.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 410 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 410-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate for

surface

mixture(1)

Measured &

tested for

conformance

(106.04 & 

105) 

Quality − Subsection

703.10

1 per

material

type

Source

of

material

Yes Before

producing −

Process

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

2 per

day per

stockpile

Crusher 

belt

(during

production)

No 24 hours

Not 

required

if using

a precrushed

commercial

source

Emulsified

asphalt(2)

Measured &

tested for

conformance

(106.04) 

Quality − Subsection

702.02

1 per

material

type

Emulsified 

asphalt 

supplier

Yes,

2 1-quart

samples

Before

incorporating

into work

−
Table 410-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Aggregate

for

surface

mixture(1)

Measured &

tested for

conformance

(106.04) 

Gradation.

See 

Table 703-6

for applicable

sieves

− AASHTO

T 27 & T 11

1 per

10,000 yd2 Stockpile Yes 24 hours −

Emulsified

asphalt(2)

" Quality − Subsection

702.02 1 per day

Mixing 

equipment

or point of

delivery

Yes,

2 1-quart

samples

− Tested by

Government

Process

control

(153.03) 

Placement

temperature − −

Daily at 

start-up & 

Contractor 

determined 

thereafter

Mixing 

equipment No

Before

incorporating

into work

−

(1) Applies to each aggregate grade provided.

(2) Applies to each asphalt material provided.
Section 411

407

Section 411. — ASPHALT PRIME COAT

Description

411.01 This work consists of applying an asphalt prime coat on a prepared surface.

Material 

411.02 Conform to the following Subsections: 

Blotter 703.12

Crushed aggregate 703.06

Emulsified asphalt 702.02

Water for construction 725.01(c)

Construction Requirements

411.03 Equipment. Provide equipment conforming to Subsection 407.05. 

411.04 Surface Preparation. If applying an asphalt prime coat to an aggregate surface, prepare the 

surface to be primed according to Subsection 301.06. If required, use sweeping or other approved methods 

to remove loose dust and fine material and lightly spray the surface with water. Protect manholes, valve 

covers, curb and gutter, and other adjacent facilities from damage or overspray. 

411.05 Weather Limitations. Apply asphalt prime coat when the following apply: 

(a) Surface is dry or slightly damp;

(b) Ambient air temperature is above 50 °F and rising; 

(c) Surface temperature in the shade is above 50 °F and rising; 

(d) Weather is not foggy; and 

(e) Precipitation is not anticipated for at least 24 hours after completing the application.

411.06 Asphalt Prime Coat Application. Apply asphalt prime coat according to Subsection 407.09. If 

no application method is designated, use Method 1. 

(a) Method 1 – topical. Dampen the surface with water before applying asphalt prime coat. Apply 

undiluted emulsified asphalt formulated as a penetrating prime coat uniformly at a rate of 0.10 to 

0.30 gallons per square yard. Obtain approval of the exact application rate. 

(b) Method 2 – inverted prime. Apply asphalt prime coat at a uniform rate of 0.20 to 0.30 gallons 

per square yard. Immediately apply crushed aggregate at a uniform rate of 20 to 25 pounds per square 

yard using an aggregate spreader. Obtain approval of the application rates for asphalt prime coat and 

aggregate. 

Do not allow the wheels of the aggregate spreader to come in contact with the emulsified asphalt. 

Immediately seat the aggregate using a roller. Operate rollers at a maximum speed of 5 miles per hour.
Section 411

408

411.07 Curing. Cure asphalt prime coat for at least 24 hours before allowing traffic or placing the 

covering course.

411.08 Maintenance. Maintain the primed surface by keeping it free of corrugations, potholing, and loose 

material until placing the covering course. If damaged, repair damaged areas and reapply asphalt prime 

coat.

Spread blotter to cover unabsorbed emulsified asphalt. Remove excess blotter after the emulsified asphalt 

is absorbed.

411.09 Acceptance. See Table 411-1 for sampling, testing, and acceptance requirements.

Crushed aggregate and blotter will be evaluated under Subsection 106.03. 

Emulsified asphalt will be evaluated under Subsections 106.02 and 106.03. 

Construction of the prime coat will be evaluated under Subsections 106.02 and 106.04. 

Measurement

411.10 Measure the Section 411 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring prime coat by the square yard, measure the length along the centerline of the roadway. 

Include treated widened areas when measuring the width. 

Payment

411.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 411 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 411-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Emulsified

asphalt

(702.02) 

Process

control

(153.03) 

Placement

temperature − −

1 per

distributor

truck 

minimum

Distributor

truck No

Before

incorporating

into work

−

Prime coat

(411.06) 

Process

control

(153.03) 

Application 

rate & daily 

yield

− − 1 per day 

minimum

Contractor 

determined No End of shift −
Section 412

410

Section 412. — ASPHALT TACK COAT

Description

412.01 This work consists of applying an emulsified asphalt tack coat on a prepared surface. 

Material 

412.02 Conform to the following Subsections: 

Emulsified asphalt 702.02

Water for construction 725.01(c)

Construction Requirements

412.03 General. Use equipment conforming to Subsection 407.05. 

Current state approved tack coat material may be used if approved. Submit proof of compliance with state 

specifications.

412.04 Surface Preparation. Clean the existing surface of loose material, dirt, or other deleterious 

material by approved methods. If the surface is concrete, remove excess joint and crack filler material. 

Remove all pavement markings except waterborne or solvent borne traffic paint by approved methods. 

Protect manholes, valve covers, curb and gutter, and other adjacent facilities from damage or overspray. 

412.05 Weather Limitations. Apply asphalt tack only when the following apply: 

(a) Surface is dry and unfrozen; 

(b) Ambient air temperature is above 35 °F and rising; 

(c) Precipitation is not anticipated before the emulsified asphalt breaks; and

(d) Weather is not foggy. 

412.06 Application. If using slow-setting emulsified asphalt, dilute by adding an equal quantity of water 

to the emulsified asphalt.

Apply the asphalt tack coat according to Subsection 407.09. Use AASHTO R 112 to determine application 

rates. Provide the CO with the target application rate for approval.

Set distributor spray bar height to ensure uniform coverage and at least a double overlap, but no more than 

triple overlap coverage. Set nozzle angle settings between 15 and 30 degrees from the center of the spray 

bar axis. Use the same size nozzles with all set at the same angle and open.

Apply the asphalt tack coat uniformly and completely by fogging with a hand spray attachment or by other 

approved methods if application with a distributor spray bar is not practical. 
Section 412

411

Squeegee the excess emulsified asphalt from the surface and dispose of according to Subsection 203.07. 

Allow the tacked surfaces to completely break before placing the covering course. Place the covering 

course within 4 hours of placing the asphalt tack coat.

412.07 Acceptance. See Table 412-1 for sampling, testing, and acceptance requirements.

Emulsified asphalt will be evaluated under Subsections 106.02 and 106.03. 

Construction of the tack coat will be evaluated under Subsections 106.02 and 106.04. 

Measurement

412.08 Measure the Section 412 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Measure asphalt tack coat including water added for dilution. Indicate a breakdown of total emulsion and 

water added on the load invoices provided to the CO. 

Do not measure asphalt tack coat used for asphalt concrete pavement patching. 

Payment

412.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 412 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 412-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Emulsified

asphalt

(702.02) 

Process

control

(153.03) 

Placement

temperature − −

1 per

distributor

truck 

minimum

Distributor

truck No

Before

incorporating

into work

−

Tack coat

(412.06) " 

Application 

rate & daily 

yield

− − 1 per day 

minimum

Contractor 

determined No End of shift −
Section 413

413

Section 413. — ASPHALT PAVEMENT MILLING

Description

413.01 This work consists of removing asphalt pavement and base by a cold milling process. 

Construction Requirements

413.02 Equipment. 

(a) Milling machine. Provide a milling machine conforming to the following:

(1) Self-propelled; 

(2) Sufficient power, traction, and stability to remove the required pavement thickness and to 

accurately maintain depth of cut;

(3) Automatic system to control grade elevations by referencing from the existing pavement with 

a ski, matching shoe, or from an independent grade control; 

(4) Automatic system to maintain profile and cross slope; 

(5) System to effectively limit dust and other particulate matter from escaping removal operations;

(6) Loading system or adequate support equipment to completely recover milled material at 

removal rate; and

(7) Cutting width equal to at least one-third of the lane width.

(b) Micro milling machine. When required, provide a micro milling machine conforming to the 

following:

(1) Conforms to the requirements of Subsection 413.02(a);

(2) Cutting drum with 1⁄4 inch or less impact spacing between teeth; and 

(3) Machine elevation control accurate to within 1⁄16 inch. 

(c) Sweeper. Provide a sweeper conforming to the following: 

(1) Self-propelled; 

(2) Vertical broom pressure control; and

(3) Vacuuming system to remove and collect debris and water.

413.03 General. Uniformly mill using a longitudinal reference to accurately guide the machine (such as 

a curb, edge of pavement, or string attached to the pavement surface). 
Section 413

Mill the transverse slope to within 1⁄4 inch in 10 feet of the required slope. Transition from one transverse 

slope to another at a uniform rate. Uniformly mill the entire roadway lane width so the cross-section of 

the new surface forms a straight line.

Transition between different depths of cut at a uniform rate of 1⁄2 inch of depth per 10 feet. At the start and 

end of the milling work, construct a smooth transition to the original surface at this rate. Do not leave an 

exposed vertical edge perpendicular to the direction of travel. If the pavement remains open to traffic, 

limit differences in elevation between adjacent lanes to less than 3 inches or sign with “Uneven Lanes”

warning signs and provide a 1V:3H fillet. Use a sweeper immediately behind the milling operations to 

remove and recover loose material. Minimize the escape of dust into the air by misting. Dispose of 

recovered milled material according to Subsection 203.07 unless required for use in Section 309 or 315. 

Measure the milled surface using a 10-foot metal straightedge at right angles and parallel to the centerline. 

Defective areas are deviations between the surface and the bottom of the straightedge more than 1⁄4 inch 

measured between two contacts of the straightedge or deviations more than 1⁄4 inch measured at the end of 

the straightedge. Submit a proposal to correct defective areas for approval. 

Before opening to traffic, patch defects in milled surface as approved. 

413.04 Micro milling. Limit travel speed to two-thirds of the cutting drum rotation speed. 

413.05 Acceptance. Asphalt pavement milling will be evaluated under Subsections 106.02 and 106.04. 

Measurement

413.06 Measure the Section 413 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring asphalt pavement milling by the square yard, measure the length horizontally along the 

centerline of the roadway. 

Payment

413.07 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 413 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 414

415

Section 414. — ASPHALT PAVEMENT CRACK AND JOINT SEALING AND 

FILLING

Description

414.01 This work consists of sealing and filling cracks and joints in asphalt pavement surfaces. 

Material 

414.02 Conform to the following Subsections: 

Hot-applied asphalt aggregate-filled mastic 702.03

Joint sealants and crack fillers 712.01(a)

Construction Requirements

414.03 General. Complete crack and joint sealing and filling in a continuous operation. 

Prevent debris from entering waterways, travel lanes open to public traffic, or areas designated not to be 

disturbed. Remove dirt, dust, vegetation, and other deleterious material from the crack and joint walls and 

cavity using a stream of air or other approved methods. Blow or brush dry material off the pavement 

surface.

414.04 Equipment. Provide equipment conforming to the following: 

(a) Router. A power rotary impact router or vertical spindle router that can create a reservoir to the 

required depth and width without damaging adjacent pavement. 

(b) Hot air lance. A hot compressed air lance that can provide clean, oil-free compressed air at a 

volume of 100 cubic feet per minute, a pressure of 120 pounds per square inch, and a temperature of 

2000 °F.

(c) Application wand. A wand attached to a heated hose attached to a heated material chamber that 

maintains material temperature within the manufacturer’s tolerances. Provide proper wand tips for 

desired application.

(d) Heating kettle. An indirect-heating double boiler that can provide constant and effective agitation. 

Fill the space between the inner and outer shells with oil or other heat transfer medium. Provide an 

accurate and calibrated thermometer with a range from 200 to 600 °F in 5 °F graduations located so 

the material temperature can be safely checked.

(e) Squeegee or screed. A hand-held squeegee or screed of appropriate configuration for filling cracks 

and joints flush with the surface, underfilling cracks and joints to recess below the surface, or 

overfilling cracks and joints to an overband shape. 

(f) Compressor. A compressor that can produce oil- and water-free air at a rate of at least 100 cubic 

feet per minute with a continuous line pressure of at least 125 pounds per square inch. 
Section 414

416

414.05 Routing. Rout 1⁄8- to 1⁄2-inch wide cracks to produce vertical, intact walls and a flat bottom with a 

reservoir centered over the crack. Make the reservoir two to three times the width of the crack. Rout cracks 

to a depth of 1⁄2 to 3⁄4 inch. 

Do not allow traffic to damage routed cracks.

414.06 Sealing and Filling. Do not seal or fill cracks and joints when the pavement surface temperature 

is below 35 °F or weather conditions include precipitation or fog. Dry the crack and joint surfaces with a 

hot air lance before sealing or filling. Keep the hot air lance moving to prevent burning the pavement 

surface. Place and finish the material within 5 minutes after heating the pavement surface with the hot air 

lance.

(a) Sealing (routed cracks and cracks or joints averaging 1⁄4 to 1 inch wide). Submit a copy of and 

follow the manufacturer’s recommendations for heating and applying the hot applied crack material. 

Heat the material to pouring temperature in a heating kettle and continuously agitate the material.

Discard sealant if:

(1) Heated above the safe heating temperature recommended by the manufacturer;

(2) Held at pouring temperature for more than 12 hours; 

(3) Reheated more than once;

(4) Not consistent or uniform in appearance; or 

(5) Recommended by the manufacturer. 

Use an application wand to place material in each crack and joint from the bottom up. Insulate the 

wand to maintain pouring temperature while placing material. Return the wand to the heating kettle 

immediately after sealing each crack. Use a squeegee or screed to strike off the material.

Seal joints between the pavement and curb and gutters.

(b) Filling (cracks averaging more than 1 inch wide). Fill each crack with an asphalt mastic 

according to the manufacturer’s recommendations or asphalt mix according to Section 403, Type II. 

Use a squeegee, screed, or other suitable equipment to force the mix into the crack. Fill each crack 

flush with the pavement surface and compact the asphalt mixture.

Do not allow traffic on sealed or filled cracks until the sealant or filler has cured or is treated with an 

approved debonding material recommended by the manufacturer. 

414.07 Resealing Cracks and Joints. Reseal cracks and joints exhibiting adhesion failure, damage, 

incomplete filling, or foreign objects in the sealant.

414.08 Acceptance. Material for asphalt pavement crack and joint sealing and filling will be evaluated 

under Subsections 106.02 and 106.03. 

Asphalt pavement crack and joint sealing and filling will be evaluated under Subsections 106.02 and 

106.04. 
Section 414

417

Measurement

414.09 Measure the Section 414 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

414.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 414 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 415

418

Section 415. — PAVING GEOTEXTILES

Description

415.01 This work consists of installing paving geotextile and asphalt binder between pavement lifts.

Material 

415.02 Conform to the following Subsections: 

Asphalt binder 702.01

Blotter 703.12

Paving geotextile 714.01(d)

Construction Requirements

415.03 Submittals. At least 14 days before starting paving geotextile installation, submit the following 

according to Subsection 104.06: 

(a) A production certification for the geotextile;

(b) An 18- by 18-inch sample from beyond the first outer wrap of the roll. Label the sample with the 

lot and batch number, date of sampling, project number, item number, manufacturer, and product 

name;

(c) The manufacturer’s recommended asphalt binder application rate based on field conditions and 

geotextile asphalt retention properties; and

(d) A plan of operations for installing the geotextile. 

415.04 General. Identify, store, and handle geotextile according to ASTM D4873 and the manufacturer’s 

recommendations. Limit exposure to ultraviolet radiation to less than 2 days.

415.05 Surface Preparation. Clean the existing surface of loose material, dirt, or other deleterious 

material by approved methods. 

415.06 Weather Limitations. Apply asphalt binder and paving geotextile when the following apply: 

(a) Surface is dry and unfrozen; and 

(b) Surface temperature is above 55 °F and rising. 

415.07 Asphalt Binder Application. Apply asphalt binder to the pavement surface according to 

Subsection 407.09 at 290 to 325 °F.

Spray the asphalt binder 6 inches wider than the paving geotextile. Do not apply the asphalt binder further 

than the temporary traffic control zone for this work.

Use the same asphalt binder grade as required in the approved JMF.
Section 415

419

415.08 Paving Geotextile Placement. Before the asphalt binder cools and loses tackiness, place the 

paving geotextile smoothly and with minimal wrinkling onto the binder. Use equipment designed to hold 

the roll and lay down the paving geotextile. Provide uniform tension and broom the geotextile smooth 

during placement. Slit, lay flat, and tack wrinkles or folds higher than 1 inch. Cut to remove folds that 

result in three or more layers of geotextile. Broom and roll the paving geotextile to maximize fabric contact 

with the pavement surface.

Overlap the geotextile 6 inches at longitudinal joints to ensure full closure. Do not overlap transverse 

joints. Butt adjacent geotextile ends together at transverse joints. Apply additional asphalt binder to paving 

geotextile overlaps to ensure proper bonding of the double fabric layer. 

If asphalt binder bleeds through the fabric, treat the affected areas with blotter according to Section 411.

Broom the excess blotter from the geotextile surface before placing the overlay. Do not turn equipment 

on the geotextile. Repair damaged fabric before placing overlay. 

Limit the lay-down temperature of the asphalt concrete overlay to no more than 300 °F.

415.09 Acceptance. Asphalt binder will be evaluated under Subsection 106.03. 

Material for paving geotextiles will be evaluated under Subsections 106.02 and 106.03. Provide a 

production certification with each shipment of geotextile. Include the name of the manufacturer, product 

name, and style number. 

Installation of the paving geotextile will be evaluated under Subsections 106.02 and 106.04. 

Blotter will be evaluated under Section 411. 

Measurement

415.10 Measure the Section 415 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

415.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 415 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 416

420

Section 416. — RESERVED
Section 417

421

Section 417. — RESERVED
Section 418

422

Section 418. — ASPHALT CONCRETE PAVEMENT PATCHING

Description

418.01 This work consists of repairing distressed areas of asphalt concrete pavement by patching.

Construction Requirements

418.02 General. The approximate type, size, and location of asphalt concrete pavement patches are shown 

in the plans. The final area will be approved. 

Place and compact asphalt concrete pavement according to Section 403 so the patched surface matches 

the same grade as the adjacent surface.

Dispose of debris and unsuitable and excess material according to Subsection 203.07. 

418.03 Asphalt Concrete Pavement Patch, Type 1. Type 1 patching consists of removal and 

replacement of asphalt concrete pavement, base, and subgrade materials.

(a) Patch areas. Extend the repair area 12 inches beyond the distressed area. If patch limits are within 

24 inches of the pavement edge, extend the patch limit to the pavement edge. Make the minimum 

transverse dimension of the patch one-half of the travel lane width and the minimum longitudinal 

dimension of the patch 36 inches.

(b) Pavement removal. Mill completely through the pavement or saw cut and remove the pavement. 

If sawcutting, cut through the existing pavement and around the perimeter of the patch area. Make saw 

cuts perpendicular to the roadway surface and at right angles to each other. Remove the pavement, 

base, and subgrade to the depth shown in the plans. 

(c) Patching. If shown in the plans, place geogrid or geotextile according to Section 207. Place and 

compact crushed aggregate according to Section 302. Asphalt millings may be used for crushed 

aggregate material. Apply an asphalt tack coat to the edges of the patch area according to Section 412. 

Provide asphalt concrete pavement with a JMF meeting the requirements of Section 403. 

418.04 Asphalt Concrete Pavement Patch, Type 2. Type 2 patching consists of removal and 

replacement of asphalt concrete pavement and a portion of the underlying materials. Remove asphalt 

concrete pavement and underlying materials to the depth shown in the plans. 

(a) Patch areas. Extend the repair area 12 inches beyond the distressed area. If patch limits are within 

24 inches of the pavement edge, extend the patch limit to the pavement edge. Make the minimum 

length and width of the patch 36 inches.

(b) Pavement removal. Remove pavement according to Subsection 418.03(b), except remove the 

pavement to expose subbase or subgrade as shown in the plans.

(c) Patching. Apply an asphalt tack coat to the edges of the patch area according to Section 412. 

Provide asphalt concrete pavement with a JMF meeting the requirements of Section 403. 
Section 418

423

418.05 Asphalt Concrete Pavement Patch, Type 3. Type 3 patching consists of removal and 

replacement of an asphalt concrete pavement.

(a) Pavement removal. Remove distressed asphalt concrete pavement by approved methods. Clean 

the patch area by sweeping or other approved methods. 

(b) Patching. Apply an asphalt tack coat to asphalt concrete surfaces within the patch area according 

to Section 412. Provide asphalt concrete pavement with a JMF meeting the requirements of 

Section 403. Place the asphalt material either by hand, with a blade, or other approved methods. 

418.06 Acceptance. Construction of asphalt concrete pavement patching will be evaluated under 

Subsections 106.02 and 106.04. 

Asphalt concrete will be evaluated under Section 403. 

Asphalt tack coat will be evaluated under Section 412. 

Crushed aggregate will be evaluated under Section 302. 

Separation and stabilization geotextiles and geogrid will be evaluated under Section 207. 

Measurement

418.07 Measure the Section 418 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

418.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 418 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
424

DIVISION 500

RIGID PAVEMENTS
Section 501

425

Section 501. — MINOR CONCRETE PAVEMENT

Description

501.01 This work consists of constructing minor concrete pavement on a prepared surface.

Material 

501.02 Conform to the following Section and Subsections: 

Coarse aggregate for concrete 703.02

Concrete curing material and additives 711

Fine aggregate for concrete 703.01

Hydraulic cement 701.01

Pozzolans 701.03

Reinforcing steel 709.01

Sealants, fillers, and seals 712.01

Water for cementitious materials 725.01(a)

Construction Requirements

501.03 Composition (Concrete Mix Design). Design and produce concrete mixtures that conform to 

Table 501-1. Submit concrete mix designs for approval at least 30 days before production. 

(a) Concrete pavement. Include the following in each mix design submittal:

(1) Type and sources of material; 

(2) Material certification for material;

(3) Saturated surface dry mass of the fine and coarse aggregate per cubic yard of concrete;

(4) Gradation of fine and coarse aggregate;

(5) Fine and coarse aggregate quality; 

(6) Water content in pounds per cubic yard of concrete; 

(7) Water to cementitious material ratio. The water to cementitious material ratio for concrete is 

the ratio of the mass of water to the combined masses of hydraulic cement and cement substitute; 

(8) Cement content in pounds per cubic yard of concrete. Pozzolans, ground iron blast-furnace 

slag, or silica fume may be substituted for cement according to Table 552-2; 

(9) Type and dosage of admixtures and reinforcing fibers used; 

(10) Target values for concrete air content;

(11) Target values for concrete slump;
Section 501

426

(12) Concrete density; 

(13) Compressive strength test results at 28 days according to Table 501-2, Note (1) & (4); and

(14) Material samples, if requested.

(b) Integral colored admixture. If integral color admixture is used, prepare five, 2- by 2-foot test 

panels. Construct the test panels using the approved mix design. Determine coloring agent batch 

amounts by weight. Use variable quantities of coloring agent as approved. Provide additional mixing 

time according to the manufacturer’s recommendations. Cure the test panels according to 

Subsection 501.10. Transport the panels to an approved location. Provide at least 2 weeks outside 

exposure. The CO will select the acceptable test panel. Use the same rate of integral color admixture 

for the item of work.

Table 501-1 

Composition of Concrete

Maximum

Water/

Cementitious

Material

Ratio

Maximum 

Slump

AASHTO

T 119, inch

Minimum

Air Content, 

percent

Maximum 

Coarse

Aggregate

Size

AASHTO M 4, 

inch(1) 

Minimum

28-Day

Compressive

Strength

AASHTO T 22, 

pounds per square 

inch

0.45 4 (fixed form) 5.0 11⁄2 4000

(1) Meet size number gradation and requirements from AASHTO M 43 for coarse aggregates. Blending 

of standard sizes to optimize gradation is allowed.

501.04 Equipment. Conform to the following:

(a) Forms. Provide straight, steel forms. For curved edges with radii less than 150 feet, provide 

flexible or curved forms. Provide forms conforming to the following:

(1) Height equal to the pavement thickness at the edge;

(2) 10-foot minimum length;

(3) Stabilizing devices to secure form to the prepared surface and to withstand paving operations

and pressure of concrete with no visible movement or settlement; 

(4) Joint locks to join form lengths tightly together; and 

(5) Clean and free of hardened concrete, dirt, distortion, and rust. 

(b) Paving and finishing.

(1) Fixed form construction. Provide equipment conforming to one of the following:

(a) Manual finishing machines or roller screeds that can consolidate and finish the concrete; 

or
Section 501

427

(b) Mechanical, self-propelled, finishing machines that can consolidate and finish the concrete 

with minimal hand finishing. Coordinate the number of driving wheels, power of the motor, 

and the machine’s mass to prevent slippage. Do not use machines that displace the fixed forms. 

(2) Vibrators. Provide internal immersed tube or multiple spud type vibrators for paving more 

than 8 inches thick. Surface pan type vibrators are acceptable for full-width concrete consolidation 

of slabs 8 inches or less in thickness. Operate the vibrators at frequencies within 5000 to 8000 

vibrations per minute, unless otherwise recommended by the manufacturer. Provide a tachometer 

for measuring vibration frequencies. Attach vibrators to the spreader or finishing machine or 

mount on a separate carriage that precedes the finishing machine. For construction of irregular 

areas, use hand-held vibrators operated at a frequency recommended by the manufacturer. 

(3) Floats. Provide mechanical or hand-operated floats designed to finish pavement surfaces 

uniformly smooth. 

(c) Concrete saws. Provide concrete saws that can saw new concrete for crack control to the required 

depth and alignment. Equip saws with blade guards and devices to control alignment and depth. 

Maintain a sufficient supply of replacement blades during sawing operations.

(d) Joint sealing. Provide sealing equipment according to the sealant manufacturer’s 

recommendations. 

501.05 Production Start-Up Procedures. At least 7 days before the start of concrete placement 

operations, conduct a pre-concrete pavement preparatory phase meeting according to 

Subsection 153.06(a). Coordinate attendance with the CO and applicable subcontractors. Submit and be 

prepared to discuss the following:

(a) Proposed pour sequence and placement schedule; 

(b) Approved concrete mix design; 

(c) QCP including technicians responsible for QC and batch tickets at the mixing plant and technicians 

responsible for QC, sampling, testing, and discharge at the project site; 

(d) Equipment, batching, mixing, placing, and curing requirements; 

(e) Subsections 106.03 and 106.04; 

(f) Jointing plan, joint forming or sawing operations, precipitation protection plan, hot and cold 

weather paving plan, and opening to traffic requirements; and 

(g) Temporary traffic control plan.

501.06 Surface Preparation, Setting Forms, and Steel Reinforcement. Maintain the roadbed surface 

according to Subsection 301.07. Maintain the surface to avoid the development of loose and uncompacted 

material. 

Set and align forms to the plan dimensions and elevations and ensure there is no bulging or warping. Set 

forms so the entire length of the form is firmly in contact with the grade. Securely brace forms so they 
Section 501

428

will not bulge or warp during concrete placement. Apply form release agent or form oil to the inside form 

faces. Do not vary the top face of the form from a true plane more than 1⁄8 inch in 10 feet.

Check the alignment and grade elevations of the forms immediately before placing the concrete and make 

any necessary corrections. Check and correct roadbed surface deformations and rutting exceeding 1⁄2 inch 

and uniformly dampen the surface before placing concrete. 

Do not start placing concrete material until the forms, reinforcement, and roadbed surface have been 

approved. 

Do not remove forms from freshly placed concrete until the concrete has set for at least 12 hours.

If shown in the plans, place steel reinforcement such as rebar, steel wire fabric, and steel mats according 

to Section 554. If placing reinforcement before placing concrete, position the reinforcement on acceptable 

supports. Do not use stones, concrete, or wood to support reinforcement. If placing reinforcement after 

placing concrete, mechanically insert the reinforcement to the required depth. Provide epoxy-coated steel 

reinforcement and steel supports. Keep epoxy-coated steel reinforcement free of damage and distortion.

501.07 Placing Concrete. Unless otherwise stated in this subsection, conform to Subsections 552.04

through 552.08 for mixing, delivery, QC, temperature limitations, weather limitations, handling, and 

placing of concrete. Do not walk in concrete with boots or shoes coated with earth or other contaminants. 

Deposit concrete between the forms to a uniform height. Deposit concrete to minimize rehandling and 

deposit without segregating the mix. Perform hand spreading with shovels, not rakes. 

Consolidate concrete to remove voids and air pockets. Use vibrators to consolidate concrete. Uniformly 

vibrate the concrete across the full width and depth of the pavement. Do not operate hand vibrators more 

than 15 seconds, or less than 5 seconds in any one location unless approved. Place vibrators in and 

withdraw from concrete vertically in a slow deliberate manner. Do not move concrete horizontally with 

vibrators. Do not allow vibrators to contact reinforcement, load transfer devices, subgrade, and side forms.

Strike off and place concrete with a form-riding paving machine or manual fixed form paving equipment. 

In irregular areas where a paving machine is impractical, place concrete using templates, screeds, or other 

approved methods. 

Carry a slight excess of concrete in front of the leading edge of the template or screed. After strike-off and 

before bleed water appears on the surface, float to the required grade and cross-section. Finish the concrete 

pavement to minus 1⁄4 inch or plus 3⁄8 inch of the thickness required.

If concrete is placed adjoining a previously constructed lane of pavement, do not operate mechanical 

equipment on the existing lane until the lane has attained one of the following: 

(a) A minimum flexural strength of 450 pounds per square inch according to AASHTO R 100 and 

AASHTO T 97; or 

(b) A compressive strength of 3000 pounds per square inch according to AASHTO T 22 and 

AASHTO R 100. 

When precipitation is threatening during paving operations, stop paving operations and protect the 

concrete pavement from precipitation with plastic sheeting or other approved methods. Remove, replace, 

or repair pavement damaged by precipitation as approved. 
Section 501

429

501.08 Joints. Construct joints at locations and dimensions shown in the plans. If jointing locations are 

not shown in the plans, submit a jointing plan according to Subsection 104.06. Show locations of 

contraction, construction, and isolation joints. 

Saw joints before uncontrolled shrinkage cracking occurs, but after concrete has hardened sufficiently to 

prevent excessive tearing or raveling. If necessary, use continuous sawing operations regardless of weather 

or daylight conditions. Do not saw a joint if a crack occurs at or near the joint location before sawing. 

Discontinue sawing if a crack develops ahead of the saw.

Remove and replace newly placed concrete pavement where uncontrolled cracking occurs. 

Do not vary longitudinal joints more than 1⁄2 inch and transverse joints more than 1⁄4 inch from true 

alignment. If curbs or medians are constructed integral with the pavement, construct transverse joints 

continuous through the curb or median. Clean joints of deleterious material, including concrete slurry, and 

protect the joints until sealed.

For joints that are saw cut, produce a uniform and straight joint. Saw joints approximately 1⁄8 inch wide 

and to a depth of at least one-third the thickness of the concrete pavement. Do not ravel the joints while 

sawing. Saw longitudinal joints immediately after sawing transverse joints. Protect the sawed concrete 

faces from drying during the curing period. 

Immediately clean freshly cut sawed joints by flushing with a jet of water under pressure and other 

necessary tools to remove the resulting slurry from the joint and immediate area. To clean joints, use air 

compressors equipped with suitable traps that can remove surplus water and oil from the compressed air.

Restore curing membrane disturbed during sawing operations by spraying disturbed areas with additional 

curing compound. 

(a) Longitudinal joints. Where required, place deformed steel tie bars perpendicular to the 

longitudinal joints on rigidly secured chairs or supports. Along longitudinal construction joints, tie 

bars may be bent at right angles against the form of the first lane constructed and straightened into 

final position before placing concrete in the adjacent lane. Repair or replace broken or damaged tie 

bars.

Approved two-piece connectors may be used instead of tie bars.

(b) Transverse contraction joints. Where required, place dowel bars through and centered on 

traverse joints and in the middle of the slab depth. Align and hold dowels parallel to the surface and 

centerline of the slab by a metal assembly that remains in the pavement and is rigidly secured to the 

base or subgrade using stakes or nails. Limit deviations from parallel to 1⁄4 inch in the length of the 

dowel bar. Ensure proper alignment of joint and dowel bar assemblies.

Coat each dowel bar with an approved bond breaker. Limit bond breaker coating thickness to 15 mils. 

During concrete placement, do not displace the dowel joint assembly. Mark the center location of the 

dowel bar to facilitate sawing operations. 

(c) Construction joints. Construct construction joints only at locations specified at the end of each 

work shift, and when concrete placement is interrupted for more than 30 minutes. If the quantity of 
Section 501

430

concrete placed forms a slab less than 10 feet long at the time of interruption, remove and dispose of 

the excess concrete to the last preceding joint according to Subsections 203.05 and 203.07. 

Where required, install dowel bars in construction joints according to Subsection 501.08(b). 

Use a metal or wooden bulkhead to form the joint, shaped to the pavement cross-section and designed 

to allow the installation of dowel bars. Set and hold bulkhead firmly in place in a plane at right angles 

to centerline and perpendicular to the surface of the pavement. 

(d) Isolation joints. Form isolation joints around manholes, utility boxes, foundations, other fixed 

objects, or as shown in the plans. Place a 1⁄2-inch pre-formed joint filler continuously around or along 

each structure that extends into or through the pavement before concrete is placed. After the concrete 

hardens, recess the joint filler about 3⁄4 inch to allow a reservoir for sealant.

501.09 Surface Finishing. Protect the surface from precipitation damage.

Float finish the surface. Remove laitance or thin grout. After floating, check the surface of the fresh 

concrete with a 10-foot metal straightedge. Lap each successive check with the straightedge 5 feet over 

the previous check path. Correct deficiencies indicated by the straightedge while the concrete is still 

plastic. Fill depressions with freshly mixed concrete, then strike off, consolidate, and refinish. Cut and 

refinish high areas. Do not apply water to the surface of the concrete during finishing operations. 

Before the concrete has initially set, work the pavement edges of isolation joints, transverse and 

longitudinal construction joints, and emergency construction joints to produce a 1⁄4 inch or less continuous 

radius and a smooth, dense mortar finish. Do not use mortar buildup to round edges. 

As soon as excess moisture has disappeared and while the concrete is still plastic enough to make a 

granular surface possible, texture the surface to produce a skid resistant surface. Use the method specified 

and conform to the following: 

(a) Transverse tine finish. Drag two layers of moistened burlap along the pavement in the direction 

of paving without tearing or marring the surface. Following the burlap drag, use a tining comb to form 

grooves in the pavement surface. Space tines randomly 1⁄2 to 3⁄4 inch apart. Produce grooves that are 

1⁄16 to 3

/16 inch wide and 1⁄8 to 3/16 inch deep. Tine perpendicular to the centerline without tearing the 

concrete surface or loosening surface aggregate.

(b) Broom finish. Broom the surface with a steel or stiff-bristled fiber broom to produce corrugations 

between 1⁄16 and 1⁄8 inch deep. Broom perpendicular to the centerline from edge to edge with adjacent 

strokes slightly overlapped. Use the same type and manufacture of broom for all paved surfaces to 

provide a consistent appearance.

(c) Exposed aggregate finish. Broom the surface. Use approved stiff brushes. Exercise care to prevent 

marring of the surface and cracking or chipping of slab edges or joints. If approved, apply a light spray 

of retardant to the unfinished surface to facilitate this work.

Broom transversely across the pavement. Pull the loosened semi-stiff mortar off the pavement. 

Remove the mortar from adjacent pavement. Broom parallel to the centerline. Continue this operation 

until coarse aggregate is exposed. Other methods of aggregate exposure may be used if approved. 
Section 501

431

After curing, wash the surface with water and brush to remove laitance and cement from the exposed 

coarse aggregate.

501.10 Curing Immediately after finishing and when marring will not occur, cure the surface and exposed 

sides of concrete for at least 72 hours. Do not leave the concrete exposed for more than 30 minutes during 

the curing period. Cure using one of the following methods: 

(a) Water method. Cure according to Subsection 552.13(b); or

(b) Liquid membrane curing compound method. Cure according to Subsection 552.13(c). 

Remove forms when the concrete has hardened sufficiently to resist damage, but no earlier than 12 hours 

after placing concrete. Protect the sides of the exposed slabs with a curing method equal to that provided 

for the surface. Prevent erosion of the base course beneath the exposed pavement edges until shoulders 

are constructed. 

501.11 Sealing Joints. Saw cut and seal joints before the pavement is opened to construction or public 

traffic.

Where sealant reservoirs are required, clean each sealant reservoir of foreign material including membrane 

curing compound and concrete slurry. Blow dry joints with moisture free compressed air. Do not apply 

sealing material unless the joint faces are clean and surface dry, and the joint is free of incompressibles.

Use preformed joint seals, silicone sealant, or hot-poured sealant for isolation joints. Use silicone or 

hot-poured sealants for longitudinal and transverse contraction joints.

(a) Silicone or hot-poured sealants. Install backer rod with a steel-wheel to the depth required. Do 

not stretch or twist the backer rod during installation. Limit the length of backer rod installed to that 

which can be sealed during the same workday.

Place joint sealing material when the air temperature is over 40 °F or according to the manufacturer’s 

recommendations. Remove excess or spilled material and clean the pavement surface. Do not use sand 

or similar material to cover the seal. For sealants that are not self-leveling, tool the surface of the 

sealant to the dimensions shown in the plans.

(b) Preformed joint seals. Provide the seal in one piece in the size specified for the joint opening. 

Install seals with a lubricant adhesive covering both sides of the joint. Compress the seal to between 

20 and 50 percent of its nominal width or according to the manufacturer’s recommendations. Install 

the top of the seal about 1⁄4 inch below the pavement surface.

Remove and replace seals that are damaged, twisted, improperly positioned, or stretched more than 

3 percent.

501.12 Pavement Straightedge Measurement. Measure the pavement surface after the concrete has 

cured. Use a 10-foot metal straightedge to measure at right angles and parallel to the centerline. Defective 

areas are deviations between the surface and the bottom of the straightedge more than 1⁄4 inch, measured 

between two contacts of the straightedge, or deviations more than 1⁄4 inch measured at the end of the 

straightedge.

Correct defective areas by diamond grinding, slab removal, or other approved methods. 
Section 501

432

501.13 Opening to Traffic. Do not allow traffic on new concrete pavement for 3 days and until one of 

the following conditions is met:

(a) Flexural strength of 550 pounds per square inch according to AASHTO T 97; or 

(b) Compressive strength of 4000 pounds per square inch according to AASHTO T 22. 

Complete testing on samples taken at the same frequency as shown in Table 501-2 for compressive 

strength testing.

Do not allow traffic on the pavement when joint sealant is tacky and traffic debris would imbed into the 

sealant.

501.14 Acceptance. See Table 501-2 for sampling, testing, and acceptance requirements.

Material for minor concrete pavement will be evaluated under Subsections 106.02 and 106.03. 

The concrete mixture’s slump, air content, density, temperature, and compressive strength will be 

evaluated under Subsections 106.02 and 106.04. 

Construction of concrete pavement will be evaluated under Subsections 106.02 and 106.04. 

Reinforcing steel will be evaluated under Section 554. 

Measurement

501.15 Measure the Section 501 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

501.16 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 501 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 501-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

(fine & coarse)

Measured &

tested for

conformance

(106.04 & 105) 

Quality − Subsections 

703.01 & 703.02

1 per

material

type

Source of

material Yes

30 days

before

paving

−

Mix Design

Concrete

composition

(501.03) 

Measured &

tested for

conformance

(106.04 & 105) 

All − Subsection

501.03

1 per

mix

design

Source of

material

If 

requested

30 days

before

paving

−
Table 501-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Concrete

Measured &

tested for

conformance

(106.04) 

Density − AASHTO

T 121

1 per

load(2)

Point of

discharge(3) No

Upon

completing

tests

−

Air content − AASHTO

T 152 or T 196 " " " " −

Slump − AASHTO

T 119 " " " " −

Temperature − ASTM C1064 " " " " −

Compressive

strength(1),(4) 

(28-day)

− AASHTO

R 100 & T 22

1 set per

200 yd2 but 

not less than

1 set per day

" Yes 28 days

Deliver

verification

cylinders to

the CO or

designated

laboratory for 

scheduled 

testing

Aggregate

(coarse

& fine)

Process

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

1 per

day min

Bin

discharge,

conveyor

belt, or

stockpile

No Before

batching −

Moisture − AASHTO

T 255 " " " " −

Concrete " Surface

tolerance −

Straightedge

measurements

Subsection

501.07

Subsection

501.07

Concrete

surface,

after floating

" 

While

concrete

is still

workable

−
Table 501-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Roadway

Concrete

pavement

Measured &

tested for

conformance

(106.04) 

Surface

tolerance −

Straightedge

measurements

Subsection

501.12

Successively,

after concrete

has hardened

Finished

pavement

surface

No 24 hours −

(1) A single compressive strength test result is the average result from two 6- by 12-inch or three 4- by 8-inch cylinders cast from the same load.

(2) This frequency may be reduced by the CO if produced material proves to be consistent.

(3) Sample according to AASHTO R 60, except composite samples are not required.

(4) Cast at least four 6- by 12-inch or six 4- by 8-inch compressive strength test cylinders and transport the cylinders to the project curing facility.
Section 502 

436

Section 502. — CONCRETE PAVEMENT RESTORATION

Description

502.01 This work consists of concrete pavement restoration. 

Material 

502.02 Conform to the following Subsections: 

Epoxy mortar 725.14(a)

Epoxy resin adhesives 725.12

Hydraulic cement 701.01

Non-shrink grout 701.04(b)(1)

Polyurethane grout 725.14(c)

Reinforcing steel 709.01

Sealants, fillers, and seals 712.01

Water for cementitious materials 725.01(a)

502.03 General. Design the concrete mix according to Subsection 501.03. If colored concrete is required, 

submit preliminary samples of the colored concrete according to Subsection 601.03(b). 

502.04 Equipment. Provide equipment conforming to the following: 

(a) Water blaster. Provide a high-pressure water jet machine with at least 2500 pounds per square 

inch pressure and that can remove residual sealant, oil, or other foreign material in joints.

(b) Air compressors. Provide air compressors with a minimum nozzle pressure of 100 pounds per 

square inch and that can dislodge loose debris and dry joints and cracks.

(c) Grout plant. Provide a grout plant that consists of a positive displacement cement injection pump 

and a high-speed colloidal mill. Operate colloidal mill at speeds necessary to make a homogeneous 

mixture.

Provide an injection pump having a pressure capability of 275±25 pounds per square inch when 

pumping a grout slurry mixed to a 12-second flow cone time. Provide an injection pump that can 

continuously pump at a minimum rate of 1.5 gallons per minute. The system may be modified by 

adding a recirculating hose and valve at the discharge end of the pump. 

Produce grout through a meter or scale that can measure the total day’s consumption. Provide hoses 

and fittings to produce a positive seal during grout injection. 

(d) Drills. Provide drills that meet the following:

(1) Drills for pavement jacking. Provide rock drills that can drill straight holes through the 

concrete slab with a minimum diameter recommended by the grout manufacturer. Provide rock 

drills weighing no more than 60 pounds that can drill with a downward pressure of no more than 

200 pounds. Provide an auger to open clogged holes and existing pavement jacking holes. 
Section 502 

437

(2) Drills for dowels and tie bars. Provide drills that can drill specified hole diameters for dowel 

bars or reinforcing steel tie bars. Provide drills for dowel bars that can drill holes that meet the 

vertical and horizontal tolerance of ±1⁄4 inch along the centerline of the dowel with respect to a 

horizontal line that is perpendicular to the plane established by the joint. 

Operate equipment to prevent damage to the structural integrity of the existing slab.

(e) Surface diamond grinder. Provide power driven, self-propelled grinding equipment, specifically 

designed to improve smoothness and texture of concrete pavement with diamond blades. Provide 

equipment that: 

(1) Cuts or planes at least 36 inches in width;

(2) Does not encroach on traffic outside of the work area; and 

(3) Grinds the surface without causing spalling. 

(f) Hydroblaster. Provide hydroblasting equipment conforming to Subsection 560.05. 

(g) Cold planing (milling) machine. Provide a micro milling machine that does not exceed the 

bearing capacity of the concrete pavement and conforming to Subsection 413.02(b). 

(h) Slab stabilization testing. Provide the following testing equipment:

(1) A 2-axle truck with dual rear wheels. Load the rear axle to 18 kips evenly distributed between 

the wheel paths; 

(2) Static load measuring gauges consisting of 4 gauges on 2-gauge mounts, 2 gauges per mount, 

that can detect slab movement under load; and 

(3) A modified Benkelman beam or similar approved device. 

(i) Polyurethane grout pump. Provide a grout pump that can inject high density polyurethane 

material through a drilled hole and beneath a slab and can control the flow rate of the material as 

required to stabilize and lift the slab.

Provide control devices that can maintain proper temperature and proportionate mixing of 

polyurethane material according to the manufacturer’s recommendations.

(j) Shotblasting. Provide equipment with an air stream free of oil according to ASTM D4285 and that 

can remove rust, oil, and other foreign material. Provide equipment meeting the requirements of 

ASTM D4259. 

502.05 Partial-Depth Patching (less than 4 inches in depth). This work consists of patching spalls, 

potholes, corner breaks, or other surface distresses in concrete pavement. 

(a) Patch material. Use a polymer concrete conforming to Section 572 for patches less than or equal 

to 11⁄2 inches deep. Use hydraulic cement concrete conforming to Section 501 for patches greater than 

11⁄2 inches deep. 
Section 502 

438

(b) Patch area preparation. Extend the limits of repair at least 4 inches outside the deteriorated area. 

Saw vertically along the perimeter of the patch area, parallel to the existing joint, and to at least 11⁄2 

inches deep. Near vertical edges from milling or grinding machines are acceptable. Repair saw 

overcuts and nicks to adjacent pavement outside the perimeter of the repair area with noncorrosive, 

non-shrink grout. 

Break out concrete within the patch area to at least 11⁄2 inches deep to expose sound concrete. Shot 

blast exposed concrete faces and reinforcing steel until free of rust and foreign material. Remove and 

replace deteriorated reinforcing steel. Clean patch area of loose particles, oil, dust, traces of asphalt 

concrete, and other contaminants, using clean water under pressure or compressed air, no more than 

24 hours before patching. If compressed air is used, provide a filter in the airline to ensure that the air 

is oil-free.

Remove non-concrete shoulders adjacent to the patch longitudinally to the depth of the patch and to a 

maximum width of 12 inches to facilitate placing formwork.

Dispose of the concrete according to Subsection 203.07. 

(c) Placing concrete. For hydraulic cement concrete, remove shot blast residue immediately before 

placing the epoxy resin adhesive. Apply an epoxy resin adhesive according to the manufacturer’s 

recommendations. Delay hydraulic cement concrete placement until the epoxy becomes tacky. 

Place and consolidate the concrete to eliminate voids at the interface of the patch and existing concrete. 

Place and consolidate hydraulic cement concrete according to Subsection 501.07. Place and 

consolidate polymer concrete according to Section 572 and methods recommended by the 

manufacturer.

(d) Joints. If a repair area abuts a working joint, repair the joint similar to the existing joint to maintain 

a working joint. Form a new joint to the same width as the existing joint. Use compressible joint filler 

material as inserts to prevent intrusion of the repair material into the joint. Seal the joint according to 

Subsection 502.07. 

(e) Finishing concrete. Finish patches according to Subsection 501.09 to match the plane and texture 

of the adjacent existing pavement. Cure hydraulic cement concrete according to Subsection 501.10. 

Cure polymer concrete as recommended by the manufacturer.

Restore and compact shoulders with material similar to the existing shoulder.

502.06 Full Depth Patching. This work consists of removing existing concrete pavement the full depth 

and replacing with new concrete according to Section 501. 

(a) Concrete removal. Saw cut slabs full depth leaving vertical edges at the limits of the patch. Do 

not damage adjacent concrete slabs.

Remove the concrete by lifting the slab without disturbing the underlying surface. Clean out the area 

with hand tools. Dispose of the concrete according to Subsection 203.07. 

Remove and replace adjacent slabs damaged by concrete removal. Repair spalls using partial-depth 

patching methods according to Subsection 502.05. 
Section 502 

439

Repair saw overcuts of repair areas and nicks to adjacent pavement outside the perimeter of the repair 

area with non-shrink grout.

(b) Roadbed preparation. Recondition the base and subgrade material within the patch area 

according to Subsection 303.06. 

If required, excavate the underlying material to a maximum depth of 12 inches and replace with 

crushed aggregate according to Section 302. Prevent adjacent concrete slabs from being undermined. 

(c) Joints. Construct joints according to Subsection 501.08. 

Install dowels, tie bars, or both into existing concrete pavement slabs as shown in the plans. Drill 

dowel or tie bar holes into the face of the existing concrete at the required diameter, length, and 

spacing. Provide a drill conforming to Subsection 502.04(d)(2). Clean and dry the holes before 

installing the dowels or tie bars. Use an epoxy resin adhesive to permanently anchor the dowel or tie 

bar into the existing concrete. Place the epoxy resin starting from the back of the hole and use enough 

quantity to ensure the epoxy material is forced up and around the dowel or tie bar after insertion. Place 

a thin, donut-shaped grout retention disk around the dowel or tie bar and up against the face of the 

existing concrete to prevent epoxy resin adhesive material from flowing out of the hole. 

Seal joints according to Subsection 501.11. 

(d) Reinforcing steel. If required, provide welded steel wire fabric reinforcement for crack control. If 

required, provide and place reinforcing bars according to Section 554. Support reinforcing bars and 

welded steel wire fabric on chairs or bolsters.

(e) Concrete placement. Construct side forms to overlap the ends of the existing slab. Securely fasten 

side forms so they do not move when concrete is placed. To accommodate forms for the patch, 

excavate the adjacent shoulders a maximum width of 12 inches. Place concrete according to 

Subsection 501.07. 

Cast each patch in one continuous full-depth operation. After removal of the forms, backfill, compact, 

and return the excavated shoulder area to its previous condition. 

(f) Finishing concrete. Finish patches according to Subsection 502.05(e). 

502.07 Resealing Joints and Crack Repair. This work consists of repairing or resealing joints and cracks 

in existing concrete pavement. 

(a) Preparation of joints and cracks. Limit the length of joints and cracks prepared to that which 

can be resealed within the same shift. Do not damage joints or previously repaired patches.

Remove existing sealant from the crack faces to expose new, clean concrete. If the crack widths vary 

and the crack faces are raveling and irregular, cut a crack reservoir to a depth of 3⁄4 inch.

Thoroughly clean the joint or crack of foreign material by shotblasting, waterblasting, or with a 

mechanical wire brush. Repeat the process until a new, clean concrete face is exposed. Dry the joint 

with compressed air.
Section 502 

440

Use sawing if other methods do not properly clean the joint. Limit sawing to exposing clean, new, 

concrete faces in the joint with a maximum allowable cut of 1⁄8 inch on each face of the joint.

(b) Backer rod. Install the backer rod to the required depth after the joints and cracks are clean and 

dry. Do not stretch or twist the backer rod during installation. Limit the length of backer rod installed 

to that which can be sealed during the same shift. 

(c) Sealant application. Seal joints and cracks immediately after placing the backer rod. Apply sealant 

according to the manufacturer’s recommendations. If the joint or crack becomes contaminated or 

damp, remove the backer rod, clean and dry the joint or crack, and reinstall a new backer rod before 

placing the sealant. For a non-self-leveling joint sealant, tool the sealant immediately after application 

to provide firm contact with the joint faces and to form the required recess below the slab surface.

502.08 Pavement Jacking. This work consists of raising and supporting the concrete pavement to the 

specified grade tolerances by drilling and injecting non-shrink or polyurethane grout. 

(a) Drilling holes. Develop a pattern for grout injection holes and submit for approval. Drill vertical 

holes less than 2 inches in diameter.

(b) Jacking. Establish string lines from the pavement high points to monitor slab movement. Lower 

an expanding rubber packer or hose into the holes. Provide a positive seal and connection to the 

discharge hose on the grout plant. Do not allow the discharge end of the packer or hose to extend 

below the bottom of the concrete pavement. 

If jacking continuously-reinforced concrete pavement, allow pumping to raise the pavement to within 

1⁄8 inch of the string line grade. Allow pumping to raise the pavement to within 1⁄4 inch of the transverse 

and longitudinal grades if jacking jointed pavement and bridge approach slabs. 

Continuous jacking pressures to 200 pounds per square inch are allowed. Use pressures to 300 pounds 

per square inch only for short periods of 30 seconds or less. If the pavement is bonded to the subbase, 

brief pressure rises of 10 seconds or less to 600 pounds per square inch may be allowed. Stop pumping 

if grout extrudes through cracks, joints, or shoulders. Discontinue pumping if back pressure in the hose 

exceeds 600 pounds per square inch. 

(c) Overjacking. Grind pavement raised above the specified tolerances to grade. Remove and replace 

the pavement according to Subsection 502.06 if the overjacking is greater than 1 inch. 

(d) Cracks. Radial cracks from the grout injection holes will be considered caused by improper 

injection technique. For slabs with more than 10 feet of new cracks, remove and replace the slab or a 

portion of slab according to Subsection 502.06. For slabs with less than 10 feet of new cracks, seal 

cracks according to Subsection 502.07. 

(e) Hole patching. After completing the jacking and the hole plugs are removed, fill drill holes flush 

with the pavement surface with a non-shrink grout or epoxy mortar. 

502.09 Undersealing and Slab Stabilization. This work consists of pumping a non-shrink or 

polyurethane grout through holes drilled in the pavement into voids underneath the slabs to stabilize and 

underseal concrete pavement.
Section 502 

441

(a) Preliminary testing. Perform testing at night or when there is no evidence of slab lock-up due to 

thermal expansion. Testing may be allowed to continue if the slabs are not interlocked or under 

compression. Provide testing equipment conforming to Subsection 502.04(h). Test designated slab 

using a static method as follows:

(1) Position one set of gauges with one gauge referenced to the corner of the slab on both sides of 

the joint near the pavement edge; 

(2) Set the gauges to zero with no load on the slab on each side of the joint; 

(3) Move the test truck into position and stop with the center of the test axle 12 inches behind the 

joint and the outside test wheel 12 inches from the pavement edge. Read the back gauge; 

(4) Move the test truck across the joint to a similar position 12 inches forward from the joint and 

stop. Read the forward gauge; and 

(5) Underseal slabs with a deflection of more than 1⁄32 inch. 

(b) Drilling holes. Develop hole pattern and submit for approval. Drill vertical holes less than 2 inches 

in diameter to provide a positive seal for the pumping nozzle. For the first undersealing, drill holes to 

a depth that penetrates unbound base or subgrade. Avoid penetrating the subgrade by more than 

3 inches.

(c) Cleaning holes. After the holes are drilled and before pumping the underseal grout, clean the hole 

with compressed air to remove debris and provide a passage for the grout. 

(d) Pumping underseal grout. Pump grout in each hole. Seal the nozzle of the discharge hose in the 

hole to maintain the grout pressure underneath the slab. Do not allow the nozzle end to extend below 

the bottom of the concrete. Monitor slab lift according to Subsection 502.08. Limit upward movement 

of the pavement to 1⁄8 inch.

Continue pumping into a hole until grout flows out other holes, joints, or cracks, or until the slab starts 

to lift. Stop grouting if there is lift in the slab or the adjacent shoulder. 

During stabilization operations, limit continuous pumping pressures to 125 pounds per square inch. 

Allow a short pressure surge of up to 300 pounds per square inch when starting to pump grout into the 

hole to ensure grout penetrates the void structure. Do not plug other holes while grouting. 

Grind pavement raised more than the 1⁄8 inch.

(e) Cracks. If cracks develop, complete the required repairs according to Subsection 502.07. 

(f) Hole patching. Patch holes according to Subsection 502.08(e). 

(g) Stability testing. Test for stability 24 hours after designated slabs have been undersealed 

according to Subsection 502.09(a). Complete a second underseal operation on slabs that continue to 

show excess movement. Submit the number, depth, and location of holes for the second undersealing 

for approval. The CO may direct replacement of slabs that continue to show movement more than that 

specified after undersealing twice. Remove and replace designated slabs according to 

Subsection 502.06. 
Section 502 

442

502.10 Surface Diamond Grinding. This work consists of grinding existing concrete pavement to 

eliminate joint or crack faults and providing positive lateral drainage. Uniformly transition auxiliary or 

ramp lane grinding from the mainline edge to provide positive drainage and an acceptable riding surface. 

Provide a grinding unit conforming to the requirements of Subsection 502.04(e). 

Produce a pavement surface that is true to grade, smooth, and consisting of a longitudinal corduroy-type 

texture. Produce grooves from 0.08 to 0.15 inch wide with a space between the grooves from 0.065 to 

0.125 inch wide. Produce peak ridges approximately 1⁄16 inch higher than the grooves. Adjust blade 

spacing to achieve the specified texture. Establish a positive and immediate means for removal of grinding 

residue. Remove solid residue from the pavement surfaces before it is blown by traffic action or wind and 

dispose of residue according to Subsection 203.07. Do not allow residue to flow into gutters or drainage 

facilities.

Measure the ground pavement surfaces according to Subsection 501.12. Straightedge requirements do not 

apply across longitudinal joints or outside of ground areas. 

502.11 Concrete Cleaning. This work consists of cleaning the existing concrete pavement surface with

an approved high-pressure washing device. Remove dust, dirt, oil, and other foreign material, including 

the existing crack sealant material, without causing damage to the surface or exposing coarse aggregate.

Vacuum the concrete surface to remove and collect water and debris after the pavement cleaning. Dispose 

of the water and debris according to Subsection 203.07.

502.12 Opening to Traffic. Do not allow traffic on restored pavement until the concrete has a compressive 

strength of 4000 pounds per square inch if tested according to AASHTO T 22 or until the grout used for 

jacking or undersealing the pavement has attained 600 pounds per square inch if tested with a 0.25-square 

inch probe according to AASHTO T 197.

As an alternative method of determining the compressive strength of the restored pavement, in situ 

compressive strength can be measured by developing a strength-maturity relationship of the approved 

concrete mixture according to AASHTO T 325. Submit the strength-maturity relationship for approval at 

least 14 days before production. Provide a concrete maturity meter during the test placement and 

production that meets the following: 

(a) Conforms to AASHTO T 325; 

(b) Rugged, waterproof, and can withstand the construction environment; 

(c) Able to operate without an external power source for at least 14 days; 

(d) Able to collect and store temperature and maturity data for at least 14 days; and

(e) Able to determine equivalent maturity hours according to the Arrhenius function.

Do not allow traffic on sealed joints while the sealant is tacky and traffic debris embeds into the sealant.

502.13 Acceptance. See Table 502-1 for sampling, testing, and acceptance requirements.

Material for concrete pavement restoration will be evaluated under Subsections 106.02 and 106.03. 
Section 502 

443

The concrete mixture’s slump, air content, density, temperature, and compressive strength will be 

evaluated under Subsections 106.02 and 106.04. 

Concrete pavement restoration construction will be evaluated under Subsections 106.02 and 106.04. 

Crushed aggregate will be evaluated under Section 302. 

Hydraulic cement concrete will be evaluated under Section 501. 

Polymer concrete will be evaluated under Section 572. 

Reinforcing steel will be evaluated under Section 554. 

Measurement

502.14 Measure the Section 502 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring grout for pavement jacking and undersealing by the cubic foot, measure by metering. 

Payment

502.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 502 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 502-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

(703.01

& 703.02) 

Measured &

tested for

conformance

(106.04 & 

105) 

Quality −

AASHTO

M 80, M 6,

& M 43

1 per

material

type

Source of

material Yes

14 days

before

paving

−

Mix Design

Concrete

composition

(501.03) 

Measured &

tested for

conformance

(106.04 & 

105) 

All − Subsection

501.03

1 per

mix

design

Source of

material Yes

14 days

before

paving

−

Production

Concrete

Measured &

tested for

conformance

(106.04) 

Density − AASHTO

T 121

1 per

load(2)

Point of

discharge(3) No

Upon

completing

tests

−

Air content −

AASHTO

T 152 " " " " −

Slump − AASHTO

T 119 " " " " −

Temperature − Field 

measured " " " " −
Table 502-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Concrete

Measured &

tested for

conformance

(106.04) 

Compressive

strength(1),(4) − AASHTO

T 23 & T 22

1 set per

200 yd2

but not

less than

1 set per 

day

Point of

discharge(3)

(4) " 

Deliver

verification

cylinders

to the CO

or

designated

location

within

28 days

Aggregate

(coarse & 

fine)

Process

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

1 per

day 

minimum

Bin

discharge,

conveyor

belt, or

stockpile

No Before

batching −

Moisture − AASHTO T 

255 " " " " −

Concrete " Surface

tolerance −

Straightedge

measurements

Subsection

501.09

Subsection

501.09

Concrete

surface,

after 

floating

" 

While

concrete

is still

workable

−
Table 502-1 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Finished Product

Concrete

pavement

Measured &

tested for

conformance

(106.04) 

Surface

tolerance −

Straightedge

measurements

Subsection

501.12

Successively,

after

concrete

has

cured

Finished

pavement

surface

No 24 hours −

(1) A single compressive strength test result is the average result from two 6- by 12-inch or three 4- by 8-inch cylinders cast from the same load and tested 

at 28 days.

(2) This frequency may be reduced by the CO if produced material proves to be consistent. 

(3) Sample according to AASHTO R 60.

(4) Make at least four 6- by 12-inch or six 4- by 8-inch compressive strength test cylinders and carefully transport the cylinders to the project curing facility. 

Two or three cylinders will be used for 28-day compressive strength tests. The remaining cylinders will be used by the CO for verification testing or other 

designated purposes.
447

DIVISION 550

BRIDGE CONSTRUCTION
Section 551

448

Section 551. — DRIVEN PILES

Description

551.01 This work consists of providing and constructing driven piles and concrete-filled pipe piles. 

Material 

551.02 Conform to the following Sections and Subsections: 

Coating material 719

Non-shrink grout 701.04(b)(1)

Piling 715

Polyester resin grout 725.14(b)

Prestressing steel 709.02

Reinforcing steel 709.01

Sandbags 713.14

Construction Requirements

551.03 Qualifications. Provide a professional engineer and a pile specialty consultant with experience 

installing driven piles and provide AWS certified welders when installing steel piles. At least 30 days 

before starting driven pile work, submit the following for approval:

(a) Professional engineer. A résumé describing at least 3 years’ experience in wave equation 

analyses.

(b) Pile specialty consultant. If dynamic load testing is specified, provide a résumé describing at least 

3 years’ experience in:

(1) Dynamic load testing and analysis;

(2) Signal matching analysis; and 

(3) Wave equation analysis including the initial wave equation analysis. 

(c) Welders. AWS certifications.

551.04 Submittals. At least 30 days before starting driven pile operations, submit the following according 

to Subsection 104.06: 

(a) Construction sequence. Start date and proposed driven pile construction sequence; 

(b) Wave equation analysis report. A wave equation analysis for the proposed pile driving system; 

(c) Equipment and analysis. The following pile-driving equipment information:

(1) General. Project and structure identification, pile-driving Contractor or subcontractor, and 

auxiliary methods of installation such as jetting or preboring and the type and use of the equipment;
Section 551

449

(2) Hammer. Manufacturer, model, type, serial number, rated energy ( _____ at _____ length of 

stroke), ram weight, modifications, and a chart from the hammer manufacturer equating stroke and 

blows per minute for the hammer to be used. A speed versus stroke calibration may be used if 

approved. 

For closed-end diesel hammers, a chart calibrated to actual hammer performance within 90 days 

of use equating bounce chamber pressure to either equivalent energy or stroke for the hammer to 

be used; 

(3) Capblock (hammer cushion). Material, thickness, area, modulus of elasticity, and coefficient 

of restitution;

(4) Pile cap. Helmet weight, bonnet mass, anvil block mass, and drivehead mass; 

(5) Pile cushion. Material, thickness, area, modulus of elasticity, and coefficient of restitution;

(6) Pile. Pile type, length (in leads), mass per linear foot, wall thickness, taper, cross-sectional 

area, design pile capacity, and tip treatment description;

(7) Test pile details. Location, type, estimated tip elevation, minimum allowable embedment, 

length, capacity, allowable compressive and tensile stresses;

(8) Subsurface conditions. Soil description, soil damping and quake parameters used in analysis, 

anticipated driving difficulties (if any); 

(9) Bearing graph analysis results. Calculated maximum compressive and tensile stresses, 

penetration resistance (blow counts), hammer stroke and energy transferred to the pile for a range 

of nominal soil resistance values. Provide an inspector’s chart with blow count versus stroke graph 

for the required nominal capacity;

(d) Splices. Details for pile field splices, pile section lengths, and elevations of splices;

(e) Pile shoes. Details for pile shoes;

(f) Pile installation log. Proposed form for recording installation of piles;

(g) Preboring. Preboring, hole cleaning and preparation, pile placement and equipment, and 

procedures for the ground conditions expected to be encountered. Include methods and certifications 

required for penetration of subsurface obstructions. If preboring disturbs the capacity of previously 

installed piles or structures, submit a plan with procedures to restore the required nominal capacity; 

and 

(h) Static load test. Drawings of the proposed loading apparatus. 

551.05 Pile Driving Equipment. Provide equipment conforming to the following requirements:

(a) Pile hammers.

(1) Gravity hammers. Gravity hammers may only be used to drive timber piles. Provide a 

hammer with a ram weighing between 2000 and 3500 pounds and limit the drop height to 12 feet 
Section 551

450

or less. Select a ram mass greater than the combined mass of the drive head and pile. Provide 

hammer guides to ensure concentric impact on the drive head.

(2) Open-end diesel hammers. Use open-end diesel hammers with pure (B100) biodiesel. Equip 

open-end (single acting) diesel hammers with a device on the ram to allow visual determination of 

hammer stroke.

(3) Closed-end diesel hammers. Use closed-end diesel hammers with pure (B100) biodiesel. 

Equip hammers with a dial gauge for measuring pressure in the bounce chamber. Ensure the gauge 

is readable from ground level. Calibrate the dial gauge to allow for losses in the gauge hose. Verify 

the accuracy of the calibrated dial gauge during driving operations by ensuring that cylinder lift 

occurs when bounce chamber pressure is consistent with the maximum energy given in the 

hammer specifications. Do not use closed-end diesel hammers that do not achieve cylinder lift at 

the maximum energy-bounce chamber pressure relationship given in the hammer specification.

(4) Air or steam hammers. Provide plant and equipment for steam and air hammers able to 

maintain the volume and pressure specified by the hammer manufacturer. Equip the hammer with 

accurate pressure gauges that are easily accessible. Use a hammer with the mass of the striking 

parts at least one-third the combined mass of the driving head and pile. Ensure the combined mass 

is at least 2750 pounds. 

Measure inlet pressures for double-acting and differential-acting air or stream hammers with a 

needle gauge at the head of the hammer when driving test piles. If required, also measure inlet 

pressures when driving production piles. A pressure versus speed calibration may be developed 

for specific driving conditions at the project as an alternative to periodic measurements with a 

needle gauge.

(5) Nonimpact hammers. Use nonimpact hammers with non-petroleum based hydraulic fluids 

and biodiesel fuels. If specified, use nonimpact hammers, such as vibratory hammers. Control the 

installation of production piles when using vibratory hammers by power consumption, rate of 

penetration, specified tip elevation, or other acceptable methods that ensure the required pile load 

capacity is obtained. Strike piles with an impact hammer of suitable energy to verify the required 

pile capacity is obtained on at least one of every ten piles. 

(6) Hydraulic hammers. Use hydraulic hammers with pure vegetable oil or grape seed oil. 

Provide a power plant for hydraulic hammers with sufficient capacity to maintain the volume and 

pressure, specified by the manufacturer, at the hammer under working conditions. Equip the power 

plant and equipment with accurate pressure gauges that are easily accessible to the CO.

(b) Approval of pile-driving equipment. Provide pile-driving equipment that allows permanent piles 

to be driven with reasonable effort and to the required depths and resistances without damage. 

Approval of pile-driving equipment will be based on a wave equation analysis. 

Use the approved equipment represented in the wave equation analysis during pile-driving operations. 

Approval of the pile-driving system is specific to the equipment submitted. If the proposed equipment 

is modified or replaced, re-evaluate and resubmit the analysis and revised data for approval before 

using. Approval of a pile hammer does not relieve the Contractor of responsibility for piles damaged 

due to driving stress. 
Section 551

451

The required number of hammer blows indicated by the wave equation at the nominal pile capacity is 

from two to ten blows per inch. 

Do not allow the pile stresses resulting from the wave equation analysis to exceed the following values:

(1) Steel piles. Limit the compressive driving stress to 90 percent of the yield strength of the pile 

material.

(2) Concrete piles. Limit the tensile (TS) and compressive (CS) driving stresses to:

TS ≤ 3 f'c

 1/2 + EPV

CS ≤ 0.85f f'c - EPV 

where:

f'c = The 28-day design compressive strength of the concrete in pounds per square inch 

EPV = The effective prestress value in pounds per square inch

(3) Timber piles. Limit the compressive driving stress to:

σdr = φda(FCO) where:

σdr = limiting driving stress (ksi)

φda = resistance factor, drivability analysis

FCO = base resistance of wood in compression parallel to the grain (ksi)

(c) Driving appurtenances.

(1) Hammer cushion. Equip impact pile-driving equipment, except gravity hammers, with a 

suitable thickness of hammer cushion material to prevent damage to the hammer or pile and to 

ensure uniform driving behavior. Fabricate hammer cushions from durable, manufactured material 

according to the hammer manufacturer’s recommendations. Do not use wood, wire rope, or 

asbestos hammer cushions. Place a striker plate, as recommended by the hammer manufacturer, 

on the hammer cushion to ensure uniform compression of the cushion material. Inspect the hammer 

cushion in the presence of the CO when starting pile driving at each structure or after each 

100 hours of pile driving, whichever is less. Replace the cushion when its thickness is reduced by 

more than 25 percent of its original thickness.

(2) Pile drive head. Provide adequate drive heads for impact hammers. Provide appropriate drive 

heads, mandrels, or other devices for special piles according to the manufacturer’s 

recommendations. Align the drive head axially with the hammer and pile. Fit the drive head around 

the pile head so that transfer of torsional forces is prevented during driving and proper alignment 

of hammer and pile is maintained.

(3) Leads. Support piles in line and position with leads while driving. Construct pile driver leads 

to allow freedom of movement of the hammer while maintaining axial alignment of the hammer 
Section 551

452

and the pile. Fit swinging leads with a pile gate at the bottom of the leads and in the case of battered 

piles, fit with a horizontal brace between the crane and the leads. Embed leads in the ground or 

constrain the pile in a structural frame (template) to maintain proper alignment. Provide leads of 

sufficient length that do not require a follower but allows proper alignment of battered piles.

(4) Followers. Use followers only if approved. If followers are allowed, drive the first pile in each 

bent or substructure unit and every tenth pile thereafter, full length without a follower, to verify 

that adequate pile embedment is being achieved to develop the required nominal capacity. Provide 

a follower of such material and dimensions that allows the piles to be driven to the required 

penetration. Hold and maintain follower and pile in proper alignment during driving. 

(5) Jetting. Use jetting only if approved. Provide jetting equipment with sufficient capacity to 

deliver a consistent pressure equivalent to at least 100 pounds per square inch at two 3⁄4-inch jet 

nozzles. Jet so as not to affect the lateral stability of the final in-place pile. Remove jet pipes when 

the pile tip is at least 5 feet above the prescribed tip elevation and drive the pile to the required 

nominal capacity with an impact hammer. Control, treat if necessary, and dispose of jet water in 

an approved manner. 

(6) Pile cushion. For concrete piles, use a new pile cushion to protect the head of each pile. Cut 

the pile cushion at least 4 inches thick and to match the cross-section of the pile top. Replace the 

pile cushion if it is compressed more than one-half its original thickness or starts to burn. For steel 

and timber piles, protect each pile with an approved driving cap. Enclose timber piles with 

approved collars or bands to prevent splitting or brooming. Replace caps when damaged. Do not 

reuse cushions or caps.

(7) Pile shoes. If specified, provide shoes to protect the pile tip from damage during driving. 

Fabricate shoes to snugly fit the pile tip. For concrete piles, attach the shoe to the pile using dowels 

or other approved methods. For steel piles, design and fit the shoe to the steel shape and weld the 

shoe to the pile so as not to stress the web or the flange. For timber piles, carefully shape the tip to 

secure an even uniform bearing for the pile shoe. Treat holes, cuts, or caps in treated timber piles 

with two-brush applications of creosote-coal tar solution according to American Wood Protection 

Association (AWPA).

551.06 Pile Lengths. Provide piles with sufficient length to obtain the required resistance and to extend 

into the pile cap or footing as indicated in the plans. Increase the length to provide fresh heading and to 

provide for the method of operation. If test piles are required, provide piles in the lengths determined by 

the test piles.

551.07 Test Piles. Install test piles if specified.

Place the piles designated as dynamic load test piles in a horizontal position and not in contact with other 

piles. Drill holes for mounting instruments near the head of the pile. Mount the instruments after the pile 

is in leads and take wave speed measurements.

Excavate the ground at the site of each test pile or production pile to the elevation of the bottom of the 

footing before the pile is driven. Provide test piles longer than the estimated length of production piles. 

Drive test piles with the same equipment as the production piles.

Drive test piles to the required nominal capacity at the estimated tip elevation. Allow test piles that do not 

attain the required nominal capacity at the estimated tip elevation to set up for 24 hours before re-driving. 
Section 551

453

Warm the hammer before re-driving starts by applying at least 20 blows to another pile. If the required 

nominal capacity is not attained on re-driving, drive a portion or the remaining test pile length and repeat 

the set up and re-drive procedure as directed. Splice and continue driving until the required nominal pile 

capacity is achieved.

Conform to the requirements for production piles when test piles are to be used in the completed structure. 

Remove test piles not incorporated in the completed structure to at least 24 inches below finished grade. 

551.08 Driven Pile Capacity. Drive piles to the specified penetration and to the depth necessary to 

achieve the required nominal pile capacity. Splice piles not obtaining the required nominal capacity at the 

ordered length, and drive with an impact hammer until the required nominal pile capacity is achieved.

Use a Saximeter or other approved equipment to record the blow count and stroke versus depth for test 

and production piles. 

Determine the nominal pile capacity of the in-place piles using dynamic load test results. If a dynamic 

load test is not specified use the wave equation to determine nominal pile capacity of the in-place pile.

(a) Wave equation. Adequate penetration is achieved when the specified wave equation resistance 

criteria are achieved within 5 feet of the designated tip elevation. Drive piles that do not achieve the 

specified resistance within these limits to a penetration determined by the CO. 

(b) Dynamic formula. Do not use the dynamic formula to determine driven pile capacity. 

551.09 Preboring. Use augering, wet rotary drilling, or other approved methods of preboring. Do not use 

a punch or a spud instead of preboring. 

Prebore the pile hole to natural ground in compacted embankments more than 5 feet deep.

In natural ground, preboring may extend to the surface of the rock or hardpan for piles end-bearing on 

rock or hardpan. Seat the pile into the end-bearing strata.

Stop preboring at least 5 feet above the estimated pile tip elevation and drive the pile with an impact 

hammer to a penetration which achieves the required nominal pile capacity for piles not end-bearing on 

rock or hardpan. Prebore holes smaller than the diameter or diagonal of the pile cross-section while 

allowing penetration of the pile to the specified depth.

Increase the hole diameter to the least dimension adequate for pile installation if subsurface obstructions 

such as boulders or rock layers are encountered. Fill remaining void space around the pile with sand or 

other approved material after driving is complete.

Do not impair the capacity of existing piles or the safety or condition of adjacent structures. If preboring 

disturbs the capacity of previously installed piles or structures, restore the required nominal capacity of 

piles and structures by approved methods. 

551.10 Preparation and Driving. Make the heads of piles plane and perpendicular to the longitudinal 

axis of the pile. Coordinate pile driving to prevent damage to other parts of the completed work. 

Drive pile heads to within 3 inches of plan location at cutoff elevation for bent caps supported by piles 

and to within 6 inches of plan location for piles capped below final grade. Locate and drive piles at least 
Section 551

454

4 inches from any edge of the cap. Drive piles so that the axial alignment is no more than 1⁄4 inch per foot 

along the longitudinal axis of the required alignment. The CO may stop driving to check the pile 

alignment. Check alignment before the last 5 feet are driven for piles that cannot be internally inspected 

after installation. Do not pull laterally on piles or splice to correct misalignment. Do not splice a properly 

aligned section on a misaligned pile. 

Place individual piles in pile groups either starting from the center of the group and proceeding outward 

in both directions or starting at the outside row and proceeding progressively across the group. 

Correct piles driven improperly, driven out of proper location, misaligned, or driven below the designated 

cutoff elevation in an approved manner. Replace piles damaged during handling or driving unless 

otherwise approved. Obtain approval for the proposed methods of correcting or repairing deficiencies. 

Submit pile driving records including Saximeter readings at the end of each work shift. 

(a) Steel piles. Provide full-length, un-spliced piles where practical.

Load, transport, unload, store, and handle steel piles to keep the metal clean and without damage. Do 

not use piles that exceed the allowed mill tolerance for camber and sweep. Steel piles damaged during 

installation are unacceptable unless the minimum tip elevation is achieved and load tests show the 

bearing capacity is 100 percent of the required nominal. Perform tests on damaged piles. If driving 

points are required, weld driving points to steel piles according to AWS, Structural Welding Code - 

Steel D1.1 or AASHTO/AWS, Bridge Welding Code D1.5 as applicable.

(b) Precast and precast prestressed concrete piles. Fabricate precast piles from Class P(AE) 

concrete and precast prestressed piles from Class P(AE) concrete according to Section 552. Conform 

to Section 554 for reinforcing steel. Conform to Section 553 for prestressing steel. If lifting anchors 

are used, maintain at least a 1-inch clearance from the pile reinforcing steel or prestressing steel.

Use metal, plywood, or dressed lumber forms that are watertight, rigid, and true to line. Use a 1-inch 

chamfer strip in corners of the forms.

Cast piles separately or, if alternate piles are cast in a tier, cast the intermediate piles at least 4 days 

after the adjacent piles are poured. Separate piles cast in tiers with tar paper or other suitable separating 

material. Place concrete in each tier in a continuous operation that prevents the formation of stone 

pockets, honeycombs, or other defects. Leave forms in place for at least 24 hours. 

Make piles straight so when a line is stretched from butt to tip on any face, the line is no more than 

1 inch from the face of the pile at any point. Make the pile surface true, smooth, even, and without 

honeycombs and voids. 

Remove lifting anchors to a depth of at least 1 inch below the concrete surface and fill the resulting 

hole with concrete. Finish each pile with a Class 1 ordinary surface finish according to 

Subsection 552.14. Cure the piles according to Subsection 552.13 or 553.06 as applicable.

If concrete test cylinders are made and tested according to Section 552, do not move piles until the 

tests indicate a compressive strength of at least 80 percent of the design 28-day compressive strength. 

Do not transport or drive piles until tests indicate the minimum design 28-day compressive strength is 

attained.
Section 551

455

If concrete test cylinders are not made, do not move piles until they have cured for at least 14 days at 

a minimum temperature of 60 °F or 21 days at a minimum temperature of 40 °F. Do not transport or 

drive piles until cured for at least 21 days at 60 °F or higher or 28 days at 40 °F or higher. If high early 

strength cement is used, do not move, transport, or drive piles until cured for at least 7 days. 

Support concrete piles during lifting or moving at the points shown in the plans. Provide support at 

the quarter points if not specified. Avoid bending the pile or breaking edges when lifting or moving 

the piles.

Reject concrete piles with reduced strength caused by external defects such as spalls, cracks, or internal 

defects such as cavities revealed with non-destructive testing.

(c) Concrete-filled steel pipe piles. Provide and handle the steel pipes according to 

Subsection 551.10(a). Cutting shoes may be inside or outside the pipe. Use high-carbon structural steel 

with a machined ledge for pipe bearing or cast steel with a ledge designed for attachment with a simple 

weld. 

Use the class of concrete designated in the plans according to Section 552. Drive pile pipes before 

placing concrete in the pipes. Do not drive piles within 15 feet of concrete-filled pile pipe until 80 

percent of the design strength is attained. Do not drive pile pipe after it is filled with concrete.

(d) Timber piles. Do not use piles with checks wider than 1⁄2 inch. Drive treated timber piles within

6 months after treatment. Handle and care for pressure-treated piles according to AWPA, Standard 

M4 Standard for the Handling, Storage, Field Fabrication and Field Treatment of PreservativeTreated Wood Products. 

551.11 Splices. Align and connect pile sections so the axis of the spliced pile is straight.

(a) Steel piles. Splices are allowed when piles lengths exceed 60 feet. Space splices at least 10 feet 

apart. Use no more than 2 splices per pile.

Use welders certified for structural welding.

Make surfaces to be welded smooth, uniform, and without loose scale, slag, grease, or other material 

that prevents proper welding. Steel may be oxygen cut. Carbon-arc gouging, chipping, or grinding 

may be used for joint preparation.

Weld according to AWS, Structural Welding Code - Steel D1.1 or AASHTO/AWS, Bridge Welding 

Code D1.5. Weld the entire pile cross-section using prequalified AWS groove weld butt joints. Weld 

so there is no visual evidence of cracks, lack of fusion, undercutting, excessive piping, porosity, or 

inadequate size. Manufactured splices may be used in place of full penetration groove butt welds if 

approved or shown in the plans. Ensure the splice develops the full strength of the pile in compression, 

tension, and bending.

Perform non-destructive examination on splices located in the upper half of the total pile length by 

performing one of the following tests: 

(1) Radiographic testing according to the requirements of AWS, Structural Welding Code - Steel 

D1.1 or AASHTO/AWS, Bridge Welding Code D1.5. 
Section 551

456

(2) Ultrasonic testing according to the requirements of AWS, Structural Welding Code - Steel D1.1

or AASHTO/AWS, Bridge Welding Code D1.5. 

Repair weld defects according to AWS, Structural Welding Code - Steel D1.1 or AASHTO/AWS, 

Bridge Welding Code D1.5. 

(b) Concrete pile splices. Use dowels or other approved mechanical means to splice precast concrete 

or precast prestressed concrete piles.

If dowels are used, cast the dowels into the tip end of the following pile with corresponding holes at 

the butt end of the driven pile. Serrate the holes to provide a mechanical bond. Clean surfaces and 

dowel holes. Separate the ends of the piles by at least 1⁄2 inch. Grout the dowels in place and allow the 

grout to cure. Enclose the gap with forms and inject a bonding agent that can withstand the impact and 

driving forces and has the same compressive strength as the pile. Follow the manufacturer’s 

recommendations for the use and curing of grouting and bonding products. 

Attach manufactured splices to the concrete piles according to the manufacturer’s recommendations. 

Ensure the splice develops strengths in compression, tension, and bending at least the strength of the 

pile being spliced. 

(c) Concrete pile extensions.

(1) Precast concrete piles. Extend precast concrete piles by removing the concrete at the end of 

the pile and leaving 40 bar diameters of reinforcement steel exposed. Remove the concrete to 

produce a face perpendicular to the axis of the pile. Securely fasten reinforcement of the same size 

as that used in the pile to the projecting reinforcing steel. Form the extension to prevent leakage 

along the pile. 

Immediately before placing concrete, wet the top of the pile thoroughly and cover with a thin 

coating of neat cement, re-tempered mortar, or other approved bonding material. Place concrete of 

the same mix design and quality as that used in the pile. Keep forms in place for at least 7 days 

after the concrete has been placed. Cure and finish according to Section 552. 

(2) Precast prestressed piles. Extend precast prestressed piles according to Subsection 551.11(b). 

Include reinforcement bars in the pile head for splicing to the extension bars. Do not drive extended 

prestressed precast piles.

(d) Timber piles. Do not splice timber piles.

551.12 Heaved Piles. Check for pile heave during the driving operation. Take level readings immediately 

after each pile is driven and again after piles within a radius of 15 feet are driven. Re-drive piles that heave 

more than 1⁄2 inch. Re-drive to the specified resistance or penetration. 

551.13 Pile Load Tests. Perform dynamic load tests at the locations shown in the plans. Static load tests 

are not required unless specified. 

(a) Dynamic load test. Provide equipment and perform dynamic load tests according to ASTM D4945 

in the presence of the CO. Mount the instruments according to Subsection 551.07. 
Section 551

457

Drive the pile to the depth at which the dynamic test equipment indicates that the required nominal 

pile capacity is achieved. If necessary to maintain stresses in the pile below the values in 

Subsection 551.05(b)(1), reduce the driving energy transmitted to the pile by using additional cushions 

or reducing the energy output of the hammer. Realign the driving system if nonaxial driving is 

indicated. 

At least 24 hours after the initial driving, re-drive each dynamic load test pile with instrumentation 

attached. Warm the hammer before re-driving by applying at least 20 blows to another pile. Re-drive 

the dynamic load test pile for a maximum penetration of 3 inches, a maximum of 20 blows, or to 

practical driving refusal, whichever occurs first. Practical driving refusal is defined as 12 blows per 

inch for steel piles, 10 blows per inch for concrete piles, and 5 blows per inch for timber piles.

Verify the assumptions used in the initial wave equation analysis submitted according to 

Subsection 551.04(b) using signal matching analysis. Analyze one blow from the original driving and 

one blow from the re-driving for each pile tested. 

Perform additional wave equation analyses with adjustments based on the signal matching analysis 

results. Provide a graph showing blow count versus nominal capacity. Provide a blow count versus 

stroke graph for the nominal capacity of open-ended diesel hammers. Provide the driving stresses, 

transferred energy, and pile capacity as a function of depth for each dynamic load test. 

Within 3 days of the completion of testing, submit the dynamic load test results according to 

Subsection 104.06. 

Based on the results of the dynamic load testing, signal matching analyses, and wave equation 

analyses, the order list and production driving criteria may be approved and the required cut-off 

elevations provided, or additional test piles and load testing may be specified. This information will 

be provided within 7 days after receipt of the order list and required test data for the test piles driven.

(b) Static load tests. Perform static load tests according to ASTM D1143 using the quick load test 

method, except as modified in this Section. 

(1) Provide a loading system that can apply 150 percent of the nominal pile capacity or 1000 tons, 

whichever is less.

(2) Construct the loading apparatus to allow increments of load to be placed gradually without 

causing vibration to the test pile. 

Perform test at least 5 days after test pile was driven unless approved. If tension (anchor) piles are 

required, drive tension piles at the location of permanent piles. Do not use timber or tapered piles 

installed in permanent locations as tension piles. Take the test to plunging failure or the capacity of 

the loading system, whichever occurs first.

The nominal bearing resistance is defined as 50 percent of the failure load. The failure load is defined 

as follows:
Section 551

458

For piles no more than 24 inches in diameter, length of side for square piles or diagonal width, the 

load that produces a settlement at failure of the pile head equal to:

Sf = S + (0.15 + 0.008D) 

For piles greater than 24 inches in diameter, length of side for square piles or diagonal width: 

where:

Sf = Settlement at failure (in)

D = Pile diameter or diagonal width (in)

S = Elastic deformation of pile (in)

Determine top elevation of the test pile immediately after driving and again immediately before load 

testing to check for heave. Wait at least 3 days between the driving of anchor or load test piles and the 

start of the load test. Before testing, re-drive or jack to the original elevation piles that heaves more 

than 1⁄4 inch. 

After completion of the load testing, remove or cut off test or anchor piling not a part of the finished 

structure at least 24 inches below either the bottom of footing or the finished ground elevation. 

Within 7 days of the completion of testing, submit the static load test results according to 

Subsection 104.06. 

Based on the results of the static load testing, the order list and production driving criteria may be 

approved and the required cut-off elevations provided or additional load tests may be specified. This 

information will be provided within 7 days after receipt of the order list and required test data for the 

test piles driven.

(c) No load test. If no load test is specified, drive each pile to the minimum tip elevation as shown in 

the plans or to practical driving refusal. Practical driving refusal is defined as 12 blows per inch for 

steel piles, 10 blows per inch for concrete piles, and 5 blows per inch for timber piles.

551.14 Pile Cutoffs. Cut off the tops of permanent piles and pile casings at the required elevation. Cut off 

the piles clean and straight and parallel to the bottom face of the structural member in which they are 

embedded. Dispose of cutoff lengths according to Subsection 203.07. 

Treat the heads of treated timber piles which are not embedded in concrete by one of the following 

methods: 

(a) Reduce the moisture content of the wood to no more than 25 percent with no free moisture on the 

surface. Brush apply one application of creosote-coal tar solution as required in AWPA Standards.

Build up a protective cap by applying alternate layers of loosely woven fabric and hot asphalt or tar, 

similar to membrane waterproofing, using three layers of asphalt or tar and two layers of fabric. Use 

fabric at least 6 inches wider in each direction than the diameter of the pile. Turn the fabric down over 
Section 551

459

the pile and secure the edges by binding with two turns of No. 10 galvanized wire. Apply a final layer 

of asphalt or tar to cover the wire. Neatly trim the fabric below the wires.

(b) Cover the sawed surface with three applications of a hot mixture of 60 percent creosote and 

40 percent roofing pitch, or thoroughly brush coat with three applications of hot creosote and cover 

with hot roofing pitch. Place a covering of galvanized sheet metal over the coating and bend down 

over the sides of each pile.

551.15 Unsatisfactory Piles. Correct unsatisfactory piles by an approved method. Methods of correcting 

unsatisfactory piles may include one or more of the following: 

(a) Use the pile at a reduced capacity.

(b) Install additional piles.

(c) Repair damaged piles. 

(d) Replace damaged piles.

551.16 Placing Concrete in Steel Pipe Piles. Clean the inside of pipe piles by removing material to the 

depth of limits of concrete fill shown in the plans. If a soil plug leaves a void deeper than the limits of 

concrete fill, fill to that depth using concrete or a bentonite grout mix batched in the proportions shown in 

Table 551-1 or other approved mix. 

Table 551-1 

Pipe Pile Fill

Material Quantity

Cement 94 lb

Bentonite 25 lb

Water 30 gal

Remove water before placing concrete or place the concrete using a tremie when water is present in the 

pile. Dispose of water according to Federal, state, and local rules and regulations. Provide suitable 

equipment for inspecting the entire inside surface of the driven pipe immediately before placing concrete.

(a) Reinforcing steel. Make the spacing between adjacent cage elements at least five times the 

maximum size of aggregate in the concrete when reinforcing steel is required.

Securely tie concrete spacers or other approved spacers at fifth points around the perimeter of the 

reinforcing steel cage. Install spacers at intervals no more than 10 feet measured along the length of 

the cage.

Place the reinforcement cage into the driven pipe when the concrete reaches the planned bottom 

elevation of the reinforcement. Support the reinforcement so it remains within 2 inches of the required 

vertical location. Support the cage from the top until the concrete reaches the top of the pile.

(b) Concrete. Construct concrete according to Section 552. Place concrete in one continuous 

operation from the bottom to the top of the pile. Consolidate the top 10 feet of the concrete pile using 

approved vibratory equipment before the initial concrete set.
Section 551

460

551.17 Acceptance. Pile material will be evaluated under Subsections 106.02 and 106.03. Provide 

production certifications with each shipment of the following: 

(a) Concrete piles;

(b) Sheet piles, steel H-piles, and steel pipes; and 

(c) Treated timber piles.

Driving piles will be evaluated under Subsections 106.02 and 106.04. 

Concrete will be evaluated under Section 552. 

Prestressing steel will be evaluated under Section 553. 

Reinforcing steel will be evaluated under Section 554. 

Measurement

551.18 Measure the Section 551 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring piles by the linear foot, measure the length of pile from the cutoff elevation to the tip.

When measuring preboring by the linear foot, measure from the ground surface to the base of the prebored 

pile hole.

Measure splices required to drive piles deeper than the estimated tip elevation.

Payment

551.19 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 551 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 552

461

Section 552. — STRUCTURAL CONCRETE

Description

552.01 This work consists of constructing structural concrete in bridges, culverts, and other structures.

Material 

552.02 Conform to the following Section and Subsections: 

Coarse aggregate for concrete 703.02

Concrete curing material and additives 711

Fine aggregate for concrete 703.01

Grout 701.04

Hydraulic cement 701.01

Pozzolans 701.03

Penetrating stain for concrete 719.05

Sealants, fillers, and seals 712.01

Structural steel 717.01

Water for cementitious materials 725.01(a)

Construction Requirements

552.03 Composition (Mix Design). Design and produce concrete mixtures that conform to the class 

specified. Submit concrete mix designs for approval at least 36 days before production. 

Provide a new mix design for approval if there is a change in a source of material or when the fineness 

modulus of the fine aggregate changes by more than 0.20. 
Section 552

462

Table 552-1 

Composition of Concrete

Class

of

Concrete

Minimum

Compressive 

Strength

@ 28-Days, f'c, 

pounds per square 

inch

Maximum

WaterCementitious

Material

Ratio

Maximum 

Coarse 

Aggregate Size, 

inch(1)

Air Content for 

Air Entrained 

Concrete, 

percent

A, A(AE) 4500 0.45 1.5 4.0 to 7.0

C, C(AE) 4500 0.45 0.75 4.5 to 7.5

D(AE)(2) 5000 0.40 1.5 4.0 to 7.0

P, P(AE)(3) See plans – 1.0 4.0 to 6.0

S (Seal) – 0.54 1.5 – 

(1) Meet size number gradation and requirements from AASHTO M 43 for coarse aggregates. Blending of 

standard sizes to optimize gradation is allowed.

(2) The maximum water-soluble chloride ion content is 0.15 percent by mass of cement. Determine the 

water-soluble chloride ion content of concrete made with mix ingredients at an age between 28 and 48 days 

according to ASTM C1218. Submit test results with the concrete mix design for approval.

(3) The maximum water-soluble chloride ion content is 0.06 percent by mass of cement. Determine the 

water-soluble chloride ion content of concrete made with mix ingredients at an age between 28 and 48 days 

according to ASTM C1218. Submit test results with the concrete mix design for approval.

Table 552-2 

Cementitious Material Requirements for Concrete

Cementitious Material

Maximum Percent of Total

Cementitious Material by

Mass

Fly ash or other pozzolans, AASHTO M 295 25

Slag, AASHTO M 302 50

Silica fume, AASHTO M 307 10

Total fly ash or other pozzolans, slag, & silica fume 50(1)

Total fly ash or other pozzolans & silica fume 35(1)

(1) Limit fly ash or other pozzolans to no more than 25 percent of the total mass of cementitious material and limit silica 

fume to no more than 10 percent of the total mass of cementitious material. 

(a) Structural concrete. Design and produce concrete mixtures that conform to Tables 552-1 and 

552-2 for the class specified. Determine design strength values according to Section 4 of ACI 301, 

Specifications for Concrete Construction. 

Verify mixture design with trial mixes prepared according to Section 4 of ACI 301 from proposed 

sources or with previous concrete production data for the mixture design submitted from proposed 

sources.

Submit concrete mix designs on Form FHWA 1608, 552 Structural Concrete Mix Design Submittal. 

Include the following in each mix design submittal: 

(1) Project identification;

(2) Name and address of Contractor and concrete producer; 

(3) Mix design designation;
Section 552

463

(4) Class of concrete and intended use;

(5) Material proportions;

(6) Name and location of material sources for aggregate, cement, admixtures, and water;

(7) Type of cement and other cementitious material, if used. Fly ash, slag cement, or silica fume 

may partially replace cement in the mix;

(8) Cement content in pounds per cubic yard of concrete; 

(9) Saturated surface dry batch mass of the coarse and fine aggregate in pounds per cubic yard of 

concrete;

(10) Water content in pounds per cubic yard of concrete; 

(11) Water to cementitious material ratio for modified concrete is the ratio of the mass of water to 

the combined masses of hydraulic cement and cement substitute;

(12) Dosage of admixtures required using the job site material, trial mixtures, and admixture 

manufacturer’s recommendations. Do not combine chemical admixtures together in a mix unless 

they are compatible. Include supporting documentation of compatibility from the manufacturers. 

(a) Air-entraining admixtures. Entrained air may be obtained with air-entraining hydraulic 

cement or air-entraining admixture.

(b) Set accelerating admixtures. Do not use chloride accelerators. Do not use set accelerating 

admixtures in prestressed concrete applications.

(c) Hydration stabilizing admixtures. Hydration stabilizing admixtures may be used to extend 

the allowable delivery time for concrete. Base the dosage on the time needed to delay the initial 

set of the concrete for delivery and discharge on the job. Include the design discharge time 

limit shown in Table 552-3. 

(13) Fine and coarse aggregate quality; 

(14) Sieve analysis of fine and coarse aggregate;

(15) Absorption of fine and coarse aggregate; 

(16) Bulk specific gravity (dry and saturated surface dry) of fine and coarse aggregate;

(17) Dry rodded density of coarse aggregate in pounds per cubic foot; 

(18) Fineness modulus of fine aggregate; 

(19) Material certifications for cementitious material, admixtures, and aggregate;

(20) Target values for concrete slump or slump flow, as appropriate, with and without high-range 

water reducers;
Section 552

464

(21) Target values for concrete air content. Include the proposed range of air content for concrete 

to be incorporated in the work. Describe the methods by which air content will be monitored and 

controlled;

(22) Concrete density; 

(23) Specified design strength and required average strength (f'cr) for the concrete mixture at 

28 days as determined by the process described in Section 4 of ACI 301. This process and 

associated calculations are outlined on Form FHWA 1608, pages 4 and 5. Pending 28-day strength 

results, a mix design may be approved on the basis that 7-day compressive strength results are at 

least 85 percent of the required average strength (f'cr) at 28 days; 

(24) Compressive strengths test results at 7 and 28 days according to Table 552-10, Note (3);

(25) Material samples, if requested;

(26) Fiber samples, if used; 

(27) Integral color admixture, if used. Do not to exceed 10 percent of the weight of the 

cementitious material; and

(28) Strength-maturity relationships, if used, according to AASHTO T 325. 

(b) Internally cured concrete (ICC). Design and produce concrete mixtures that conform to 

Tables 552-1 and 552-2 for the class of concrete specified. Provide aggregate according to the class 

specified, except substitute a portion of the normal weight fine aggregate (on a cubic yard basis) for 

lightweight fine aggregate (LWFA) conforming to AASHTO M 195. 

Determine the quantity of LWFA (lb/yd3

) by the following calculations:

cementitious factor = cementitious content (lb/yd3

) /100 

where:

cementitious content is the inclusion of portland cement and supplementary cementitious materials 

in the submitted concrete mixture;

 

 

Round calculated LWFA quantity to nearest pound per cubic yard. 

Adjust the concrete mix design normal weight fine aggregate quantity after determining the saturated 

surface dry (SSD) volume of the LWFA. Subtract the SSD LWFA volume from the original volume 

of normal weight fine aggregate. Calculate new adjusted SSD weight of normal weight fine aggregate 

on a pound per cubic yard basis. 
Section 552

465

Determine design strength values according to Section 4 of ACI 301. In addition, design structural 

concrete mixes according to the following: 

(1) ACI 211.1, Standard Practice for Selecting Proportions for Normal, Heavy Weight and Mass 

Concrete; and

(2) ACI 211.3, Guide for Selecting Proportions of No-Slump Concrete. 

Submit ICC mix designs according to Subsection 552.03(a). 

(c) Self-consolidating concrete (SCC). Design and produce SCC mixtures that conform to Section 4 

of ACI 301. Provide a maximum water to cementitious material ratio of 0.40. See Table 552-1 for 

minimum compressive strength requirements and air entrainment. Provide maximum coarse aggregate 

size less than or equal to 1 inch. Conform to size number gradation and requirements from AASHTO 

M 43 for coarse aggregates. Blending of standard sizes to optimize gradation is allowed. Design the 

mix to have slump flow according to ASTM C1611, static segregation according to ASTM C1610, 

and passing ability according to ASTM C1621 suitable for the application of SCC.

Submit SCC mix designs according to Subsection 552.03(a). 

(d) Integral color admixture. When an integral color admixture is specified, prepare five 2- by 2-foot 

test panels. Construct the test panels using the proposed mix design. Determine coloring agent batch 

amounts by weight. Use variable quantities of coloring agent as approved. Provide additional mixing 

time according to the manufacturer’s recommendations. Complete a Class 1 finish according to 

Subsection 552.14(a). Cure the test panels similar to the structure. Transport the panels to an approved 

location. Provide at least 2 weeks outside exposure. The CO will select the acceptable test panel. Use 

the same rate of integral color admixture for the item of work.

552.04 Mixing. Use a batching plant, mixer, and agitator conforming to AASHTO M 157. Mix the 

concrete in a central-mix plant or in truck mixers. Operate equipment according to the manufacturer’s 

recommendations. Produce concrete of uniform consistency. 

(a) Batching tolerances. Batch the concrete according to the approved mix design and Table 552-3. 

Table 552-3 

Batching Tolerances

Material Tolerance, 

Percent (±)

Cement 1

Water 1

Aggregate 2

Additive 3

(b) Central-mix plant. Dispense liquid admixtures through a controlled flowmeter. Use dispensers 

with sufficient capacity to measure, at one time, the full quantity of admixture required for each batch. 

If more than one admixture is used, dispense each with separate equipment.

Charge the coarse aggregate, one-third of the water, and all air-entraining admixture into the mixer 

first, then add remainder of the material.
Section 552

466

Mix for at least 50 seconds. Start mixing time after all cement and aggregate are in the drum. Add the 

remaining water during the first quarter of the mixing time. Add 4 seconds to the mixing time if timing 

starts the instant the skip reaches its maximum raised position. Transfer time in multiple-drum mixers 

is included in mixing time. Mixing time ends when the discharge chute opens. 

Remove the contents of an individual mixer before a succeeding batch is charged into the drum. 

(c) Truck mixer. Do not use mixers with blades worn 1 inch or more below the original manufactured 

height. Do not use mixers and agitators with accumulated hard concrete or mortar in the mixing drum.

Add admixtures to the mix according to the manufacturer’s recommendations. 

Charge the batch into the drum so a portion of the mixing water enters before the cement.

Mix each batch of concrete according to AASHTO M 157. 

552.05 Delivery. Produce and deliver concrete to allow a continuous placement with no concrete 

achieving initial set before the remaining concrete being placed adjacent to it. Deliver, handle, and place 

concrete to minimize rehandling of the concrete and prevent damage to the structure. Do not place concrete 

that has developed an initial set or exceeds discharge time limits shown in Table 552-4. Do not re-temper 

concrete by adding water. 

If a hydration stabilizing admixture is approved for use in the concrete mix, deliver and place the concrete 

within the approved design discharge time limit. Limit the slump loss to no more than 2 inches during the 

stabilization period. An approved and compatible hydration activator may be used at the discharge site to 

ensure proper placement and testing.

(a) Truck mixer and agitator. Use the agitating speed for rotation after mixing. When a truck mixer 

or truck agitator is used to transport concrete that is completely mixed in a stationary central 

construction mixer, mix during transportation at the manufacturer’s recommended agitating speed. Do 

not exceed 100 total revolutions at mixing speed, including both initial mixing and remixing. Do not 

exceed 300 total revolutions, including both mixing and agitating speed. 

If the concrete has not obtained an initial set, water and admixtures in the approved mix design may 

be added one time at the project to obtain the required slump or air content. Limit the total of water in 

the mix to not exceed the maximum water to cementitious material ratio of the approved mix design. 

Remix the concrete and added water or admixtures with 30 revolutions at mixing speed. After the 

initial introduction of mixing water to cement or cement to aggregates, complete the remixing within 

the time shown in Table 552-4. After starting the addition of the cement, complete the discharge of 

the concrete within the time shown in Table 552-4. 
Section 552

467

Table 552-4 

Concrete Remixing and Discharge Time Limits

Cement Type(1) Admixtures

Remixing

Time Limit,

hour

Discharge

Time Limit,

hour

Type I, IA, II, IIA, V, or approved

blended hydraulic cement None 0.75 1.00

Type I, IA, II, IIA, V, or approved

blended hydraulic cement

AASHTO M 194,

Type B, D, or G 1.25 1.50

Type I, IA, II, IIA, V, or approved

blended hydraulic cement

Hydration

stabilizer 3.00

Approved design

discharge time limit,

3.50 maximum

Type III None 0.50 0.75

Type III AASHTO M 194,

Type B, D, or G 1.00 1.25

(1) AASHTO M 85 or AASHTO M 240 as applicable. 

(b) Non-agitating equipment. Non-agitating equipment may be used to deliver concrete if the 

concrete discharge is completed within 20 minutes from the starting of the addition of the cement to 

the mixing drum. Use equipment with smooth, mortar tight, metal containers that can discharge the 

concrete at a controlled rate without segregation. Provide covers when needed for protection. 

552.06 Quality Control of Mix. Prevent segregation, contamination, or other harmful effects during 

handling and storage of material. Do not use cement and fly ash containing evidence of moisture 

contamination. Provide aggregate with uniform moisture content at the time of batching.

Submit and follow a QCP according to Section 153 and the following: 

(a) Preparatory phase meeting. Conduct a pre-concrete preparatory phase meeting according to 

Subsection 153.06(a) at least 7 days before the start of structural concrete production operations. 

Include a representative from the QC testing lab. Be prepared to discuss the following: 

(1) Proposed concrete placement schedule;

(2) Approved concrete mix design and determination of batch weights; 

(3) Contractor QC, and the minimum frequency schedule for sampling and testing;

(4) Batching, mixing, placing, and curing requirements; and 

(5) Subsections 106.03, 106.04, and 106.05. 

(b) Mixing. Provide a supplier representative to be responsible for the mixing operations and QC

including: 

(1) Proper storage and handling of components of the mix; 

(2) Proper maintenance and cleanliness of plant, trucks, and other equipment;

(3) Sampling and testing according to Table 552-10; 

(4) Adjusting the mix proportions to maintain the required water to cementitious material ratio;
Section 552

468

(5) Computing batch masses for each day’s production; 

(6) Checking of the plant’s calibration; and 

(7) Completing batch tickets. Include the following:

(a) Concrete supplier;

(b) Ticket serial number;

(c) Date and truck number; 

(d) Contractor;

(e) Structure or location of placement;

(f) Mix-design and concrete class; 

(g) Component quantities and concrete total volume; 

(h) Moisture corrections for aggregate moisture;

(i) Total water in mix at plant;

(j) Time of batching;

(k) Maximum water that may be added to the mix at the project; and

(l) If a hydration stabilizing admixture is used, the slump at the plant after adding the stabilizer.

Provide documentation for Subsections 552.06(b)(3), (4), (5), and (7) as they are completed.

(c) Delivery and discharge. The QCM is responsible for concrete delivery and discharge including: 

(1) Verifying adjustments to the mix comply with the specifications before discharge; and

(2) Completing the batch ticket for each load by recording the apparent water to cementitious 

material ratio and the time.

552.07 Temperature, Weather, and Mass Concrete Conditions. Maintain the temperature of the 

concrete mixture immediately before placement between 50 and 90 °F, except for bridge decks between 

50 and 80 °F.

(a) Cold weather. Cold weather is defined as a period when the following conditions exist for more 

than 3 consecutive days:

(1) Average of the highest and the lowest temperatures occurring during the period from midnight 

to midnight is less than 40 °F; and

(2) Air temperature is not greater than 50 °F for more than one-half of a 24-hour period. 
Section 552

469

When cold weather is expected or has occurred within 7 days of anticipated concrete placement, 

submit a detailed plan for the producing, transporting, placing, protecting, curing, and temperature 

monitoring of concrete during cold weather. For each concrete placement and concrete element type, 

submit a plan for temperature recording device placement. ACI 306, Guide to Cold Weather 

Concreting may be used for guidance in developing the plan. Include procedures for accommodating 

abrupt changes in weather conditions. Allow at least 7 days for review and approval of the plan. Do 

not start placement until the plan is approved. 

Have material and equipment required for protection available at the project before starting cold 

weather concreting.

Remove snow, ice, and frost from the surfaces, including reinforcement and subgrade, against which 

the concrete is to be placed. Heat surfaces that come into contact with fresh concrete to at least 35 °F 

and maintain the temperature of these surfaces at 35 °F or above during concrete placement. 

Place heaters and direct ducts to avoid concrete drying or fire hazards. Vent exhaust flue gases from 

combustion heating units to the outside of enclosures. Do not damage the mix while heating the 

concrete components. Do not heat cement or allow the cement to come into contact with aggregates 

that are hotter than 100 °F. Do not heat aggregates with a direct flame or on sheet metal over fire. Do 

not heat fine aggregate by direct steam. Do not add salts to prevent freezing. 

Use protection measures for at least 7 days as identified in the cold weather plan to meet the 

requirements shown in Table 552-5. 

Provide and place continuously recording surface temperature measuring devices that are accurate 

within ±2 °F. Provide a datalogging device and collect temperature data every 15 minutes in the first 

48 hours and at 1-hour intervals after that for at least 14 days. Verify that data logger and temperature 

sensors are working before starting cold weather concrete placement. Download and submit data daily.

At a minimum, place temperature recording devices at corners and selected surfaces of the concrete 

placement. Install temperature recording devices at a depth of 2 inches from the surface of the 

concrete. For circular cross-sections place at least three surface measuring devices at 120-degree 

intervals. Place two temperature measurement devices at the center of the concrete placement.

Do not exceed a temperature differential of 60 °F during the protection period as measured from the 

center of the placement and a point 2 inches from the surface along the shortest line from the geometric 

center to the nearest surface of the element. Notify the CO if maximum allowable differential is 

exceeded and adjust protection to reduce temperature differential to below 60 °F.

At the end of the protection period, allow the concrete to cool gradually over 24 hours at a rate less 

than the maximum values shown in Table 552-5. Start the cooling process when the average wind 

speed is less than 10 miles per hour as measured 3 feet from the concrete surface. Remove protection 

when the concrete surface temperature is within 25 °F of the ambient air temperature.
Section 552

470

Table 552-5 

Cold Weather Concrete Surface Temperatures

Minimum Section Size

Dimension < 12 inches 12 to < 36 inches 36 to 72 inches > 72 inches

Minimum temperature of concrete 

during protection period 55 °F 50 °F 45 °F 40 °F

Maximum allowable temperature 

drop in a 24-hour period after end

of protection

50 °F 40 °F 30 °F 20 °F

(b) Hot weather. Hot weather is defined as any time during the concrete placement when the ambient 

air temperature at the work site is above 90 °F.

Cool surfaces that come in contact with the mix to below 90 °F by covering with wet burlap or cotton 

mats, fog spraying with water, covering with protective housing, or by other approved methods. 

During placement, maintain concrete temperature by using any combination of the following: 

(1) Shade the material storage areas or production equipment.

(2) Cool aggregate by sprinkling. 

(3) Cool aggregate and water by refrigeration or replacing a portion or all the mix water with flaked 

or crushed ice to the extent that the ice completely melts during mixing of the concrete. 

(c) Evaporation. When placing concrete in bridge decks or other exposed slabs, limit expected 

evaporation rate to less than 0.1 pound per square foot per hour as determined by Figure 552-1. 

When necessary, take one or more of the following actions:

(1) Construct windbreaks or enclosures to effectively reduce the wind velocity throughout the area 

of placement.

(2) Use fog sprayers upwind of the placement operation to effectively increase the relative 

humidity. 

(3) Reduce the temperature of the concrete according to Subsection 552.07(b). 

(d) Precipitation. Protect the concrete from precipitation during and after placement.
Section 552

471

Figure 552-1 

Evaporation Rate of Surface Moisture 

Source: “Plastic Cracking of Concrete.” Engineering Information, National 

Ready Mixed Concrete Association/National Sand and Gravel Association, 

July 1960, 2 pp.

Note: Example shown by dashed lines is for an air temperature of 65 °F, 

relative humidity of 45 percent, concrete temperature of 65 °F, and a wind 

velocity of 15 miles per hour. This results in a rate of evaporation of 

0.13 pounds per square foot per hour.

(e) Mass concrete. Mass concrete is considered any element shown in the plans with a least dimension 

greater than or equal to 4 feet and having a volume to surface ratio (V/S) greater than 1.5 feet.

Provide temperature control of mass concrete to minimize potential cracking and to limit the maximum 

temperature of concrete during the curing process. Provide temperature control according to ACI 

207.1R, Guide to Mass Concrete and ACI 207.4R, Report on Cooling and Insulating Systems for Mass 

Concrete. 

(1) Temperature limitations. Limit the maximum temperature differential between the geometric 

center and a point 2 inches from the nearest surface to the requirements shown in Table 552-6. 

To use this chart:

1. Enter with air 

temperature, move 

up to relative 

humidity.

2. Move right to 

concrete 

temperature. 

3. Move down to 

wind velocity.

4. Move left, read 

approximate rate of 

evaporation. 
Section 552

472

Table 552-6 

Maximum Temperature Differential During Curing Period

Curing Period Maximum Temperature Differential

Less than 48 hours 40 °F

Next 2 to 7 days 50 °F

Next 8 to 14 days 60 °F

Maintain these temperature conditions from time of concrete placement until all interior concrete 

temperatures are decreasing. Do not allow surface mounted temperature sensors to measure 

differential temperatures.

Do not remove protection until the temperature difference between the geometric center of the mass 

and forecasted low ambient temperature in the next 48 hours is less than 60 °F.

Do not exceed 160 °F for the maximum peak curing temperature.

(2) Temperature control. Control the maximum temperature and temperature differentials in the 

mass concrete according to the following:

(a) Submittals. Submit a mass concrete placement and curing plan for approval at least 14 days 

before the scheduled concrete placement for a particular mass concrete element. Include the 

following information in the plan:

(1) A heat generation analysis for the geometry of each mass concrete element according 

to ACI 207.2R, Report on Thermal and Volume Change Effects on Cracking of Mass 

Concrete. Determine the predicted concrete temperature at the center and 2 inches inside 

of the exterior surface exposed to air for a time period until all concrete temperatures are 

decreasing and the maximum temperature differential has been reached and starts to 

decrease, and estimate the protection period. Perform analyses for the anticipated mean 

weekly ambient or enclosure air temperatures for the period of the proposed placement, 

and for temperatures ±10 °F of the mean weekly ambient air temperature;

(2) Models developed for thermal dissipation analyses (such as the Schmidt method 

according to ACI 207.1R) with the site and element specific input data, output, and results;

(3) Placement and curing methods indicating how temperature controls are to be achieved; 

and 

(4) Proposed changes to the approved concrete mix design. 

(b) Temperature monitoring. Provide temperature monitoring devices to record temperature 

development between the interior and the exterior of the element at points shown in the 

approved mass concrete placement and curing plan. Monitor at least two independent sets of 

interior and exterior points for each element to provide redundancy in case of device failure. 

Locate monitoring points at the geometric center and a point 2 inches to the nearest surface of 

the element for the exterior point.

Use automatic sensing and monitoring devices that record information at a maximum interval 

of one hour. Provide devices that operate within a temperature range of 0 to 180 °F with an 

accuracy of ±2 °F. Take readings and record data at intervals less than six hours to ensure that 
Section 552

473

the automatic devices are working properly and that the temperatures are within allowable 

limits. Start the intervals of one and six hours immediately after placing is complete and 

continue until 24 hours after the following:

(1) Maximum temperature differential is reached and starts to drop;

(2) Maximum peak curing temperature is reached and starts to drop; and 

(3) Curing is complete and protection is removed. 

Submit temperature readings to the CO daily.

If monitoring indicates the maximum temperature differential or curing temperature will, or 

has exceeded the temperature requirements, take immediate action to retard further increase in 

temperatures. Make necessary revisions to the approved plan to not exceed the maximum 

differential and curing temperatures on remaining placements. Submit revisions to the mass 

concrete placement and curing plan for approval before implementation.

(3) Crack repair. Submit a crack repair plan for approval.

Repair mass concrete cracks between 0.010 and 0.060 inch in width according to Section 561. 

Evaluate mass concrete cracks greater than 0.060 inch in width to determine whether the cracks 

compromise the structure. Submit findings and proposed corrective work for approval. 

Do not repair cracks until all concrete cooling operations are completed. 

552.08 Handling and Placing Concrete. Handle, place, and consolidate concrete by methods that do not 

cause segregation and will result in dense homogeneous concrete that is free of voids and rock pockets. 

Construct reinforcing steel according to Section 554. Do not displace reinforcing steel or other material 

that is to be embedded in the concrete during concrete placement. Do not retemper concrete by adding 

water to the mix. Use temporary form spreader devices as appropriate.

Place concrete continuously between planned construction or expansion joints. Control the delivery rate, 

placing sequence, and construction methods to ensure fresh concrete is placed and consolidated against 

previously placed pre-initial set concrete. Do not allow time between the placement of successive batches 

to exceed 30 minutes. 

Do not damage previously placed concrete or break the bond between the concrete and reinforcing steel. 

Keep workers off fresh concrete. Do not support platforms for workers and equipment directly on 

reinforcing steel. Once the concrete is set, do not disturb the forms or reinforcing bars that project from 

the concrete until it is of sufficient strength to resist damage.

Remove and replace concrete represented by cylinders having a compressive strength less than 90 percent 

of the minimum 28-day strength (f'c).

Design and construct temporary works according to Section 562. Remove mortar, debris, and foreign 

material from the forms and reinforcing steel. Do not place concrete until the forms, embedded material, 

and the adequacy of the foundation material have been inspected. Uniformly moisten the forms and 
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474

subgrade immediately before concrete is placed against them. Use an approved form release agent to 

produce a minimum of staining, air holes, and hydration discoloration. 

(a) Sequence of placement. For strength determination, use either AASHTO T 22 or T 325. 

(1) Substructures. Do not place loads on substructure elements including foundations, bents, 

piers, or abutments until concrete cylinder tests from the same concrete cured under the same 

conditions as the substructure element indicate that the concrete has at least 80 percent of its 

required 28-day compressive strength.

(2) Vertical members. For vertical members less than 15 feet in height, allow the concrete to set 

for at least 30 minutes before placing integral horizontal members. For vertical members 15 feet 

or greater in height, allow the concrete to set for at least 12 hours. Do not transfer loads from 

horizontal members until the concrete has attained the specified strength and has been in place at 

least 7 days. 

Do not mount friction collars or falsework brackets on vertical members until the concrete has 

cured for at least 7 days or has attained the specified strength. 

(3) Superstructures. Strip substructure forms and inspect concrete for defects before placing 

superstructure concrete.

For concrete placed in T-beams or deck girders with depths greater than 48 inches, allow 5 days 

cure time for the stem concrete before placing the top or deck slab. 

For box girders, do not place the top slab until the stems have 5 days cure time.

(4) Arches. Place concrete for arches in alternate lateral sections to minimize shrinkage stresses. 

Consider deflections of the arch centering. Place other sections symmetrically with respect to the 

center of the bridge span. Where wide barrel arches require a longitudinal joint, place concrete on 

each side of the joint independently of the centering to avoid relative settlements. Bond the sections 

together using suitable keys or dowels. 

(5) Box culverts. Place the box culvert base slab and allow 24 hours before constructing the 

remainder of the culvert.

(b) Placing methods. Use equipment of sufficient capacity that is designed and operated to prevent 

mix segregation and mortar loss. Do not use equipment that causes vibrations that could damage the 

freshly placed concrete. Do not use equipment with aluminum parts that come in contact with the 

concrete. Remove set or dried mortar from inside surfaces of placing equipment.

Place concrete as close as possible to its final position. Consolidate concrete in horizontal layers 

greater than 18 inches thick. Do not exceed the vibrator capacity to consolidate and merge the new 

layer with the previous layer. Do not place concrete at a rate that exceeds the design loading of the 

forms.

Do not drop unconfined concrete more than 5 feet. Concrete may be confined by using a tube fitted 

with a hopper head or other approved devices that prevent mix segregation and mortar spattering. This 

does not apply to cast-in-place piling or drilled shaft when concrete placement is completed before 

initial set occurs in the bottom of the piling.
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Operate concrete pumps so that a continuous stream of concrete without air pockets is delivered at the 

tube discharge. 

(c) Consolidation. Provide sufficient hand-held internal concrete vibrators or mechanical vibrator 

gangs suitable for the conditions of concrete placement. Use vibrators conforming to Table 552-7. 

Provide rubber-coated vibrators when epoxy-coated reinforcement is used.

Provide a spare vibrator on site in case of breakdown. Use external form vibrators only if the forms 

have been designed for external vibration and if internal vibration is not possible.

Table 552-7 

Hand-held Vibratory Requirements

Head Diameter, inch Frequency,

vibrations/minute Radius of Action, inch

3⁄4 to 11⁄2 9000 to 15,000 3 to 6

11⁄4 to 21⁄2 8500 to 12,500 5 to 10

2 to 31⁄2 8000 to 12,000 7 to 14

Consolidate concrete by mechanical vibration immediately after placement. Manipulate vibrators to 

thoroughly work the concrete around reinforcement, embedded fixtures, corners, and angles in the 

forms. Do not cause segregation. Do not consolidate concrete placed under water. Supplement 

vibration with spading, as necessary, to ensure smooth surfaces and dense concrete along form 

surfaces, in corners, and at locations impossible to reach with the vibrators.

Vibrate the concrete at the point of deposit and at uniformly spaced points not farther apart than one 

and one-half times the radius over which the vibration is visibly effective. Insert vibrators so that the 

affected vibrated areas overlap. Do not use vibrators to move concrete. Insert vibrators vertically and 

slowly withdraw from the concrete. Vibrate with sufficient duration and intensity to thoroughly 

consolidate the concrete, but not to cause segregation. Do not vibrate at one point long enough to cause 

localized areas of grout to form. Do not vibrate reinforcement. 

Mechanical vibration or consolidation is not required for SCC.

(d) Underwater placement. Underwater placement of concrete is allowed only for concrete mixtures 

designed for underwater placement according to Subsection 552.03. Use tremies, concrete pumps, or 

other approved methods for placement. 

(1) Tremies. Use watertight tremies, with a diameter sufficient to ensure that aggregate-induced 

blockages will not occur. Use multiple tremies as required. Make tremies that can be rapidly 

lowered to slow or stop the flow of concrete. 

Seal the discharge end and fill the tremie tube with concrete at the start of concrete placement. 

Keep the tremie tube full of concrete to the bottom during placement. If water enters the tube, 

withdraw the tremie and reseal the discharge end. Maintain continuous concrete flow until the 

placement is completed.

(2) Concrete pumps. Use pumps with a device at the end of the discharge tube to seal out water 

while the tube is first being filled with concrete. When concrete flow is started, keep the end of the 
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discharge tube full of concrete and below the surface of the deposited concrete until placement has 

been completed. 

Place underwater concrete continuously from start to finish in a dense mass. Place each succeeding 

layer of concrete before the preceding layer has taken initial set using more than one tremie or pump 

if necessary. Keep the concrete surface as horizontal as practical. Do not disturb after placement. 

Maintain still water at the point of deposit.

Dewater after test specimens cured under similar conditions indicate that the concrete has sufficient 

strength to resist the expected loads. Remove laitance or other unsatisfactory material from the 

exposed concrete.

(e) Concrete railings and parapets. Use smooth, tight-fitting, rigid forms. Neatly miter corners. 

Place concrete railings and parapets after the falsework for the supporting span is released. Remove 

forms without damaging the concrete. Finish corners to be true, clean-cut, and without cracks, spalls, 

or other defects.

552.09 Construction Joints. Place construction joints at locations shown in the plans. Obtain approval 

for additional construction joints. 

Extend reinforcing steel uninterrupted through construction joints. Embed lap splices or mechanical 

splices within the concrete. Do not use dowels. At horizontal construction joints, place gauge strips inside 

the forms along exposed faces to produce straight joint lines. 

When the joint is between fresh and newly hardened concrete, rough float the first placement to thoroughly 

consolidate the surface and leave the surface in a roughened condition. Clean the joint surface of laitance, 

curing compound, and other foreign material. Use an abrasive blast or other approved methods to expose 

the aggregate on the joint surface. Re-tighten forms where the joint overlaps the first placement. 

Immediately before placing new concrete, flush the joint surface with water and allow it to dry to a surface 

dry condition. 

When the joint is between existing concrete and a new placement, abrasive blast clean or use other 

approved methods to remove laitance and foreign material, to expose clean aggregate, and to roughen the 

joint surface. Before concrete placement, apply approved bonding products to the joint surface according 

to the manufacturer’s recommendations.

552.10 Expansion and Contraction Joints. 

(a) Open joints. Form open joints with a wooden strip, metal plate, or other approved material. 

Remove the joint forming material without chipping or breaking the corners of the concrete. Do not 

extend reinforcement across an open joint. 

(b) Filled joints. Cut pre-molded expansion joint filler to the shape and size of the surface being 

jointed. Secure the joint filler on one surface of the joint using galvanized nails or other approved 

means. Splice according to the manufacturer’s recommendations. After form removal, remove and 

neatly cut concrete or mortar that has sealed across the joint. Fill joint gaps 1⁄8 inch or wider with 

approved filler. Place necessary dowels, load transfer devices, and other devices as shown in the plans 

or as directed. 
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477

(c) Steel joints. Fabricate plates, angles, or other structural shapes accurately to conform to the 

concrete surface. Submit proposed joint opening to ensure optimal joint operation for the ambient 

temperature at the time of placement for approval. Securely fasten the joints to keep them in the correct 

position. Maintain an unobstructed joint opening during concrete placement. 

(d) Compression joint seals. Use one-piece compression joint seals for transverse joints and the 

longest practical length for longitudinal joints. Clean and dry joints and remove spalls and 

irregularities. Apply a lubricant adhesive as a covering film to both sides of the seal immediately 

before installation. Compress the seal and place it in the joint according to the manufacturer’s 

recommendations. Ensure the seal is in full contact with the joint walls throughout its length. 

Remove and discard seals that are twisted, curled, nicked, or improperly formed. Remove and reinstall 

joint seals that elongate more than 5 percent of their original length when compressed. Remove excess 

lubricant-adhesive before it dries.

(e) Elastomeric expansion joint seal. Install the joint according to the manufacturer’s 

recommendations and as shown in the plans. 

(f) Asphaltic plug joint. Install the joint according to the manufacturer’s recommendations and as 

shown in the plans. 

552.11 Watertight Integrity Test. After completion of each expansion joint within the limits of the 

bridge, perform a watertight integrity test on the top surface to detect leakage. Notify the CO 5 working 

days before performing watertight integrity test. For each joint, perform the watertight integrity test and 

inspection in the presence of the CO. 

Cover the entire joint system with either water ponded to a depth of at least 1 inch or continuously flowing 

water directly over full plan area of joint for at least 4 hours. Inspect the underside of the joints for evidence 

of dripping water or moisture for the duration of water application and for 2 hours after water supply is 

removed. 

The joint system is considered watertight when no free dripping water or moisture on underdeck surfaces 

beneath and adjacent to the joint is observed. Before performing the test, submit a detailed procedure for 

the watertight integrity test for approval. Submit photographic documentation performing the watertight 

integrity test. Include date, time, and location of joint inspections. 

If the joint system leaks, locate the place of leakage and perform repair measures necessary to stop the 

leakage according to the manufacturer’s recommendations.

After repair measures to eliminate leakage are taken, perform a subsequent water integrity test subject to 

the same conditions as the original test until watertight integrity results show no dripping water or 

moisture. Subsequent tests carry the same responsibility as the original test.

552.12 Finishing Plastic Concrete. Strike off concrete surfaces that are not placed against forms. Float 

finish the concrete surface. Remove laitance or thin grout. Carefully tool non-chamfered edges with an 

edger. Leave edges of joint filler exposed.

Protect the surface from precipitation damage.
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Provide at least two non-sagging and non-vibrating work bridges that can support the workers and 

equipment during placement, finishing, and curing operations. Place the work bridges at a reasonable 

height above the concrete surface to not impede worker performance and not touch the finished or fresh 

concrete surface.

(a) Striking off and floating. For bridge decks or top slabs of structures serving as finished 

pavements, use an approved power-driven finishing machine equipped with a screed that oscillates in 

a transverse direction. A power-screed or roller-screed is not allowed. Use hand-finishing methods for 

irregular areas if approved.

Strike off surfaces. Do not support rails within the limits of the concrete placement without approval.

Set rails or headers on non-yielding supports so the finishing equipment operates without interruption 

over entire surface being finished. Extend rails beyond both ends of the scheduled concrete placement 

a sufficient distance to enable finishing machine to finish the concrete being placed.

Set rails the entire length of continuous girder structures before placing deck concrete. 

Adjust rails, headers, and strike-off equipment to the required profile and cross-section allowing for 

anticipated settlement, camber, and deflection of falsework.

At least 1 day before starting delivery and placement of concrete, operate the finishing machine over 

the entire area to be finished to check for excessive rail deflections, deck thickness, reinforcing steel 

cover, and to verify proper operation of equipment. Make necessary corrections before concrete 

placement starts.

After placing the concrete, operate finishing machine over the concrete as needed to obtain the required 

profile and cross-section. Always keep a slight roll of excess concrete in front of the cutting edge of 

the screed. Maintain this excess of concrete to the end of the pour or form and then remove and waste 

it. Adjust rails or headers as necessary to correct for unanticipated settlement or deflection.

Remove rail supports embedded in the concrete to at least 2 inches below the finished surface. Clean 

the voids of dust and debris using compressed air or other means. Apply approved bonding material 

in the voids. Fill the voids with fresh concrete of the same type and property as previously placed. 

Finish the surface with a float, roller, or other approved devices as necessary to remove local 

irregularities.

Remove excess water, laitance, and foreign material brought to the surface using a squeegee or 

straightedge drawn from the center of the slab towards each edge. Do not apply water to the surface 

of the concrete during finishing operations. 

(b) Straightedge measurement. Check horizontal surfaces with a 10-foot metal straightedge. Check 

the entire surface parallel to the centerline of the bridge. Overlap the straightedge at least one-half of 

the length of the previous straightedge placement. 

Correct deviations more than 1⁄8 inch from the testing edge of the straightedge. For deck surfaces that 

are to receive an overlay, correct deviations more than 1⁄4 inch.
Section 552

479

(c) Texturing. Finish after floating or at a time when finishing operations will not displace aggregate. 

Produce a skid-resistant surface texture on driving surfaces by grooving. Use one of the following or 

a combination for other surfaces as required. 

(1) Grooved finish. Use a float having a single row of fins. Space fins 1⁄2 to 3⁄4 inch on centers. 

Make the grooves 1⁄16 to 3⁄16 inch wide and 1⁄8 to 3⁄16 inch deep. Groove perpendicular to the centerline 

without tearing the concrete surface or loosening surface aggregate. 

On bridge decks, discontinue grooving 12 inches from curb face and provide a longitudinal 

troweled finish on the surface of gutters.

(2) Sidewalk finish. Strike off the surface using a strike board and then float the surface. Use an 

edging tool on edges and expansion joints. Broom the surface using a broom with stiff bristles, 

broom perpendicular to the centerline from edge to edge with adjacent strokes slightly overlapped. 

Produce regular corrugations not over 1⁄8 inch in depth without tearing the concrete. Correct porous 

spots, irregularities, depressions, small pockets, and rough spots while the concrete is plastic. 

Groove contraction joints at the required interval using an approved grooving tool. 

(3) Troweled and brushed finish. Use a steel trowel to produce a slick, smooth surface free of 

bleed water. Brush the surface with a fine brush using parallel strokes.

(4) Exposed aggregate finish. Strike off the surface using a strike board and then float the surface. 

Use an edging tool on transverse and longitudinal joints that are against forms or existing 

pavement. Do not edge transverse joints in a continuous lane pour or longitudinal joints in a 

continuous dual lane pour. 

Broom the surface as soon as the concrete hardens sufficiently to prevent particles of gravel from 

being dislodged. Use approved stiff brushes. Exercise care to prevent marring the surface and 

cracking or chipping of slab edges or joints. Apply a light spray of retardant to the unfinished 

surface to facilitate this work, if approved.

Broom transversely across the pavement. Pull the loosened semi-stiff mortar off the pavement. 

Remove the mortar from adjacent pavements. Then broom parallel to the pavement centerline. 

Continue this operation until coarse aggregate is exposed. Other methods of aggregate exposure, 

such as using a water spray attachment on a special exposed aggregate broom, will be allowed if 

satisfactory results are demonstrated.

After curing according to Subsection 552.13(b) or (c), wash the surface with water and brush to 

remove laitance and cement from the exposed coarse aggregate.

(d) Surface underneath bearings. Finish bearing surfaces to within 1⁄8 inch of plan elevation.

If a masonry plate is to be set directly on the concrete or on filler material less than 1⁄8 inch thick, finish 

the surface with a float to an elevation slightly above plan elevation. Grind the surface as necessary to 

provide a full and even bearing after the concrete has set.

If a masonry plate is to be set on filler material between 1⁄8 and 1⁄2 inch thick, finish the surface with a 

steel trowel. Finish or grind the surface so that it does not vary from a straightedge in any direction by 

more than 1⁄4 inch. 
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480

If a masonry plate is to be set on filler material greater than 1⁄2 inch thick or when an elastomeric 

bearing pad is to be used; finish the surface to a plane surface free of ridges.

(e) Surface underneath waterproofing membrane deck seal. Finish to a smooth surface, free of 

ridges and other projections. 

552.13 Curing Concrete. Start curing immediately after the free surface water has evaporated and the 

finishing is complete. If the surface of the concrete starts to dry before the selected cure method can be 

implemented, keep concrete surface moist using a fog spray without damaging the surface. 

Keep surfaces to be rubbed moist after forms are removed. Cure immediately following the first rub.

Cure the top surfaces of bridge decks using the liquid membrane curing compound method combined with 

the water method. Apply liquid membrane curing compound immediately after finishing. Apply the water 

cure within 4 hours after finishing. 

Cure concrete uninterrupted for at least 7 days. If pozzolans more than 10 percent by mass of the hydraulic 

cement are used in the mix, cure uninterrupted for at least 10 days.

(a) Forms in-place method. For formed surfaces, leave the forms in-place without loosening. If forms 

are removed during the curing period to facilitate rubbing, only strip forms from those areas able to 

be rubbed during the same shift. During rubbing, keep the surface of the exposed concrete moist. After 

the rubbing is complete, continue curing process using the water method for the remainder of the 

curing period. 

(b) Water method. Keep the concrete surface continuously wet by ponding, spraying, or covering 

with material that is kept continuously and thoroughly wet. Covering material may consist of cotton 

mats, multiple layers of burlap, or other approved material that does not discolor or otherwise damage 

the concrete.

Cover the covering material with a waterproof sheet material that prevents moisture loss from the 

concrete. Use the widest sheets practical. Lap adjacent sheets at least 6 inches, and tightly seal seams 

with pressure sensitive tape, mastic, glue, or other approved methods. Secure material so that wind 

does not displace it. Immediately repair sheets that are broken or damaged. 

(c) Liquid membrane curing compound method. Do not use the liquid membrane method on 

surfaces to receive a rubbed finish. Use on construction joint surfaces is allowed only if the compound 

is removed by sandblasting before placement of concrete against the joint. 

Only use Type 2, white-pigmented liquid membrane on the top surfaces of bridge decks or on surfaces 

not exposed to view in the completed work. Use Type 1-D, clear curing compounds, on other surfaces 

and on colored concrete. 

Mix membrane curing solutions containing pigments before use. Continue to agitate during 

application. Use equipment that can produce a fine spray. Apply the curing compound at a minimum 

rate of 1 gallon per 150 square feet in one or two uniform applications. If the solution is applied in 

two applications, follow the first application with the second application within 30 minutes, and apply 

at right angles to the first application.
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Immediately apply a new coat over the damaged areas if the membrane is damaged by precipitation 

or other means during the curing period. 

552.14 Finishing Formed and Deck Concrete Surfaces. Before finishing, remove and replace or repair 

rock pockets or honeycombed concrete, as approved. Refinish concrete surfaces exposed to view that have 

become streaked or unsightly according to the appropriate class. Finish sound, formed concrete surfaces 

as follows:

(a) Class 1 – Ordinary surface finish. Finish the following surfaces with a Class 1, ordinary surface 

finish:

(1) Under surfaces of slab spans, box girders, filled spandrel arch spans, and the roadway deck 

slab between superstructure girders;

(2) Interior vertical surface or T-girders of superstructures; and

(3) Surfaces to be buried and culvert surfaces above finished ground that are not visible from the 

traveled way or a walkway. 

Start finishing as soon as the forms are removed. Remove fins and irregular projections from surfaces 

that are exposed or will be waterproofed. Remove bulges and offsets with carborundum stones or 

discs. Remove localized, poorly-bonded rock pockets or honeycombed concrete, and replace with 

sound concrete or packed mortar in an approved manner. Fill holes using a mortar composed of cement 

and fine sand from the approved mix design and mixed in the same proportions as the concrete being 

finished. Float to an even, uniform finish. A bonding agent may be used with approval. 

Clean and point form tie cavities, holes, broken corners and edges, and other defects. Saturate the area 

with water. Finish the area with mortar that is less than 1-hour old. After the mortar is set, rub it if 

required, and continue curing. Match exposed surfaces to surrounding concrete. 

Carefully tool and remove free mortar and concrete from construction and expansion joints. Leave 

joint filler exposed for its full length with clean, true edges.

Rub or grind bearing surfaces on piers and abutments to the specified elevation and slope. 

If the final finished surface is not true and uniform, rub the surface according to Subsection 552.14(b). 

(b) Class 2 – Rubbed finish. Finish the following surfaces with a Class 2, rubbed finish: 

(1) Surfaces of bridge superstructures, except those surfaces designated to receive another finish;

(2) Surfaces of bridge piers, piles, columns and abutments, and retaining walls above finished 

ground and to at least 12 inches below finished ground; 

(3) Surfaces of open spandrel arch rings, spandrel columns, and abutment towers; 

(4) Surfaces of pedestrian undercrossings, except floors and surfaces to be covered with earth;

(5) Surfaces of culvert headwalls and endwalls that are above the finished ground and visible from 

the traveled way or walkway; 
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482

(6) Inside surfaces of culvert barrels higher than 48 inches that are visible from the traveled way. 

Finish for a distance inside the barrel at least equal to the height of the culvert; and

(7) Surfaces of railings.

Finish according to Subsection 552.14(a). 

Thoroughly wash the surface of the concrete with water. 

Apply mortar composed of cement and fine sand from the approved mix design and mixed in the same 

proportions as the concrete being finished. Apply mortar that can be finished in the same day. 

Rub the mortar with burlap or a piece of carpet as soon as it takes initial set. If the mortar has attained

final set, then rub the surface with a carborundum stone and water until form marks, projections, and 

irregularities are removed. Grinding is not allowed.

Fog-spray water over the finish as soon as the mortar has attained final set. Keep the surface damp for 

at least 2 days. 

Leave a uniform surface without unsound patches, paste, powder, and objectionable marks. Continue 

to apply a Class 2 rubbed finish until the entire surface has a smooth texture and uniform color. 

(c) Class 3 – Tooled finish. Finish according to Subsection 552.14(a). Do not use mortar blocks or 

wires to set reinforcing steel near the formed surface of areas to receive a tooled finish. Let the concrete 

set for 14 days or longer if necessary to prevent the aggregate particles from being picked out of the 

surface. Produce a tooled finish using pneumatic power tools. Chip away the surface mortar and break 

the aggregate particles to expose a grouping of broken aggregate particles in a matrix of mortar. 

Produce a tooled finish on a small test area for approval before proceeding. Adjust the work procedures 

to produce a satisfactory finish and use the same procedures to finish the designated area.

(d) Class 4 – Sandblasted finish. Finish according to Subsection 552.14(a). Let the concrete cure for 

at least 14 days. Protect adjacent surfaces that are not to be sandblasted. Sandblast a small test area for 

approval before proceeding. Use hard, sharp sand to produce an even fine-grained surface in which 

the mortar is cut away leaving the aggregate exposed. Do not remove mortar beyond one-third the 

diameter of the coarse aggregate.

(e) Class 5 – Wire brushed or scrubbed finish. Finish according to Subsection 552.14(a). Start as 

soon as the forms are removed. Scrub the surface with stiff wire or fiber brushes using a solution of 

muriatic acid. Mix the solution in the proportion of 1 part acid to 4 parts water. Scrub until the cement 

film or surface is completely removed and the aggregate particles are exposed. Leave an evenly 

pebbled texture having the appearance of fine granite to coarse conglomerate depending upon the size 

and grading of aggregate. Wash the entire surface with water containing a small quantity of ammonia.

(f) Class 6 – Penetrating stain. Build at least three 2- by 2-foot concrete color sample panels with 

varying shades of color. Use concrete from the approved mix design. After the test panels have had at 

least 2 weeks of outside exposure, the CO will select a test panel to serve as a guide for the colored 

finish. Preserve the approved color sample panel. Color designated surfaces to match the color of the 

approved sample. 
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483

Complete the designated finish. Do not apply the stain finish until concrete placement for the structure 

is complete. Remove dust, foreign matter, form oil, grease, and curing compound with a 5 percent 

solution of trisodium phosphate and rinse the concrete surface with clean water.

Use paper, cloth, or other means to protect surfaces not to be stain finished. Apply the finish to a dry 

concrete surface when the surface temperature is 40 °F or higher and the air temperature in the shade 

is anticipated to be 40 °F or higher during the 24 hours following application. 

Apply the stain finish according to the manufacturer’s recommendations. Spray, brush, or roll on the 

first coat of penetrating sealer and stain base. Spray, brush, or roll on the finish coat after the first coat 

has thoroughly dried. Apply finish to provide a uniform, permanent stain, without runs and sags to the 

surfaces.

Remove stain from areas not intended to be covered by the finish using an approved method. 

(g) Class 7 – Grooved finish. Texture the riding surfaces by mechanical grooving. Cut grooves into 

the hardened concrete using a mechanical water-cooled diamond edge blade saw device which 

produces straight, uniformly spaced grooves at 3⁄4-inch intervals. Provide a groove width of 1⁄8 inch 

±0.02 inch and a groove depth of 1⁄8 inch plus 1⁄16 inch or minus zero inch. Apply grooved finish after 

defects to riding surfaces have been corrected.

552.15 Concrete Anchorage Devices. Use chemical, grouted, or cast-in-place concrete anchorage devices 

for attaching equipment or fixtures to concrete.

Provide the following for approval:

(a) Concrete anchorage device sample; 

(b) Manufacturer’s installation instructions; and

(c) Material data and certifications.

Fabricate metal parts of the anchorage devices from stainless steel or from steel protected with a corrosion 

resistant metallic coating that does not react chemically with concrete. Provide anchorage devices 

complete with hardware. 

For chemical or grouted anchors, conduct a system approval test on one anchor on the project, not to be 

incorporated in the work. Conduct a static load test according to ASTM E488. Demonstrate that the 

anchorage device can withstand a sustained direct tension test load according to Table 552-8 for at least 

48 hours with movement no more than 1⁄32 inch. Demonstrate that when loaded to failure the anchor device 

demonstrates a ductile failure of the anchor steel, not a failure of the chemical, grout, or concrete.
Section 552

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Table 552-8 

Sustained Load Test Values

Anchorage Device

Stud Size, inch

Tension Test

Load, pound

3⁄4 5000

5⁄8 4100

1⁄2 3200

3⁄8 2100

Install concrete anchorage devices according to the manufacturer’s recommendations and so that the 

attached equipment or fixtures bear firmly against the concrete. Torque installed nuts to the values shown 

in Table 552-9 unless otherwise specified in the manufacturer’s recommendations. Set bearing anchor 

bolts according to Subsection 564.09. 

In the presence of the CO, proof load a random sample of at least 10 percent of the anchors to 90 percent 

of the yield stress of the steel. If an anchor fails, reset the failed anchor and proof load the reset anchor 

and 100 percent of remaining anchors. The proof load may be applied by torquing against a load indicator 

washer, applying a direct tension load to the anchor, or another approved method. After proof loading, 

release the load on the anchor and retighten the nuts to the torque shown in Table 552-9 or according to 

the manufacturer’s recommendations.

Table 552-9 

Torque for Anchorage Devices

Anchorage Device

Stud Diameter, inch

Torque, 

foot-pound

3⁄4 125

5⁄8 90

1⁄2 60

3⁄8 35

552.16 Loads on New Concrete Structures. Do not allow traffic on concrete approach slabs and bridge 

decks until concrete has attained the design compressive strength and has been in place 14 days or longer. 

Construction loads less than 4000 pounds may be placed on the approach slab or deck 7 days after the 

concrete is placed and the concrete in the entire span has attained a compressive strength of at least 

70 percent of the specified design strength. 

For precast concrete multi-beam sections, do not allow vehicles on any span until the grout has attained a 

strength of 3000 pounds per square inch and tie rods have been tightened.

For post-tensioned concrete structures, do not allow vehicles over 4500 pounds on any span until the 

prestressing steel for that span is tensioned, grouted, and cured; the grout has obtained a strength of 

3000 pounds per square inch; and the tie rods are tightened. Vehicles weighing less than 4500 pounds may 

be allowed on a span if the mass of the vehicle was included in the falsework design. 

552.17 Geocomposite Sheet Drain System and Weep Hole System. Place geocomposite sheet drain 

system and weep hole system according to Section 605. 
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485

552.18 Acceptance. See Table 552-10 for sampling, testing, and acceptance requirements. 

Material for concrete will be evaluated under Subsections 106.02 and 106.03. Provide production 

certifications with each shipment of cementitious material.

The concrete mixture’s slump, air content, density, and temperature will be evaluated under 

Subsections 106.02 and 106.04. 

Concrete compressive strength will be evaluated under Subsection 106.05. The lower specification limit 

is the minimum required compressive strength at 28 days (f'c) specified.

Construction of concrete structures will be evaluated under Subsections 106.02 and 106.04. 

Concrete crack repair will be evaluated under Section 561. 

Geocomposite sheet drain systems and weep hole systems will be evaluated under Section 605. 

Reinforcing steel will be evaluated under Section 554. 

Temporary works will be evaluated under Section 562. 

Measurement

552.19 Measure the Section 552 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring structural concrete by the cubic yard, measure in the structure. 

Do not measure the volume of concrete required, outside the neat lines of a footing, to pour against rock 

as shown in the plans. 

Do not measure concrete for precast and prestressed concrete structural members.

Payment

552.20 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 552 pay items listed in the bid schedule, except the structural concrete contract price will be 

adjusted according to Subsection 106.05. Payment will be full compensation for the work prescribed in 

this Section. See Subsection 109.05. Payment for structural concrete will be made at a price determined 

by multiplying the contract price by the compressive strength pay factor. 
Table 552-10 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

(fine & 

coarse)

Measured &

tested for

conformance

(106.04 & 

105) 

Quality −

Subsections

703.01 & 

703.02

1 per

material

type

Source of

material Yes Beforeproducing −

Mix Design

Concrete

composition

Measured &

tested for

conformance

(106.04) 

All − Subsection

552.03

1 per

mix

design

Source of

material

If

requested

Before

producing −

Production

Produced

aggregate

(fine & 

coarse)

Process 

control

(153.03) 

Gradation − AASHTO

T 27 & T 11

1 per

day

Flowing

aggregate

stream

(bin, belt,

discharge

conveyor 

belt,

or stockpile)

Yes Before

batching −

Fineness

modulus − AASHTOT 27 − " " " −

Moisture test − AASHTO

T 255 − " " " −
Table 552-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Concrete

(552.03)

(1)

Process 

control

(153.03) 

Density − AASHTO

T 121

1 per load 

after 

0.25 yd3

minimum is 

discharged(4)

Point of

discharge at 

truck

No

Upon

completing

tests

−

Air content −

AASHTO

T 152 or

T 196

" " " " −

Slump(5) − AASHTO

T 119 " " " " −

Slump flow(6) − ASTM

C1611 " " " " For SCC mixes only

Temperature − ASTM

C1064 " " " " −

Concrete

(552.03)

(1)

Measured &

tested for

conformance

(106.04) 

Density − AASHTO

T 121

1 per load 

after 

0.25 yd3

minimum is 

discharged(4)

Discharge

at

point of

placement

No

Upon

completing

tests

−

Air content −

AASHTO

T 152 or

T 196

" " " " −

Slump(5) − AASHTO

T 119 " " " " −

Slump flow(6) − ASTM

C1611 " " " " For SCC mixes only

Temperature − ASTM

C1064 " " " " −
Table 552-10 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Concrete

(552.03)

(1)

Statistical

(106.05) 

Compressive

Strength(2),(3)

(28-day)

II AASHTO

R 100 & T 22

1 set per

30 yd3

but not less 

than

1 per day & 

at least

5 sets total

Discharge

stream at

point of

placement

Yes 28 days

Deliver

verification

cylinders to

the CO or

designated

laboratory

for 

scheduled 

testing

(1) Sample according to AASHTO R 60, except composite samples are not required.

(2) Cast at least four compressive strength test cylinders for 6- by 12-inch specimens or six compressive strength cylinders for 4- by 8-inch 

specimens and transport the cylinders to the job site curing facility.

(3) A single compressive strength test result is the average result from two 6- by 12-inch or three 4- by 8-inch cylinders cast from the same load.

(4) If three successive samples are tested and compliance with the specifications is indicated, screening tests may be reduced to an approved 

frequency. Resume testing frequency if a test shows a failing temperature, air content, or slump, or if directed.

(5) If a hydration stabilizer is used, limit slump loss to 2 inches as compared to slump recorded at the batch plant.

(6) Use ASTM C1611 instead of AASHTO T 119 for SCC mixes.
Section 553

489

Section 553. — PRESTRESSED CONCRETE

Description

553.01 This work consists of prestressing precast or cast-in-place concrete by providing, placing, and 

tensioning prestressing steel. This work also includes installing precast, prestressed members, except 

piling. 

Material 

553.02 Conform to the following Subsections: 

Anchorage devices 722.01

Grout for post-tensioned structures 701.04(c)

Non-shrink grout 701.04(b)(1)

Prestressing steel 709.02

Construction Requirements

553.03 Qualifications. Provide a professional engineer, a precast concrete manufacturing plant and QCM, 

grouting supervisor, and grouting personnel with experience in prestressing precast or cast-in-place 

concrete. At least 30 days before starting prestressed concrete work, submit the following for approval:

(a) Professional engineer. PCI Plant Quality Control Technician/Inspector Certification, Level I or 

higher; 

(b) Precast concrete manufacturing plant and QCM. Appropriate certifications;

(c) Grouting supervisor. A résumé describing experience on projects of similar complexity and 

American Segmental Bridge Institute (ASBI) grouting certification;

(d) Grouting personnel. A résumé for each individual describing experience on projects of similar 

complexity; and

(e) Plant certification. PCI or equivalent NPCA certification.

553.04 Submittals. Perform prestressing by either pre-tensioning or post-tensioning methods. If a method 

is proposed that is not in the contract, submit detailed drawings of the method, material, and equipment 

proposed for approval at least 30 days before starting prestressing. At least 30 days before starting 

prestressed concrete work, submit the following according to Subsection 104.06: 

(a) Method and sequence of stressing;

(b) Complete details and test results for the prestressing steel and anchoring devices;

(c) Anchoring stresses; 

(d) Arrangement of the prestressing steel in the members;

(e) Tendon elongation calculations for jacking procedures; 
Section 553

490

(f) Number, spacing, and method of draping pre-tensioned strands;

(g) Other substantiating calculations for the pre-tensioning or post-tensioning method;

(h) Type of tendon ducts for post-tensioning; 

(i) Pressure grouting material and equipment for post-tensioning; 

(j) Locations of grout inlets and outlets; 

(k) Samples of wire or strand; and 

(l) Additions or rearrangement of reinforcing steel and changes in concrete dimensions. 

553.05 Prestressing Steel. Provide prestressing steel that is bright and free of corrosion, dirt, grease, wax, 

scale, rust, oil, and other foreign material that may prevent bond between the steel and the concrete. Do 

not use prestressing steel that has sustained physical damage or is pitted.

Do not splice prestressing steel strands.

Do not weld or ground welding equipment on forms or other steel in the member after the prestressing 

steel is installed.

Failure of one wire in a 7-wire prestressing strand is acceptable if 85 percent of the required tension load 

is attained before failure and if the failed strand does not constitute more than 2 percent of the total area 

of strands in an individual beam or girder.

Extend bars using couplers which, when assembled, have at least the tensile strength of the bars.

Package prestressing steel to protect it from physical damage and corrosion during shipping and storage. 

Place a corrosion inhibitor in the package. Use a corrosion inhibitor that has no deleterious effect on the 

steel, concrete, or bond strength of steel to concrete. Replace or restore damaged packaging. 

Mark the shipping package with a statement that the package contains high-strength prestressing steel and 

a warning to use care in handling. Identify the type, kind, and quantity of corrosion inhibitor used, 

including the date when placed, safety regulations, and instructions for use. Assign a lot number and tag 

for identification purposes to wire, strand, anchorage assemblies, and bars. 

Provide representative samples of prestressing steel from prestressed members fabricated off site. In the 

case of wire or strand, take the sample from the same master roll.

(a) Pre-tensioning method. Provide a sample at least 6 feet long of each strand size from each coil.

(b) Post-tensioning method. Provide samples of the following lengths: 

(1) For wires requiring a head, 15 feet.

(2) For wires not requiring a head, sufficient length to make up one parallel-lay cable 5 feet long 

consisting of the same number of wires as the cable to be provided. 

(3) For strands provided with fittings, 5 feet between near ends of fittings.
Section 553

491

(4) For bars to be provided with threaded ends and nuts, 5 feet between threads at ends.

553.06 Concrete. Construct concrete according to Section 552. Construct reinforcing steel according to 

Section 554. 

Make at least one set of release strength test cylinders according to AASHTO T 23 in addition to those 

required to determine the 28-day compressive strength. Cure the release strength test cylinders with the 

concrete member they represent.

Rough cast the top surface of members against which concrete will be cast. Rake the top surface of 

members receiving a concrete overlay to a depth of 3⁄8 inch. Sidewalk finish the top surface of members 

receiving an asphalt overlay according to Subsection 552.12(c)(2). For bridge deck surfaces to be covered 

with a waterproofing membrane, finish to a smooth surface without ridges and other projections, and 

according to the waterproofing membrane manufacturer’s recommendations.

Cure the girder in a saturated atmosphere of at least 90 percent relative humidity. Cure time may be 

shortened by heating the outside of impervious forms with radiant heat, convection heat, conducted steam, 

or hot air.

Apply radiant heat by pipes circulating steam, hot oil, hot water, or electric heating elements. Inspect 

casting beds to ensure uniform heat application. Use a suitable enclosure to contain the heat. Minimize 

moisture loss by covering exposed concrete surfaces with plastic sheeting or liquid membrane curing 

compound according to Subsection 552.13. Sandblast curing compound from concrete bonded surfaces. 

Envelop the entire surface with saturated steam. Completely enclose the casting bed with tightly 

constructed housing to prevent the escape of steam and exclude outside air. Use steam at 100 percent 

relative humidity. Do not apply the steam directly to the concrete. 

If using hot air, obtain approval of the method to envelop and maintain the girder in a saturated 

atmosphere. Do not allow dry heat to touch the girder surface. 

For heat curing methods: 

(a) Keep unformed girder surfaces in a saturated atmosphere throughout the curing time. 

(b) Embed a thermocouple, linked with a thermometer accurate to ±5 °F, 6 to 8 inches from the top or 

bottom of the girder on its centerline and near its midpoint.

(c) Monitor with a recording sensor, accurate to ±5 °F, arranged and calibrated to continuously record, 

date, and identify concrete temperature throughout the heating cycle. 

(d) Submit the temperature record when requested. 

(e) Heat concrete to no more than 100 °F during the first 2 hours after placing concrete, and increase 

the temperature no more than 40 °F per hour to a maximum of 160 °F.

(f) Cool concrete, after curing is complete, no more than 40 °F per hour until a temperature 20 °F 

above the temperature of the air to which the concrete will be exposed has been attained. 

(g) Keep the temperature of the concrete above 60 °F until the girder attains release strength.
Section 553

492

Cure precast, prestressed members to the release compressive strength. Release compressive strength is 

attained when the average strength of two representative test cylinders is greater than the minimum 

required strength and the individual strength of any one cylinder is no more than 5 percent below the 

required strength. 

Do not expose the concrete to temperatures below 40 °F for at least 7 days after casting. 

553.07 Tensioning. Use hydraulic jacks to tension prestressing steel.

Calibrate measuring devices at least once every 6 months and if they appear to be giving erratic results. 

Calibrate the jack and gauge as a unit with the cylinder extension in the approximate position that it will 

be at final jacking force. Keep a certified calibration chart with each gauge.

If a pressure gauge is used, only gauge loads from one-fourth to three-fourths of the total graduated 

capacity of the gauge, unless calibration data clearly establishes consistent accuracy over a wider range. 

Use a pressure gauge with an accurate reading dial at least 6 inches in diameter.

Measure the force induced in the prestressing steel using calibrated jacking pressure gauges, load cells, or 

a calibrated dynamometer. Take elongation measurements of the prestressing steel. Determine the 

required elongation from average load-elongation curves for the prestressing tendons used. 

For pre-tensioned members, if there is a discrepancy between the gauge pressure and elongation of more 

than 5 percent in tendons over 50 feet in length or 7 percent in tendons of 50 feet or less in length, 

determine the source of error before proceeding. Do not allow discrepancies in post-tensioned members 

to exceed 7 percent.

If the jacking system is equipped with an automatic release valve that closes when the required prestressing 

force is achieved, measure strand elongation for the first and last tendon tensioned and for at least 

10 percent of the remaining tendons. 

If a load cell is used, do not use the lower 10 percent of the manufacturer’s rated capacity of the load cell 

to determine the jacking force.

Do not exceed a temporary tensile stress of 80 percent of the specified minimum ultimate tensile strength 

of the prestressing steel. Anchor prestressing steel at an initial stress that will result in the retention of the 

required working stress after all losses.

For pre-tensioned members, do not allow the initial release stress after seating, and before other losses, to 

exceed 70 percent of the specified minimum ultimate tensile strength of the prestressing steel for 

stress-relieved strands and 75 percent for low-relaxation strands. For post-tensioned members, do not 

allow the initial release stress after seating to exceed 70 percent of the specified minimum ultimate tensile 

strength of the prestressing steel.

553.08 Pre-tensioned Members. Construct pre-tensioned members to the tolerances shown in 

Table 553-1. 

(a) Prestressing steel. Protect prestressing steel placed in the stressing bed from contamination and 

corrosion if the stressing bed is to be exposed to weather for more than 36 hours before encasement in 

concrete.
Section 553

493

Ensure strands are free of kinks or twists. Accurately hold prestressing steel in position and tension. 

Do not allow strands to unwind more than one turn. Keep a record of the jacking force and elongation 

measurements after the strands are tensioned to 20 percent of final jacking force.

Tension prestressing steel to the required stress. Provide a professional engineer to perform elongation 

computations. Include in elongation computations the strand anchorage slippage, splice slippage, in 

place horizontal movement of the structural member during prestressing operations, and prestressing 

steel temperature changes between the time of tensioning and the time when the concrete takes its 

initial set.

Maintain the prestress bed forms, strands, and reinforcement bar temperature within 25 °F of the 

temperature of the concrete to be placed in the forms. Support strands with rollers at points of direction 

change when strands are tensioned in a draped position. Use free-running rollers with minimal friction. 

Initially, when strands are tensioned and then pulled into the draped position, tension to no more than 

the required tension minus the increased tension due to forcing the strand to a draped profile. If the 

load in a draped strand at the dead end, as determined by elongation measurements, is less than 

95 percent of the jack load, tension the strand from both ends of the bed. Ensure the load, as computed 

from the sum of elongations produced by jacking at both ends, is within 5 percent of the jack load.

Within 3 hours before placing concrete, check the tension on the prestressing strands. Obtain approval 

for the method and equipment for checking the loss of prestress. If strands are tensioned individually, 

check each strand for loss of prestress. Retension to the original computed jacking stress for strands 

that show a loss of prestress more than 3 percent. If strands are tensioned in a group, check the entire 

group for total loss of prestress. Release and retension the entire group if the total prestress shows a 

loss more than 3 percent or if individual strands appear significantly different from the rest of the 

strands in the group. 

(b) Releasing steel. Release the prestress load to the concrete after the concrete has attained its 

required release compressive strength. Cut or release strands so that lateral eccentricity of the prestress 

force is minimized. Cut off prestressing steel flush with the end of the member, except as shown in 

the plans.

(c) Debonding strands. Use solid or split plastic sheathing with a thickness of at least 1⁄32 inch to 

debond strands. Before placing concrete, use tape to thoroughly seal split and solid sheathing including 

ends to prevent the migration of concrete mortar along the strand. 
Section 553

494

Table 553-1 

Prestressed Concrete Member Tolerances

Property Tolerance

Post-Tensioned Members

Position of post-tensioning ducts ±1⁄4 in

Position of tendon anchorage bearing plates ±1⁄4 in

Precast Concrete I-Beams and T-Beams

Length ±1⁄8 in per 10 ft

Width (overall) +3⁄8 in, -1⁄4 in

Depth (overall) +1⁄2 in, -1⁄4 in

Depth (flanges) -1⁄4 in

Width (web) +3⁄8 in, -1⁄4 in

Deviation from straight line parallel to centerline of member 1⁄8 in/10 ft

Variation from end squareness or skew ±3⁄16 in/ft, ±1 in maximum

Camber variation from design camber ±1⁄8 in/10 ft, ±1 in maximum

Position of strands ±1⁄4 in

Position of hold-down points for depressed strands ±6 in

Position of plates other than bearing plates ±1 in

Position of bearing plates ±5⁄8 in

Tipping and flushness of plates ±1⁄4 in

Tipping and flushness of bearing plates ±1⁄8 in

Position of inserts for structural connections ±1⁄2 in

Position of stirrups:

 Longitudinal spacing ±2 in

 Projection above top ±3⁄4 in

Local smoothness(1) ±1⁄4 in per 10 ft

(1) Does not apply to top surface left rough to receive a topping or to visually concealed surfaces.
Section 553

495

Table 553-1 (continued)

Prestressed Concrete Member Tolerances

Property Tolerance

Precast Concrete Box Beams, Flat Slabs, and Decked Girders

Length ±1⁄8 in per 10 ft

Width (overall) ±1⁄4 in

Depth (overall) ±1⁄4 in

Depth (top flange) ±1⁄2 in

Depth (bottom flange) +1⁄2 in, -1⁄8 in

Width (web) ±3⁄8 in

Deviation from straight line parallel to centerline of 

member:

 Up to 40 ft member length ±1⁄4 in

 40 to 60 ft member length ±3⁄8 in

 Greater than 60 ft member length ±1⁄2 in

Variation from end squareness or skew ±1⁄8 in per ft

 Horizontal ±1⁄2 in maximum

 Vertical ±1⁄2 in

Camber variation from design camber ±1⁄4 in per 10 ft, ±1⁄2 in maximum

Differential camber between adjacent members

of the same design ±1⁄8 in per 10 ft, 1⁄2 in maximum

Position of strands ±1⁄4 in

Position of hold-down points for depressed strands ±6 in

Position of plates other than bearing plates ±1 in

Position of inserts for structural connections ±1⁄2 in

Position of stirrups:

 Longitudinal spacing ±1 in

 Projection above top +1⁄4 in, -3⁄4 in

Position of dowel tubes ±5⁄8 in

Position of tie rod tubes:

 Parallel to length ±1⁄2 in

 Vertical ±3⁄8 in

Position of slab void:

 End of void to center of tie hole ±1⁄2 in

 Adjacent to end block ±1 in

Local smoothness(1) ±1⁄4 in per 10 ft

(1) Does not apply to top surface left rough to receive a topping or to visually concealed surfaces.

553.09 Storing, Transporting, and Erecting. Do not ship prestressed concrete members until concrete 

cylinder tests, manufactured of the same concrete and cured under the same conditions as the members; 

indicate that the concrete in each member has attained the minimum required design strength and is at 

least 7 days old or at least 10 days old for decked Bulb-T sections.

Before transporting prestressed concrete members, provide written certification from a professional 

engineer that the members were fabricated, visually inspected, and meet minimum quality requirements.
Section 553

496

Install points of support designed by a professional engineer to prevent cracking or damage during hoisting 

and handling. Store, transport, and erect precast, prestressed girders, slab units, and box units in the upright 

position with the points of support and directions of the reactions, with respect to the member, 

approximately the same as when the member is in its final position. Prevent cracking or damage during 

hoisting, handling, and storing of the precast units. 

Use high-pressure water blasting to remove debris and paste in the keyways immediately before placing 

mortar. Remove free-standing water and allow keyways to surface dry. Use non-shrink grout in keyways 

between multibeam members, blockouts, and set anchor bolts and dowels. Strike off exposed grout on 

surfaces until flush. Cure the non-shrink grout according to the manufacturer’s recommendations. Apply 

the same surface texture finish to the surrounding concrete as soon as the non-shrink grout or concrete has 

sufficiently set.

Repair concrete defects according to Section 572. Replace units damaged by improper handling or storing 

if the CO determines them irreparable.

553.10 Post-Tensioned Members. Construct post-tensioned members to the tolerances shown in 

Table 553-1. Construct supporting falsework so that the superstructure is free to lift off the falsework and 

shorten during post-tensioning. Detail formwork left inside box girders to support the roadway slab to 

offer minimum resistance to girder shortening due to shrinkage and post-tensioning. 

(a) Ducts. Use mortar-tight ducts that are sufficiently rigid to maintain their shape and alignment 

during concrete placement and grout installation. Use ducts with minimum wall thicknesses 

conforming to Table 553-2. 

Table 553-2 

Minimum Duct Wall Thicknesses

Duct Minimum Thickness, gauge

Metal duct, diameter ≤ 25⁄8 in 26

Metal duct, diameter > 25⁄8 in 24

HDPE 14

HDPP 14

Metal duct with bar tendons preassembled with duct 31

For tendons composed of single prestressing bars, provide ducts with an internal duct diameter of at 

least 1⁄4 inch larger than the outside diameter of the prestressing bar. For multiple wire, bar, or strand 

tendons, provide a duct nominal internal cross-sectional area of at least 21⁄4 times the net area of the 

prestressing steel. When tendons are to be placed by the pull through method, provide a duct nominal 

internal cross-sectional area of at least 21⁄2 times the net area of the prestressing steel.

Make positive joints between duct sections. Do not make angles at the joints. Use waterproof tape at 

the joints. Do not use duct tape. Bend ducts without crimping or flattening. Use ferrous metal or 

polyethylene couplings to connect ducts to anchoring devices. 

Protect ducts against crushing, excessive bending, dirt contamination, and corrosive elements during 

transport, handling, and storing. 
Section 553

497

In case of duct damage, seal duct with waterproof tape, or splice a duct coupler over the damaged 

section to form a seal that prevents cement paste from entering the duct during the placement of 

concrete and to prevent leakage during grouting operations. 

Provide ducts and anchorage assemblies with inlets for the injection of grout into the duct after 

prestressing according to PTI, Guide Specification for Grouting of Post-Tensioned Structures. 

Provide ducts with outlets to allow the escape of air, water, grout, and bleed water according to PTI, 

Guide Specification for Grouting of Post-Tensioned Structures. 

Provide inlets and outlets with an inner diameter of at least 3⁄4 inch for strand tendons and of at least 

1⁄2 inch for single bar tendons. Extend the length of outlets a sufficient distance out of the concrete 

member to allow for the proper closing of the outlets.

Place inlets and outlets, at a minimum, in the following locations: 

(1) Anchorage area of the tendon; 

(2) High points of the duct, when the vertical distance between the highest and lowest point is 

more than 24 inches; 

(3) Inlet at or near the lowest point of the tendon; 

(4) Outlet at low points of the duct;

(5) Major changes in the cross-section of the duct, such as couplers and anchorages; and

(6) Outlet at a distance less than 36 inches downstream from high point outlets. 

Provide positive mechanical shut-off valves for inlets and outlets. Provide inlets and outlets with 

valves, caps, or other devices that can withstand the grouting pressure.

Securely fasten ducts in place to prevent movement. Maintain distances from the forms by stays, 

blocks, ties, hangers, or other approved supports. Use precast mortar blocks of approved shape and 

dimensions. Separate layers of ducts by mortar blocks. 

Space duct supports according to PTI, Guide Specification for Grouting of Post-Tensioned Structures. 

Cover the ends of ducts to prevent the entry of water or debris.

Connect inlets and outlets to the duct with metallic or plastic structural fasteners. Do not use 

components that react with concrete, cause corrosion of the prestressing steel, or contain water soluble 

chlorides. 

(b) Placing concrete. Where the end of a post-tensioned assembly is not covered by concrete, recess 

the anchoring devices so that the ends of the prestressing steel and all parts of the anchoring devices 

are at least 2 inches inside the end surface of the members.

Before placing concrete, demonstrate that ducts are unobstructed. Immediately after concrete 

placement, blow out ducts with compressed, oil-free air to break-up and remove mortar in the conduit 

before it hardens. Approximately 24 hours after the concrete placement, flush ducts with water 
Section 553

498

containing lime (calcium oxide) or slaked lime (calcium hydroxide) at a rate of 0.1 pound per gallon. 

Blow the water out with compressed, oil-free air.

For post-tensioned members that are to be steam cured, do not install prestressing steel until curing is 

complete.

(c) Anchorages and distribution. Provide at least 10 days’ notice before installing end fittings or 

heading wires. 

When wires are used, provide an edge distance for any hole for prestressing wire through a stressing 

washer, unthreaded bearing ring, or plate of at least 1⁄4 inch from the root of any threads or the edge of 

any ring, plate, or washer. 

Anchor post-tensioned prestressing steel at the ends by permanent type anchorage devices that can

develop equal to or greater than 95 percent of the ultimate tensile strength of the prestressing steel. 

Provide a steel distribution plate or assembly to effectively distribute the compressive stresses from 

the anchoring device to the concrete. 

Do not exceed 3000 pounds per square inch for the final unit compressive stress on the concrete

directly beneath the plate or assembly. Do not allow bending stresses induced by prestressing to exceed 

the yield point of the material in the plates or assemblies or cause visible distortion in the anchorage 

plate when 100 percent of the nominal load is applied. 

Enclose loop tendon anchorages in ducts for their entire length. 

(d) Prestressing steel. Use a corrosion inhibitor to protect prestressing steel installed in ducts before 

placing and curing the concrete. Use a corrosion inhibitor that does not adversely affect the steel, 

concrete, or bond strength of the steel to concrete. 

If prestressing steel is installed in the ducts within 10 days after concrete curing, stressing, and grouting 

are completed, no corrosion inhibitor is required. 

(e) Post-tensioning. Wait at least 10 days after the last concrete has been placed in the member or 

until tests on concrete cylinders indicate that the concrete has attained the minimum required 

compressive strength. Demonstrate that the prestressing steel is free and unbonded in the duct. 

Straighten wires if necessary to produce equal stress in all wires, wire groups, or parallel lay tendons 

that are stressed simultaneously. Remove side forms for girders before post-tensioning. 

Record gauge pressures and prestressing steel elongation continuously while tensioning prestressing 

steel and submit records.

Determine the loss due to friction in the prestressing process according to AASHTO, LRFD Bridge 

Design Specifications. 

Use shims or other approved devices to achieve the specified anchor set loss.

(f) Grouting. Provide grout and prestressing steel that is free of dirt, loose rust, grease, or other 

deleterious material. Bond post-tensioned prestressing steel to the concrete by filling the void space 

between the duct and tendon with grout according to PTI, Guide Specification for Grouting of PostTensioned Structures. 
Section 553

499

Before starting grouting operations, provide the required testing equipment on site for checking grout 

workability (flow cone), temperatures, and other specified tests.

Use grouting equipment that can operate continuously with little variation of pressure, which also 

includes a system for recirculating the grout while actual grouting is not in progress. Use grouting 

equipment that can maintain a pressure on completely grouted ducts and id fitted with a valve that can 

be locked off without loss of pressure in the duct. 

Provide written certification that ingredients used in the grout meet the ASTM requirements contained 

in PTI, Guide Specification for Grouting of Post-Tensioned Structures. Include the following: 

(1) Cement mill test reports;

(2) Mineral additives test reports;

(3) Chemical admixtures reports; and

(4) Test reports for other ingredients used in the grout.

For prepackaged grouts, provide the manufacturer’s current certified mill test reports for the product.

Do not use compressed air to aid in the pumping of grout. 

Provide grout pumps of a positive displacement type, that can provide a continuous flow of grout and 

maintain an outlet pressure of at least 150 pounds per square inch and has a pressure gauge with a fullscale reading of no more than 300 pounds per square inch. 

Grout only when the efflux time of a grout sample immediately after mixing is between 11 and 

30 seconds according to ASTM C939. When hot weather conditions may cause quick setting of the 

grout, cool the grout by approved methods, as necessary, to prevent blockages during pumping 

operations. When freezing weather conditions are possible during and following placement of grout, 

protect the grout from damage by freezing according to PTI, Guide Specification for Grouting of PostTensioned Structures. 

Provide a supply of potable water and standby flushing equipment that can develop a pumping pressure 

of 250 pounds per square inch with sufficient capacity to flush out partially grouted ducts. 

Clean ducts of material that would impair bonding of the grout or interfere with grouting procedures. 

Blow out each duct with compressed, oil-free air. Check inlets and outlets for their capacity to accept 

injection of grout by blowing compressed, oil-free air through the system and proving each inlet and 

outlet in turn.

Pass grout through a screen with 1⁄8-inch maximum clear openings before entering the grout pump. 

Open grout vents before the start of grouting. Completely fill the duct by injecting grout from the 

lowest end of the tendon in an uphill direction. Pump grout continuously through the duct and waste 

at the outlet until no visible slugs of water or air are ejected, and the efflux time of ejected grout is 

between 11 and 30 seconds. Maintain a continuous, one-way flow of grout within a grouting stage. 

Close outlets in a similar manner one after the other in the direction of the flow. Close outlets placed 

a short distance downstream from a high point before the associated high point outlet. Increase the 
Section 553

500

grouting pressure at the injection end to at least 100 pounds per square inch and hold for at least 

10 seconds. Do not remove or open valves and caps until the grout has set. 

Abrasive blast clean the concrete surface of recessed anchorage assemblies. Fill anchor recesses with 

concrete conforming to the requirements for the structure and finish flush.

Remove ends of vents 1 inch below the roadway surface after grouting has been completed. 

Permanently seal recess areas.

Do not release the falsework under the bottom slab supporting the superstructure until at least 48 hours 

after grouting the post-tension prestressing steel or until the grout strength is obtained. 

553.11 Coating Steel. Use a wire brush or abrasive blast to remove dirt and residue not firmly bonded to 

the metal or concrete surfaces. Clean and coat the exposed ends of the prestressing steel, post-tensioned

anchor head assemblies, and a 1-inch strip of adjoining concrete.

Mix zinc-rich coating material conforming to MIL-DTL-24441. Work the coating material into voids in 

the prestressing tendons. Apply one thick coat to surfaces that will be covered with concrete. Apply two 

coats to surfaces not covered with concrete.

553.12 Continuity of Prestressed Girders. Construct continuity diaphragms between precast girders at 

least 90 days after girders have been prestressed. Submit supporting calculations conforming to AASHTO, 

LRFD Bridge Design Specifications when establishing continuity less than 90 days after girders have been 

prestressed.

553.13 Acceptance. See Tables 552-10 and 553-3 for sampling, testing, and acceptance requirements.

Prestressing steel, anchor devices, and material for concrete and grout will be evaluated under 

Subsections 106.02 and 106.03. Provide production certifications with each shipment of hydraulic cement 

and prestressing steel.

Grouting will be evaluated under Subsections 106.02 and 106.04. 

Concrete will be evaluated under Section 552. 

Concrete repairs will be evaluated under Section 572. 

Reinforcing steel will be evaluated under Section 554. 

Temporary works will be evaluated under Section 562. 

Measurement

553.14 Measure the Section 553 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

553.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 553 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 553-3 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

Concrete

composition

Measured &

tested for

conformance

(106.04) 

All − Subsection

552.03

1 per

mix

design

Source of

material

If

requested

Before

producing −

Production

Concrete

(552.03)

(1)

Process 

control

(153.03) 

Density − AASHTO

T 121

1 per load 

after 

0.25 yd3

minimum is 

discharged(4)

Point of

discharge at 

truck

No

Upon

completing

tests

−

Air content −

AASHTO

T 152 or

T 196

" " " " −

Slump(5) − AASHTO

T 119 " " " " −

Slump flow(6) − ASTM

C1611 " " " " For SCC mixes only

Temperature − ASTM

C1064 " " " " −
Table 553-3 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

Concrete

(552.03)

(1)

Measured &

tested for

conformance

(106.04)

Density − AASHTO T 121

1 per load 

after 

0.25 yd3

minimum is 

discharged(4)

Discharge

at

point of

placement

No

Upon

completing

tests

−

Air content − AASHTO T 152 

or T 196 " " " " −

Slump(5) − AASHTO T 119 " " " " −

Slump flow(6) − ASTM C1611 " " " " For SCC 

mixes only

Temperature − ASTM C1064 " " " " −

Concrete

(552.03)

(1)

Measured &

tested for

conformance

(106.04) 

Compressive

strength(2),(3) − AASHTO

R 100 & T 22

1 per

30 yd3

Discharge

stream at

point of

placement

No

Upon

completing

tests

−

Grout(7)

Measured &

tested for

conformance

(106.04) 

Compressive 

strength − ASTM C109 1 set of 3 per day Grout plant No

Upon 

completing 

tests

−

(1) Sample according to AASHTO R 60, except composite samples are not required.

(2) Cast at least four compressive strength test cylinders for 6- by 12-inch specimens or six compressive strength cylinders for 4- by 8-inch 

specimens and transport the cylinders to the job site curing facility. In addition to the test cylinders required to determine 28-day strength, cast 

two release cylinders for each concrete member. Cure the release-strength cylinders with the concrete member that they represent

(3) A single compressive strength test result is the average result from two 6- by 12-inch or three 4- by 8-inch cylinders cast from the same load.

(4) If three successive samples are tested and compliance with the specifications is indicated, screening tests may be reduced to an approved 

frequency. Resume testing frequency if a test shows a failing temperature, air content, or slump, or if directed.

(5) If a hydration stabilizer is used, limit slump loss to 2 inches as compared to slump recorded at the batch plant.

(6) Use ASTM C1611 instead of AASHTO T 119 for SCC mixes.

(7) Sample and test according to PTI, Guide Specification for Grouting of Post-Tensioned Structures.
Section 554

503

Section 554. — REINFORCING STEEL

Description

554.01 This work consists of providing and placing reinforcing steel. 

Material 

554.02 Conform to the following Subsection: 

Reinforcing steel 709.01

Construction Requirements

554.03 Order Lists. On reinforcing steel order lists, use the same respective bar marks for labeling as 

shown in the plans. Submit order lists and bending diagrams for approval. Approval does not relieve the 

Contractor of responsibility for the accuracy of the lists and diagrams. Do not order material until the lists 

and diagrams are approved.

Do not fabricate vertical reinforcement in columns, walls, piers, and shafts until footing elevations are 

established in the field.

554.04 Identification. Ship bar reinforcement in standard bundles, tagged and marked according to CRSI, 

Manual of Standard Practice. 

Provide the following information with each shipment of steel to the project:

(a) Name and location of the steel rolling mill;

(b) Manufacturing process; 

(c) Heat numbers; 

(d) Sizes;

(e) Specifications;

(f) Copies of mill test analyses for chemical and physical tests; and

(g) Consignee and destination of shipment. 

554.05 Bending. Fabricate reinforcing bars according to ACI SP-66, ACI Detailing Manual. Cold bend 

reinforcing bars that require bending. Limit the overall height or drop bending tolerance of deck truss bars 

to plus 0 inch or minus 1⁄4 inch. Do not bend bars that are partially embedded in concrete, except as shown 

in the plans or otherwise allowed. 

Provide standard hooks conforming to ACI SP-66. 

554.06 Protection of Material. Store reinforcing steel above the ground on platforms, skids, or other 

supports. Protect reinforcing steel from physical damage, rust, and other surface deterioration. 
Section 554

504

Use reinforcing steel only when the surface is clean and the minimum dimensions, cross-sectional area, 

and tensile properties conform to the physical requirements for the size and grade of steel specified.

Do not use reinforcing steel that is cracked, laminated, or is covered with dirt, rust, loose scale, paint, 

grease, oil, or other deleterious material.

554.07 Epoxy-Coated Reinforcing Steel. Support coated bars on padded contact areas. Lift with a strong 

back, spreader bar, multiple supports, or a platform bridge to prevent bar-to-bar abrasion. Do not drop or 

drag bundles. 

Before placement, inspect bars for coating damage. Replace and do not use bars with a total damaged area 

in any 12-inch length that is more than 5 percent of the surface area of that length of the bar.

Clean other damaged coatings by removing surface contaminants and the damaged coating. Roughen the 

area around the damage and remove rust by blast cleaning or power tool cleaning. Patch defects in the 

coating that are discernible to the unaided eye using a prequalified patching material conforming to ASTM 

A934 for epoxy-coated prefabricated reinforcement or ASTM A775 for epoxy-coated reinforcement. 

Overlap the patching material onto the original coating for 2 inches or according to the manufacturer’s 

recommendations. Provide at least 8-mil dry film thickness on the patched areas.

Take necessary steps to minimize damage to the coating of installed bars. Clean and patch damage to 

coatings noted after installation. Promptly treat the bar according to the resin manufacturer’s 

recommendations and before detrimental oxidation occurs.

For epoxy-coated prefabricated reinforcement conforming to ASTM A934, coat mechanical splices after 

splice installation according to ASTM A934 for patching damaged epoxy coatings. For epoxy-coated 

reinforcement, coat mechanical splices after splice installation according to ASTM A775 for patching 

damaged epoxy coatings. 

554.08 Placing and Fastening. Place, fasten, and support the bars according to the CRSI, Manual of 

Standard Practice. Coat chairs, tie wires, and other devices used to support, position, or fasten 

epoxy-coated reinforcement with a dielectric material.

Use precast concrete blocks or metal supports. Attach concrete block supports to the supported bar with 

wire cast in the center of each block. Use Class 1 (plastic protected) or Class 2, Type B (stainless steel 

protected) metal supports in contact with exposed concrete surfaces. Use stainless steel conforming to 

ASTM A493, Type 430. 

Space slab bar supports no more than 48 inches apart transversely or longitudinally. Do not use bar 

supports either directly or indirectly to support runways for concrete buggies or other similar construction 

loads. Replace damaged supports. 

Place bars no more than 11⁄2 inches from the plan location. Do not cumulate spacing variations. Do not 

allow the average of any two adjacent spaces to exceed the required spacing. Place reinforcing steel in 

deck slabs within 1⁄4 inch of the vertical plan location. Using a template, check the clear cover over deck 

reinforcing steel before placing deck concrete.

Provide 2 inches clear cover for reinforcement. The tolerance on minimum concrete cover is minus 3⁄8 

inch. For concrete surfaces cast against the ground provide at least 3 inches of clear cover over 

reinforcement.
Section 554

505

Tie reinforcing at intersections around the perimeter of each mat and at no more than 24-inch centers or 

at every intersection, whichever is greater. Tie bridge deck reinforcing bars at no more than 12 inches or 

every intersection, whichever is greater.

Tie bundle bars together at intervals no more than 6 feet. Do not bundle bars unless the location and splice 

details are specified.

Do not place concrete in members until the reinforcing steel placement is approved.

554.09 Splices. Do not splice, except as shown in the plans, without approval. Provide lap lengths shown 

in the plans. 

Make lapped splices by placing the reinforcing bars in contact and wiring them together to maintain the 

alignment and position of the bars. 

If welding of reinforcing steel is allowed, use welders with current certifications and weld according to 

AWS D1.4, Structural Welding Code – Steel Reinforcing Bars. Do not weld reinforcing steel conforming 

to AASHTO M 31 or corrosion-resistant reinforcing steel bars. Do not weld reinforcing steel if its carbon 

equivalent exceeds 0.55 percent.

Mechanical couplers may be used if approved. Use couplers with a strength that is at least 125 percent of 

the required yield strength of the reinforcing steel. Do not exceed 0.01 inch total slip of the reinforcing 

bar within the splice sleeve when loading in tension to 30.0 kips per square inch and relaxing to 3.0 kips 

per square inch for bar sizes up to No. 14 as measured between gauge points clear of the splice sleeve.

For mechanical couplers used in the superstructure slab, use only butt type splices.

Use only epoxy coated mechanical couplers for joining epoxy coated reinforcing. For corrosion-resistant 

steel reinforcing bars, use only mechanical butt couplers of the same material as the bars being spliced.

Provide clear coverage at splice sleeves of at least 1.75 inches measured from the surface of the concrete 

to the outside face of the sleeve. Do not place slab bar mechanical splices adjacent to each other.

Use mechanical splices according to the manufacturer’s recommendations.

If welded wire fabric is shipped in rolls, straighten into flat sheets before placing. Splice sheets of mesh 

or bar mat reinforcement by overlapping at least 1-mesh width plus 2 inches. Securely fasten at the ends 

and edges. 

554.10 Acceptance. Reinforcing steel and epoxy coating material will be evaluated under 

Subsections 106.02 and 106.03. Provide a production certification with each shipment of reinforcing steel.

Placement of reinforcing steel will be evaluated under Subsections 106.02 and 106.04. 

Measurement

554.11 Measure the Section 554 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Do not measure reinforcing steel laps added for the Contractor’s convenience. 
Section 554

506

Do not measure reinforcing steel for precast, prestressed concrete structural members.

Payment

554.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 554 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 555

507

Section 555. — STEEL STRUCTURES

Description

555.01 This work consists of constructing steel structures and the steel structure portions of composite 

structures.

Material 

555.02 Conform to the following Section: 

Structural metal 717

Construction Requirements

555.03 Submittals. Submit the following according to Subsection 104.06: 

(a) Steel certifications. Provide copies of mill orders at the time orders are placed with the 

manufacturer. Provide certified mill test reports and production certifications before the start of 

fabrication using material covered by these reports.

Include on certified mill test reports the chemical analyses and physical test results for each heat of 

steel used in the work and for steels with specified impact values, include the results of Charpy Vnotch impact tests. Confirm on the test report that the material was so produced when fine-grain 

practice is specified.

Provide production certifications instead of mill test reports for material that is not normally supplied 

with mill test reports and for items such as fills, minor gusset plates, and similar material when 

quantities are small and the material is taken from stock. 

(b) Fabrication drawings. Show complete detailed dimensions and sizes of component parts of the 

structure and details of miscellaneous parts.

Show the direction of plate rolling where specific orientation of plates is required. Show plate girder 

flanges and webs cut from plates so the long dimension of the girder parallels the rolling direction. 

Identify the type and grade of each piece that is to be made of steel other than AASHTO M 270, 

Grade 36 steel.

Show assembly marks that are cross-referenced to the original pieces of mill steel and their certified 

mill test reports.

Show shop-welded splice locations. Locate shop-welded splices to avoid points of maximum tensile 

or fatigue stress. Locate splices in webs at least 12 inches from shop splices, flange butt joints, or 

stiffeners. Additional nondestructive tests may be required on shop-welded splices.

(c) Erection drawings. Fully illustrate the proposed method of erection. Show details of falsework 

bents, bracing, guys, dead-men, lifting devices, and bridge member attachments. Show the erection 

sequence, crane and barge locations, crane capacities, lifting point locations, and bridge member 
Section 555

508

masses. Show complete details for anticipated phases and erection conditions. If required during 

drawing review, provide calculations showing that allowable stresses are not exceeded and that 

member capacities and final geometry are correct. Include drawings for temporary works according 

to Section 562. 

(d) Camber diagram. Show the camber at each truss or arch rib panel point, at field splice locations, 

and at the specified span length fractions of continuous beams and girders or rigid frames. Show 

calculated cambers to be used in preassembly of the structure according to Subsection 555.14. 

(e) Transportation drawings. Show support points, tie-downs, temporary stiffening trusses or beams, 

and other details needed to support and brace the member. Provide calculation sheets showing 

self-weight plus dynamic load allowance stresses induced by the loading and transportation procedure. 

Use dynamic load allowance stresses of at least 100 percent of the self-weight dead load stress. Do 

not allow fatigue stresses to exceed the constant-amplitude fatigue threshold for the appropriate 

categories. Verify computed girder stresses satisfy the AASHTO, LRFD Bridge Design Specifications. 

Ship and store members in the same orientation as the completed structure unless otherwise approved.

555.04 Fabrication Notice. Give written notice at least 21 days before starting fabrication work. Do not 

manufacture material before notification and drawings are approved. 

555.05 Inspection. Ultrasonically inspect girder flanges before fabrication according to ASTM A578 and 

the following:

(a) Inspect after flanges are stripped from the master plate;

(b) Use ASTM A578, Supplementary Requirement S2.1 for acceptance standards; and 

(c) Inspect flanges in the plant or warehouse where the flanges are stripped.

555.06 Storing Material. Store structural material above the ground on platforms, skids, or other 

supports. Keep material free of dirt, grease, and other foreign matter. Protect from corrosion and stray 

electrical currents.

555.07 Fabrication. Fabricate structural steel in a fabricating plant that is certified under the AISC, 

Quality Certification Program. Provide and fabricate fracture critical elements according to AASHTO, 

LRFD Bridge Design Specifications and Clause 12 of the AASHTO/AWS D1.5, Bridge Welding Code. 

Remove mill scale and foreign material from exterior surfaces of exterior girders of uncoated weathering 

steel by blast cleaning according to SSPC-SP6, Commercial Blast Cleaning. Then dry the surface and 

apply at least three uniform applications of water mist at 24-hour intervals to ensure uniform weathering. 

Do not heat curve steel girders.

Do not drill, cut, or weld portions of structural members unless shown in the plans or approved in writing.

Coat structural steel according to Section 563. 

Fabricate bearing devices according to Section 564. 
Section 555

509

(a) Steel identification. Use a system of assembly-marking of individual pieces and cutting 

instructions (generally by cross referencing of the assembly-marks shown in the drawings with the 

corresponding item covered on the mill purchase order). Provide information to the shop that maintains 

the identity of the original piece.

Identify material provided from stock by heat number and mill test report.

During fabrication and before assembling members, show the specification of each piece of steel. 

Mark steel using steel die stamping or firmly attaching a substantial tag to pieces of steel which will 

be subject to fabricating operations which might obliterate paint marking before assembling into 

members. These fabrication operations include blast cleaning, galvanizing, heating for forming, or 

coating. 

Use low-stress type steel die stamps. Avoid impressions near edges of tensile-stressed plate members. 

Do not use die stamps on fracture-critical members.

Provide an affidavit certifying the identification of steel has been maintained throughout the 

fabrication operation. 

(b) Plates. 

(1) Rolling direction. Cut and fabricate steel plates for main members and splice plates for flanges 

and main tension members, so that the primary direction of rolling is parallel to the direction of 

the principal tensile and compressive stresses.

(2) Plate cut edges.

(a) Edge planing. Remove sheared edges on plates thicker than 5

⁄8 inch to a depth of 1⁄4 inch 

beyond the original sheared edge or beyond re-entrant cuts produced by shearing. Fillet reentrant cuts before cutting.

(1) Oxygen cutting. Perform oxygen cutting according to AASHTO/AWS D1.5, Bridge 

Welding Code. 

(2) Visual inspection and repair of plate cut edges. Visually inspect and repair plate cut 

edges. Conform to AASHTO/AWS D1.5, Bridge Welding Code. 

(b) Flange plates. Provide flange plates with either oxygen-cut edges that have ground corners 

chamfered at least 1⁄16 inch or provide universal mill plates.

(c) Web plates. Use oxygen cutting to provide the prescribed camber in web plates of built-up 

beams and girders, box girders, and box arches. Cut sufficient extra camber into the webs to 

provide for camber losses due to welding and cutting. 

(d) Truss members. Prepare longitudinal edges of plates in welded sections of truss web and 

chord members by oxygen cutting. Use grinding to chamfer the edges of the corners of plates 

at least 1⁄16 inch if plates are not joined by welding.

(e) Stiffeners and connection plates. Sheared edges may be used on plate thicknesses up to 

3⁄4 inch for stiffeners and connection plates welded transverse to girder webs and flanges. 
Section 555

510

Universal mill plate may be used for plate thicknesses up to 1 inch. Provide other stiffeners 

and connection plates with oxygen-cut edges.

(f) Lateral gusset plates. Bolted lateral gusset plates may be provided with sheared edges 

provided the thickness is less than or equal to 3⁄4 inch. Oxygen cut, parallel to lines of stress, 

gusset plates and other connections welded parallel to lines of stress in tension members where 

the plate thickness exceeds 3⁄8 inch. 

(g) Splice plates and gusset plates. Provide with oxygen-cut edges.

(h) Bent plates. Provide un-welded, load-carrying, rolled steel plates.

Bend plates at right angles to the direction of rolling, except cold-bent ribs for orthotropic-deck 

bridges may be bent in the direction of rolling. 

Before bending, round the plate corners to a radius of 1⁄16 inch throughout the portion of the 

plate where the bending occurs.

Cold bend fracture-critical steels and nonfracture-critical plates and bars.

The minimum bending radius for plates bent perpendicular to the direction of rolling is 5 times 

the plate thickness, except for cross-frame or diaphragm connection plates up to 3⁄4-inch thick, 

for which the bending radius is 1.5 times the plate thickness. 

Orient bend lines perpendicular to the direction of the final rolling of the plate where possible. 

For plates bent parallel to the direction of rolling, the minimum bending radius is increased to 

7.5 times the plate thickness, except for web splice plates, fillers, gusset plates not serving as 

chord splices, connection plates, and web stiffeners.

Hot bend steel members only if allowed in the plans. Hot bend the plates at a temperature less 

than 1200 °F, except for Grades HPS 70W and HPS 100W. Do not heat Grades HPS 70W and 

HPS 100W to a temperature greater than 1100 °F.

(c) Stiffener fit. Fabricate (mill, grind, or weld) girder end bearing stiffeners and concentrated load 

bearing stiffeners to provide full bearing on the flanges to which the load is transmitted or received. 

Fabricate intermediate stiffeners to provide a tight fit against the compression flange.

(d) Abutting joints. Mill or saw cut abutting joints in truss and column compression members to

obtain a square joint and uniform bearing. Other joints not required to be faced may have openings up 

to 3⁄8 inch. 

(e) Bearing surface facing. Finish bearing surfaces as shown in Table 555-1 and American Society 

of Mechanical Engineers (ASME) B46.1, Surface Texture (Surface Roughness, Waviness and Lay), 

Part I. 
Section 555

511

Table 555-1 

ASME Surface Roughness Values

Bearing Surface

Surface

Roughness Value, 

microinch

Steel slabs 2000

Heavy plates in contact in shoes to be welded 1000

Milled ends of compression members, milled or ground 

ends of stiffeners & fillers 500

Bridge rollers & rockers 250

Pins & pin holes 125

Sliding bearings 125

Machine sliding bearings with a surface roughness greater than 75 microinches so the lay of the cut is 

parallel to the direction of movement.

Fabricate bearing parts to provide uniform even contact with the adjacent bearing surface. Limit the 

maximum gap between bearing surfaces to 0.04 inch. Machine the base plate sliding surfaces if the 

plane and true base and sole plates exceed the surface roughness value shown in Table 555-1. 

Machine surfaces of fabricated assemblies only when heat treatment and fabrication on the assembly 

is complete.

(f) Straightening material. Straighten plates, angles, other shapes, and built-up members using 

methods that do not fracture or damage the metal when approved. 

Use mechanical means or a limited amount of localized heat when approved. Do not exceed the 

temperatures shown in Table 555-2 and control the heat application with temperature-indicating 

crayons, liquids, or bimetal thermometers. Remove external forces from the material to be 

straightened, except for the mechanical stress designed to be used in conjunction with the heat. 

Table 555-2 

Maximum Straightening and 

Stress Relieving Holding Temperatures

Material Maximum Temperature, °F

Grades HPS 70W & HPS 100W 1100

Other Steels 1200

555.08 Annealing and Stress Relieving. Normalize and anneal (full annealing) according to ASTM 

A941. Maintain uniform temperatures throughout the furnace during the heating and cooling so the 

temperature at no two points on the member differs by more than 100 °F.

Record each furnace charge, identify the pieces in the charge, and show the temperatures and schedule 

used. Provide proper instruments including recording pyrometers for determining member temperatures. 

Provide records of the treatment operation for approval.

Do not anneal or normalize Grade HPS 100W or HPS 70W steel members without approval. See 

Table 555-2 for the maximum stress relieving holding temperature for these grades.
Section 555

512

Relieve stress from members (such as bridge shoes, pedestals, or other parts that are built-up by welding 

sections of plate together) according to Subsection 4.4 of the AASHTO/AWS D1.5, Bridge Welding Code. 

555.09 Bolt Holes. Punch or drill bolt holes. If required below, either subpunch or subdrill holes 3⁄16 inch 

smaller than the nominal bolt diameter and after assembling ream or drill full size.

(a) Punched holes. Unless subpunching and reaming is required by Subsection 555.09(h), punch 

material forming parts of a member composed of 5 thicknesses or less of metal if the material thickness 

is no greater than: 

(1) 3⁄4 inch for Grade 36 steel; 

(2) 5⁄8 inch for Grade 50, 50W, 50S, and HPS 50W steel; or 

(3) 1⁄2 inch for Grade HPS 70W and HPS 100W steel. 

Punch holes 1⁄16 inch larger than the nominal bolt diameter. Ream holes that require enlarging to admit 

bolts. Produce clean cut holes without torn or ragged edges. 

(b) Reamed or drilled holes. Subdrill and ream or drill holes full-size where there are more than five 

thicknesses or where the main material is thicker than Subsections 555.09(a)(1) through (3). 

Assemble and securely hold together connecting parts that are being reamed or drilled and match-mark 

before disassembling. Where practical, use twist drills, twist reamers, or roto-broach cutters directed 

by mechanical means. Ream or drill cylindrical holes 1⁄16 inch larger than the nominal bolt diameter 

that are perpendicular to the member. Remove burrs on the outside surfaces.

(c) Accuracy of holes. Drilled or reamed holes may be up to 1⁄32 inch larger than the true decimal 

equivalent of the nominal diameter of the drill or reamer. Punched holes may be slightly conical. 

Slotted holes produced by flame-cutting or a combination of drilling or punching and flame cutting, 

may be up to 1⁄32 inch larger than the nominal width. Grind flame cut surfaces smooth to a maximum 

surface roughness of 1000 microinches.

(d) Accuracy of hole group before reaming. Punch, subpunch, or subdrill holes to allow a cylindrical 

pin 3⁄16 inch smaller in diameter than the nominal size of the punched hole can be inserted in holes after 

assembling (before reaming). In addition, produce at least 75 percent of the contiguous holes in the 

same plane such that a cylindrical pin 1⁄8 inch smaller in diameter than the nominal size of the punched 

hole can be inserted perpendicular to the face of the member without drifting. 

(e) Accuracy of hole group after reaming. Use dimensioned steel templates with hardened steel 

bushings in the holes. Use connection centerlines when locating templates from the milled or scribed 

ends of members. Produce at least 85 percent of the holes in a contiguous group of holes with a 

maximum offset of 1⁄32 inch between adjacent thicknesses of metal after reaming or drilling.

(f) Numerically-controlled drilled field connections. Drill or punch full-sized bolt holes in 

unassembled pieces and connections using numerically-controlled drilling or punching equipment. 

(g) Holes for ribbed bolts, turned bolts, or other approved bearing-type bolts. Provide finished 

holes with a driving fit.
Section 555

513

(h) Preparation of field connections. Drill full size holes through all thicknesses of material 

assembled in proper position for field connections and field splices. Do not punch full-size holes in 

longitudinal main load-carrying members, transverse floor beams, or components designated as 

fracture critical members. Other options include the following:

(1) Main members of trusses, arches, continuous beam spans, bents, towers (each face), plate 

girders, and rigid frame connections and splice holes. Subpunch or subdrill and ream while 

assembled or drill full size to a steel template.

(2) Rolled beam stringers continuous over floor beams or cross frames. Drill full-size holes 

for field splices unassembled to a steel template.

(3) Floor beam and stringer field end connection holes. Subpunch and ream while assembled 

or drill full size to a steel template.

(4) Cross frames, lateral bracing components, and the corresponding holes in connection 

plates between girders and cross frames or lateral components. Punch full-size holes.

Locate, position, and firmly bolt the template in place when reaming or drilling full size 

field-connection holes through a steel template. Use duplicates of templates used for reaming matching 

members or the opposite faces of a single member. Locate templates used for connections on like parts 

or members so that the parts or members are duplicates and require no match-marking.

555.10 Pins and Rollers. 

(a) Fabricating pins and rollers. Fabricate straight and smooth pins and rollers without flaws.

Forge and anneal pins and rollers or use cold-finished carbon steel shafting for diameters less than 

9 inches. Slowly cool forged pins to a temperature below the critical range to prevent damage from 

rapid cooling. Bore a hole in the pin at least 2 inches in diameter full-length along the pin axis before 

annealing. 

(b) Boring pin holes. Do not exceed the pin diameter by more than 1⁄50 inch for pins 5 inches or less 

in diameter or exceed by more than 1⁄32 inch for larger pins when boring pin holes. Bore pin holes 

smooth, straight, at right angles with the axis of the member, and parallel with each other. Produce the 

final surface using a finishing cut. 

Produce a maximum variation in the distance outside-to-outside of end holes in tension members and 

inside-to-inside of end holes in compression members of 1⁄32 inch from that specified. Bore pin holes 

in built-up members after the member is assembled.

(c) Threads for bolts and pins. Conform to the ASME B1.1, Unified Inch Screw Threads (UN, UNR, 

and UNJ Thread Forms), Class 2A for external threads and Class 2B for internal threads. Provide six 

threads per inch for pin ends with a diameter of 13⁄8 inches or greater.

555.11 Eyebars. Provide eyebars that are straight and without twists. Limit the inclination of bars to the 

plane of the truss to a 0.5 percent slope.
Section 555

514

Locate pin holes on the centerline of the eyebar. Securely clamp eyebars that are to be placed side-by-side 

in the structure in the order they are to be placed on the pin. Bore the pin holes to the finished diameter 

from both ends or flame cut the pin holes at least 2 inches smaller than the finished pin diameter.

Simultaneously cut the edges of eyebars that lie between the transverse centerline of their pin holes with 

two mechanically operated torches abreast of each other guided by a substantial template to prevent 

distortion of the plates.

Use low-stress type steel die stamps to match-mark eyebars for shipment and erection. Locate stamps on 

the visible edge each member when the bars are nested in place on the structure.

555.12 Assembly Bolting. Clean metal contact surfaces. Assemble, securely pin, and draw together 

member parts. Drill, ream, and bolt the assembly. If necessary, take assembly apart to remove burrs and 

shavings produced by the operation. 

Assemble the members without twists, bends, and other deformation. Drift only enough to bring the parts 

into position without enlarging holes or distorting metal.

555.13 Welded Connections. Conform to AASHTO/AWS D1.5, Bridge Welding Code. Install shear 

connector studs according to Chapter 9. Perform preproduction testing according to Subsection 9.7.1 and 

inspect installed studs according to Subsection 9.8. 

555.14 Preassembly of Field Connections. Submit method and details of preassembly for approval.

Preassemble field connections of truss, arch, continuous beam, plate girder, bent, tower, and rigid frame 

main members. Use preassembly methods and details consistent with approved erection procedures and 

camber diagrams.

Assemble girders and beams in their cambered (no load) condition. When members are assembled with 

webs vertical, support the members at intervals of 20 feet, or two-tenths of the span length, whichever is 

less. When the webs are horizontal, support intervals may be increased provided there is no noticeable 

deflection between points of support. 

Assemble trusses in full dead-load position unless the design of the structure provides for secondary 

stresses created by the fully cambered assembly. Start assembly from a location in the structure and 

proceed in one or both directions. Support trusses at each panel point. Preassemble at least 

three contiguous panels. For successive assemblies, include at least one section or panel of the previous 

assembly plus two or more sections or panels added at the advancing end. For structures longer than 

150 feet, make each assembly at least 150 feet long.

Verify the geometry of the completed structure or unit. Verify or prepare field splices.

(a) Bolted connections. Where applicable, assemble major components with milled ends of 

compression members in full bearing. While assembled, ream subsized holes to the specified size.

(b) Check assembly. Make a check assembly for each major structural type of each project based on 

proposed order of erection, joints in bearings, special complex points, or similar considerations. 

Assemble at least three contiguous shop sections. For trusses, assemble members in at least three 

contiguous panels, but at least the number of panels associated with three contiguous chord lengths 

(such as the length between field splices). Other shop assemblies are not required.
Section 555

515

Obtain approval of each assembly before reaming holes or dismantling the assembly. Inaccurate 

camber, alignment, hole alignment, milled joint fit, or other problems may require additional check 

assemblies.

(c) Field-welded connections. Do not field weld connections unless specifically shown in the 

drawings. Verify the fit of members, including the proper space between abutting flanges, with the 

segment preassembled.

(d) Match marking. Match mark connecting parts preassembled in the shop to ensure proper fit in 

the field. Provide a diagram showing match-marks.

555.15 Connections Using Unfinished or Turned Bolts. Use bolts conforming to ASTM A307, Grade 

A with single self-locking nuts or double nuts. Use beveled washers where bearing faces have a slope 

more than 1:20 with respect to a plane normal to the bolt axis.

For turned bolts, provide hex headed bolts of the nominal size specified with a body surface ANSI 

roughness less than 125 microinches. Ream holes to provide for a light driving fit. Keep bolt threads 

outside of the holes. Provide a washer under the hexagonal nut.

555.16 Connections Using High-Strength Bolts.

(a) Bolted parts. Use only steel material within the grip of the bolt with no compressible material 

(such as gaskets or insulation). Fabricate steel parts to fit solidly together after bolts are stressed. 

Remove burrs that prevent solid seating. Limit the slope between the bolted surface and the plane 

normal to the bolt axis to 1:20. 

(b) Surface conditions. Clean dirt, foreign material, and scale (except tight mill scale) from joint 

surfaces at the time of assembly. Remove coating, including inadvertent overspray, from areas within 

the bolt pattern. In non-coated joints, exclude or remove coating closer than 1 inch or one bolt 

diameter, whichever is larger, from the edge of holes.

(c) Rotational-capacity tests. If ordered, or if bolt assembly components were relubricated, perform 

field rotation-capacity tests according to ASTM F3125 Annex A2 for ASTM F3125 bolts, and ASTM 

F3148 Annex A1 for ASTM F3148 bolts. Rotational-capacity testing are not required for twist-off 

bolts (ASTM F3125 Grade F1852 or F2280). 

(d) Pre-installation verification (PIV) testing. Provide a calibrated bolt tension measuring device 

with bushings and hardened spacers to test the diameter and lengths of bolt assemblies used in the 

project. Provide documentation of annual testing by an approved testing agency confirming the 

accuracy of the bolt tension measuring device.

At the start of work, perform a PIV test in a bolt tension measurement device using a representative 

sample of at least 3 fastener assemblies of each rotation-capacity lot and assembly orientation to be 

used in the work. Demonstrate the method used to develop a snug condition. Validate the installation 

method after snugging develops a tension equal to or greater than shown in Table 555-3. Perform 

periodic retesting when ordered.
Section 555

516

Table 555-3 

Minimum PIV Fastener Tension(1)

Nominal Bolt Diameter, inch

Specified Minimum 

Tensile Strength of 

120(2) ksi,

pounds

Specified Minimum 

Tensile Strength of 

144(3) or 150(4) ksi,

pounds

1⁄2 13,000 16,000

5⁄8 20,000 25,000

3⁄4 29,000 37,000

7⁄8 41,000 51,000

1 54,000 67,000

11⁄8 67,000 84,000

11⁄4 85,000 107,000

13⁄8 102,000 127,000

11⁄2 124,000 155,000

(1) Equal to 1.05 times minimum installation tension.

(2) Includes ASTM F3125 Grade A325 and F1852 bolts.

(3) Includes ASTM F3148 Grade 144 bolt.

(4) Includes ASTM F3125 Grades A490 and F2280 bolts.

Start all verification tests from the same condition. Install the bolting assembly in a calibrated bolt 

tension measuring device so that at least three and no more than five threads are located between the 

bearing face of the nut and the bolt head. Install the bolting assembly to the snug tight condition using 

the tools, bolting components, assembly configuration, and installation methods to be used in the work.

Perform verification tests for bolts too short to be installed in a bolt tension measuring device in solid 

steel plates with direct tension indicators (DTIs) instead of a tension measuring device. First calibrate 

the DTI lot with a longer grip surrogate bolt in the bolt tension measuring device. Pretension the 

assembly to the required verification tension shown in Table 555-3 and measure an average gap to the 

nearest 0.001 inch. Install the short bolt assembly in the solid steel plate with the DTI from the 

calibrated lot and perform the prescribed pre-tensioning method. Verify that the average gap in the 

calibrated DTI is no more than the calibrated gap determined from the surrogate bolt calibration. 

Do not use DTIs as a bolt tension measurement device for the turn-of-nut and combined installation 

methods. 

(1) Turn of nut verification. After snugging the bolt assembly in the bolt tension measurement 

device, apply the rotation shown in Table 555-4 to the bolt assembly. After rotation, confirm the 

bolt tension exceeds that shown in Table 555-3. If tension is less than shown in Table 555-3, 

determine the cause and resolve before installing bolt assemblies. Cleaning, lubrication, and 

retesting of these bolting assemblies is allowed if all assemblies are treated in the same manner.

To verify bolts that are too short to fit in a bolt tension measuring device, install the bolt in a solid 

steel plate, snug tighten, and apply the prescribed number of turns from Table 555-4. Fracture of 

the fastener or stripped threads results in failure of the test. After the assembly is removed, run the

nut down the bolt by hand. If the nut can be run down the complete thread length of the bolt, 

excluding thread run-out, the threads are not stripped and the bolt assembly passes the PIV test.
Section 555

517

Table 555-4(1)

Nut Rotation from the Snug-Tight Condition(2)

Bolt Length

Measured from

Underside of Head

to End of Bolt

Geometry of Outer Faces of Bolted Parts

Both Faces

Normal to

Bolt Axis

One Face Normal to

Bolt Axis &

Other Face Sloped

No More than 1:20

(Bevel Washer Not Used)

Both Faces Sloped

No More Than

1:20 from Normal

to Bolt Axis

(Bevel Washers Not Used)

Up to & including

4 diameters 1

⁄3 turn 1⁄2 turn 2⁄3 turn

Over 4 diameters,

but no more than

8 diameters

1

⁄2 turn 2⁄3 turn 5⁄6 turn

Over 8 diameters,

but no more than

12 diameters

2

⁄3 turn 5⁄6 turn 1 turn

(1) Applicable only to connections where all material within the grip of the bolt is steel.

(2) Nut rotation is relative to bolt, regardless of the element (nut or bolt) being turned.

The tolerance is minus 0, plus 60°.

(2) Calibrated wrench verification. After snug tightening the bolt assembly in the bolt tension 

measurement device, determine the torque required for the installation tool to develop a pretension 

in the bolting assembly to at least the required verification tension shown in Table 555-3. Use the 

largest torque measured from the three assemblies tested as the minimum installation torque. Use 

the nut as the turned element in the calibrated wrench method.

When tightening from a snug-tight condition, verify that the wrench adjustment selected by the 

calibration does not produce a nut rotation greater than shown in Table 555-4. If the rotation is 

greater than shown in Table 555-4, determine the cause and resolve before bolt assemblies are 

installed in the work. Cleaning, lubrication, and retesting of these bolting assemblies is allowed if

all assemblies are treated in the same manner.

(3) Twist-off tension control bolt verification. After snug tightening the bolt assembly in the bolt 

tension measurement device, tighten the assembly with the installation tool until the splined end 

shears off. After the splined end has sheared off, confirm the bolt tension exceeds the required 

verification tension shown in Table 555-3. If tension is less than shown in Table 555-3, determine 

the cause and resolve before installing bolt assemblies.

(4) DTI verification. Perform PIV testing for each combination of bolt, nut, and washer rotationalcapacity lot; DTI lot; DTI position and orientation; turned element (bolt head or nut) planned in 

the work, and when the condition of the fasteners or the knowledge or practice of the wrench 

operator is in question. Position the DTI under the stationary element or place a hardened washer 

between the DTI and the turned element. Follow the DTI manufacturer’s recommendations for 

placement and type of hardened washers. If the bolt is the turned element, place the DTI on the 

nut side of the fastener assembly.

Depending on the DTI position and orientation, a flat plate bushing may be needed for bolt tension 

measurement device. Install the bolt, nut, washer, and DTI assembly in the bolt tension 

measurement device so that at least three and preferably no more than five threads are located 

between the bearing face of the nut and the bolt head. Tension the bolt to the load shown in 
Section 555

518

Table 555-3. If an impact wrench is used, ensure the tension developed using the impact wrench 

is no more than two-thirds of the required tension. Use a non-impacting method to achieve the 

required tension. Ensure the number of refusals of the 0.005-inch tapered feeler gauge is no more 

than shown in Table 555-5. 

Table 555-5 

DTI 0.005-Inch Feeler Gauge Verification Refusal Requirements

DTI Spaces

Maximum Verification Refusals

Coated DTIs under 

turned element All other cases

4 3 2

5 4 2

6 5 3

7 6 3

8 7 4

9 8 4

Further tension the bolt until the feeler gauge is refused at all spaces without dead flatting the DTI. 

Do not exceed 95 percent of the average peak tension from the rotation-capacity test results in the 

bolt in this condition. Remove the bolt from the bolt tension measurement device and run down 

the nut by hand for the complete thread length of the bolt excluding thread run-out. 

If any of the above three criteria are not met, determine the cause and resolve before installing 

bolt, nut, washer, and DTI. 

(5) Combined method verification. Apply the manufacturer’s recommended initial torque and 

ensure the bolt tension device reads more than the manufacturer’s minimum initial tension. Apply 

the manufacturer’s recommended angle and ensure the bolt tension measurement device reads a 

final tension at least the required verification tension shown in Table 555-3. If final tension is less 

than shown in Table 555-3, determine the cause and resolve before installing bolt assemblies.

(e) Washers. Conform to ASTM F436. Use a hardened beveled washer where the outer face of the 

bolted parts has a slope greater than 1V:20H with respect to a plane normal to the bolt axis.

Use hardened square or rectangular beveled washers for American Standard Beams and Channels.

If necessary, clip washers on one side to within seven-eighths times the bolt diameter measured from 

the washer center.

Under the following conditions use hardened washers for connections using ASTM F3125, Grade 

A325 and Grade A490 bolts: 

(1) Under the turned element if the tensioning is done by the calibrated wrench method; 

(2) Under both the head and the nut when Grade A490 bolts are installed in material having a 

specified yield point less than 40 kips per square inch; and 

(3) As shown in Table 555-6. 
Section 555

519

Table 555-6 

Washer Requirements for Oversize or Slotted Holes in Outer Plies

Bolt Specified 

Minimum 

Tensile 

Strength

Nominal Bolt 

Diameter, 

inch

Hole Type in Outer Ply

Oversized or Short-Slotted Long-Slotted

120 ksi 1⁄2 to 11⁄2

ASTM F436(1) Minimum 5

/16 in-thick plate washer 

or continuous bar

144 ksi,

150 ksi

≤ 1

> 1

ASTM F436 extra thick or 

ASTM F436 with minimum 

3⁄8 in-thick plate washer or 

continuous bar(1)

ASTM F436 with minimum 

3⁄8 in-thick plate washer or 

continuous bar

(1) Not required under the head of ASTM F3125/F3125 Grades F1852 and F2280, or ASTM F3148 Grade 144 

bolting assemblies with round heads that meet the requirements of ASME B18.2.6 Fasteners for Use in Structural 

Applications and have a bearing circle diameter satisfying the requirements of the relevant ASTM Standard.

Do not use multiple stacked washers to satisfy thickness requirements.

Alternate design fasteners that provide a bearing circle on the head or nut of at least the diameter of 

an ASTM F436 hardened washer may be used without washers. 

(f) Installation. Use fasteners of the same rotation-capacity lot number for each connection. Protect 

fasteners from dirt and moisture. Only remove the fasteners from protected storage that are to be 

installed and tensioned during a work shift. Return unused fasteners to protected storage at the end of 

each shift. Do not remove as-delivered lubricant from fasteners. Discard and replace fasteners for 

slip-critical connections that accumulate rust or dirt before installing. 

Snug-tighten all assemblies using the same means and methods as proven in the PIV test. Start 

snugging with the most rigid part of the connection and proceeding to the free edges. Repeat the 

snug-tightening sequence until the entire connection is in a snug-tight condition.

Install fasteners with specified washers according to Subsection 555.16(e) in properly aligned holes. 

Tension according to Subsections 555.16(f)(1) through (5). Tension within 10 days of snugging. If 

there is longer than 10 days between snugging and tension, remove of representative assemblies from 

the work and conduct new PIV tests. 

When it is impractical to turn the nut, tension the fastener by turning the bolt, except for the calibrated 

wrench method, while preventing the nut from rotating when approved. Provide adequate capacity and 

sufficient air to tension each bolt in 10 seconds if impact wrenches are used.

Do not reuse ASTM F3125 Grade A490 fasteners or any fastener which has been galvanized or coated. 

If approved, non-galvanized ASTM F3125 Grade A325 bolts may be reused once. Touching up or retorquing previously tensioned bolts (which may have been loosened by the tensioning of adjacent 

bolts) will not be considered reuse if the tensioning continues from the initial position and does not 

require greater rotation than shown in Table 555-4. 

(1) Turn of nut installation. After snug tightening, apply the applicable rotation shown in 

Table 555-4 using the same means and methods proven in the PIV test. Apply the rotation starting 

with bolts in most rigid part of the connection and proceeding to the free edges. Prevent rotation 

of the part not turned by the wrench during the tensioning operation. 
Section 555

520

(2) Calibrated wrench installation. After snug tightening, apply the maximum torque as 

determined in PIV testing to every nut starting with the most rigid part of the connection and 

proceeding to the free edges. The bolt cannot be the turned element. Return the wrench to touch 

up previously tensioned bolts which may have been relaxed as a result of the subsequent tensioning 

of adjacent bolts until all bolts are tensioned to the prescribed amount. Use the calibrated wrench 

method only when wrenches are calibrated using the PIV test on a shift basis. Recalibrate wrenches 

when a significant difference is noted in the surface condition of the bolts, threads, nuts, or 

washers. If manual torque wrenches are used, torque nuts in the tensioning direction when torque 

is measured.

If tightening from a snug-tight condition, verify that the wrench adjustment selected by the 

calibration does not produce a nut rotation greater than shown in Table 555-4. 

(3) Twist-off tension control bolt installation. After snug tightening, shear off the splined ends 

using the same installation tool used in the PIV test. 

(4) DTI installation. After snug tightening, ensure no DTI has more refusals than shown in 

Table 555-7. Replace DTIs that fail the requirement. Continue to tighten the assemblies until the 

number of refusals is equal to or greater than shown in Table 555-7 and the feeler gauge can be 

partially entered in at least one gap. 

Table 555-7 

DTI 0.005-Inch Feeler Gauge Installation Refusal Requirements

DTI Spaces

Minimum Verification Refusals

Coated DTIs under 

turned element All other cases

4 3 3

5 4 3

6 5 4

7 6 4

8 7 5

9 8 5

(5) Combined method installation. Install bolt assemblies in the connection and torque to the 

initial installation torque provided by the manufacturer. Progress torquing systematically from the 

most rigid part of the joint to its free edges. Return the wrench to “touch up” previously snugged 

bolts. After snug tightening, apply the manufacturer’s specified rotation to every turned element. 

If the bolt length measured from the underside of the head to the end of the bolt exceeds 

12 diameters, determine the required rotation by actual tests in a tension device simulating the 

actual conditions. 

(6) Alternate design bolt installation method. If approved, provide alternate fasteners that meet 

the material, manufacturing, and chemical composition requirements of ASTM F3125, Grade 

A325 or A490 and: 

(a) Meet the mechanical property requirements of the same specification in full-size tests; and

(b) Have body diameter and bearing areas under the head and nut, or their equivalent, at least 

those provided by a bolt and nut of the same nominal dimension. 
Section 555

521

Install alternate design bolts in connection holes according to the manufacturer’s recommendations 

and pull the plies to firm contact throughout the connection. Tighten bolts snug-tight without 

yielding or fracturing the control or indicator element of the fastener.

Further tension fasteners starting with bolts in most rigid part of the connection and proceeding to 

the free edges. Proper tensioning of the bolts may require more than a single cycle of systematic 

partial tensioning. Replace individual fastener assemblies if yielding or fracture occurs before the 

final tensioning cycle. 

Verify the tension according to Subsection 555.16(d). 

(7) Inspection. Inspect the tensioned fasteners in the presence of the CO. Replace or re-tension 

loose or relaxed fasteners. Do not remove fasteners by cutting with a torch. 

(a) Non-threaded fasteners. Ping each fastener with a hammer to test for soundness.

(b) Threaded fasteners. Use an inspection torque wrench to verify tensioning unless alternate 

fasteners or DTI devices are used allowing verification by other methods. 

Calibrate the inspection torque wrench at least once each inspection day. Individually place 

three fastener assemblies of the same grade, size, and condition as those under inspection in a 

device calibrated to measure bolt tension. Use a washer under the part turned in tightening each 

bolt if washers are used on the structure. Use the same material that abuts the part turned in the 

tension measuring device as used on the structure if washers are not used on the structure. In 

the calibration device, tighten each bolt to the specified tension. Apply the inspecting wrench 

to the tightened bolt to determine the torque required to turn the nut or head 5 degrees, 

approximately 1 inch at a 12-inch radius, in the tightening direction. Use the average of the 

torque required for all three bolts as the job-inspection torque.

Randomly select 10 percent (at least two) of the tensioned bolts on the structure in each 

connection represented by the test bolts. Apply the job-inspection torque to each selected bolt 

with the inspecting wrench turned in the tensioning direction. If this torque turns no bolt head 

or nut, the fastener is properly tensioned. If the torque turns one or more bolt heads or nuts, 

apply the job-inspection torque to all bolts in the connection. Re-torque and re-inspect fasteners 

whose head or nut turns. 

555.17 Welding. Comply with AASHTO/AWS D1.5, Bridge Welding Code for welding, welder 

qualifications, prequalification of weld details, and inspection of welds. For tubular connections, conform 

to AWS D1.1, Structural Welding Code – Steel, Section 10, Part D. 

Do not weld or tack brackets, clips, shipping devices, or other non-required material to members unless 

shown in the drawings. 

555.18 Erection. Install falsework and forms according to Section 562. Coat structural steel according to 

Section 563. Use steel erectors certified under the AISC, Quality Certification Program. 

(a) Handling and storing material. Place stored material on skids above ground. Keep material clean 

and properly drained. Place and shore girders and beams upright. Support long members (such as 

columns and chords) on skids placed close enough together to prevent deflection damage. 
Section 555

522

(b) Bearings and anchorages. Provide and install bridge bearings according to Section 564. 

(c) Erection procedures. Erect according to the approved drawings. Submit revised drawings and 

verification of stresses and geometry for modifications to or deviations from the approved erection 

procedure for approval. 

(1) Erection stresses. Allow for erection stresses locked in the structure caused by erection 

methods or equipment that differ from those previously approved. Provide additional material 

necessary to keep both temporary and final stresses within the allowable limits used in the design.

Provide temporary bracing or stiffening devices to accommodate handling stresses in individual 

members or segments.

(2) Maintaining alignment and camber. Support structural segments to produce the proper 

alignment and camber in the completed structure. Install cross frames and diagonal bracing during 

erection to provide stability and ensure correct geometry. Provide temporary bracing at any stage 

of erection.

(d) Field assembly. Clean bearing surfaces and permanent contact surfaces. Assemble material as 

shown in the approved drawings and match-marks. Do not hammer, damage, or distort members. 

For bolted splices and field connections, fill one-quarter of the holes with bolts and one-quarter of the 

holes with cylindrical erection pins before placing permanent fasteners. For continuous units, pin and 

bolt all beam and girder splices and bring the splices to the correct elevations before permanently 

fastening. For bolted connections, use fit-up bolts with the same nominal diameter as the permanent 

fasteners, and use cylindrical erection pins with a diameter 1⁄32 inch larger than the bolts. Evenly space 

the pins around the connection. Place pins in the corner holes of the splice plates. Systematically 

remove fitting-up bolts and cylindrical erection pins and replace them with tightened high-strength 

bolts. Start from the most rigid part of connection and proceed to the free edges. 

Release temporary erection supports at a splice or connection only after bolts are installed and 

tightened. Show special assembly and support situations on the erection drawings. 

(e) Pin connections. Use pilot and driving nuts when driving pins. Drive pins so that the members 

fully bear on the pins. Screw pin nuts tight and burr the threads at the face of the nut with a pointed 

tool. 

(f) Misfits. Correct minor misfits using small amounts of reaming, cutting, grinding, and chipping. 

Remove and replace members misfit due to shop fabrication error or deformation during handling or 

transporting. 

555.19 Contact with Other Material. Place an unvulcanized virgin polychloroprene rubber (neoprene) 

waterproofing sheet between the structural steel and timber surfaces. Provide a continuous 1⁄8-inch thick 

sheet conforming to AASHTO M 215, with a low temperature Grade 2 and a hardness of 50±5. 

555.20 Acceptance. Material for steel structures will be evaluated under Subsections 106.02 and 106.03. 

Construction of steel structures will be evaluated under Subsections 106.02 and 106.04. 

Bearing devices will be evaluated under Section 564. 
Section 555

523

Coatings will be evaluated under Section 563. 

Temporary works will be evaluated under Section 562. 

Measurement

555.21 Measure the Section 555 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring structural steel by the pound, measure structural steel computed according to AASHTO, 

LRFD Bridge Construction Specifications. 

When measuring structural steel by the contract quantity, changes in quantities resulting from alternative 

details proposed by the Contractor and accepted as a part of the drawings are not subject to adjustment 

according to Subsection 109.06. 

Payment

555.22 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 555 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 556

524

Section 556. — BRIDGE RAILING

Description

556.01 This work consists of providing, erecting, removing, and resetting bridge railings. 

Material 

556.02 Conform to the following Subsections: 

Aluminum alloy for bridge rail 717.10

Aluminum bolt heads and nuts 717.11

Aluminum welding wire 717.12

Box beam rail 724.01(b)

Construction Requirements

556.03 General. Accurately place anchor bolts to provide correct and true alignment of the railing. Set 

anchor bolts so that they project no more than 3⁄8 inch beyond the nut when tightened. Chamfer or round 

by grinding or filing sharp exposed metal edges. 

Do not erect railing until centering or falsework for the supporting span is removed. Construct bridge 

railing so that it does not follow unevenness in the curb, sidewalk, or wall that supports the railing. Install 

railing to present a smooth and uniform appearance in its final position. Set posts vertical. 

556.04 Concrete Railing. Conform to Section 552. Construct reinforcing steel according to Section 554. 

556.05 Steel Railing. Conform to Section 555. 

556.06 Aluminum Railing. Conform to Section 555, except as modified by the following: 

(a) Cutting. Material that is 1⁄2 inch thick or less may be cut by shearing, sawing, or milling. Saw or 

mill material that is over 1⁄2 inch thick. Do not flame cut. Make cut edges true, smooth, and without 

excessive burrs or ragged breaks. Fillet reentrant cuts by drilling before cutting.

(b) Bending. Material may be heated to a maximum 400 °F for no more than 30 minutes to facilitate 

bending. 

(c) Rivet and bolt holes. Drill rivet and bolt holes to finished size or subpunch smaller than the 

nominal diameter of the fastener and ream to size. Subpunch to a diameter that is smaller than that of 

the finished hole by at least one-quarter the thickness of the piece. Make the finished diameter of holes 

no more than 7 percent greater than the nominal diameter of the fastener, except:

(1) Fabricate slotted bolt holes as required; and

(2) Fabricate anchor bolt holes up to 25 percent larger, no more than 1⁄2 inch larger than the nominal 

bolt diameter.

(d) Welding. Weld according to AWS D1.2, Structural Welding Code - Aluminum. 
Section 556

525

(e) Contact with other material. Protect aluminum alloys that contact other material as follows:

(1) Aluminum alloys in contact with other metals. Coat the contacting surfaces with dielectric 

aluminum-impregnated caulking compound or place a synthetic rubber gasket between the 

surfaces.

(2) Aluminum alloys in contact with stone or concrete.

(a) If a bond is not required, coat the contacting surfaces with aluminum-impregnated caulking 

compound or with heavy bituminous coating pigmented with aluminum powder or paste. 

(b) If a bond is required, coat the contacting aluminum surface with zinc-chromate coating. 

Allow coating to dry before installation.

(3) Aluminum alloys in contact with wood. Coat the contacting wood surface with three coats 

of coating material according to Section 563 and coat the contacting aluminum surface with 

aluminum-impregnated caulking compound.

556.07 Timber Railing. Conform to Section 557. 

556.08 Remove and Reset Bridge Railing. Salvage the existing bridge railings and appurtenances

according to Subsection 203.04. Reset bridge railings as shown in the plans. Replace railings, supports, 

and hardware damaged during removal, storage, or resetting. 

556.09 Coating. Conform to Section 563. 

556.10 Acceptance. Material (except concrete, coating, reinforcing steel, structural steel, and timber) for 

bridge railings will be evaluated under Subsections 106.02 and 106.03. Submit a production certification 

with each shipment of bridge railing.

Construction of bridge railings will be evaluated under Subsections 106.02 and 106.04. 

Coatings will be evaluated under Section 563. 

Concrete will be evaluated under Section 552, except compressive strength will be evaluated under 

Subsection 106.04. 

Reinforcing steel will be evaluated under Section 554. 

Steel structures will be evaluated under Section 555. 

Timber structures will be evaluated under Section 557. 

Measurement

556.11 Measure the Section 556 pay items listed in the bid schedule according to Subsection 109.02. 
Section 556

526

Payment

556.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 556 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 557

527

Section 557. — TIMBER STRUCTURES

Description

557.01 This work consists of fabricating, treating, erecting, and coating structural timber.

Material 

557.02 Conform to the following Section and Subsections: 

Galvanized coatings 717.07

Gray iron castings 717.04(c)

Malleable iron castings 717.04(d)

Material for timber structures 716

Structural carbon steel 717.01(a)

Construction Requirements

557.03 General. Excavate and backfill according to Section 208. 

Use slings or other devices to protect the corners of heavy timbers and banded packages of lighter timber.

Cut and form lumber and timber so joints have even bearing over their entire contact surface. Do not use 

shims in making joints. Close all joints. Drive nail and spike heads flush with the wood surface. 

Use the same end, face, and edge of the timber member for all layout dimensions. Bore holes from mating 

faces.

557.04 Storing Material. Store material in an area cleared of weeds, rubbish, or other deleterious material. 

Elevate material at least 8 inches above the ground. Provide sufficient support to prevent sagging. 

Open-stack untreated material to shed water. Allow for free air circulation by stacking material in layers 

on stickers that extend across the full width of the stack. Align stickers vertically and space them at regular 

intervals.

Close-stack treated material to shed water.

Protect material from the elements. Use water-resistant paper or opaque polyethylene film if material is 

be covered. Do not use impervious membranes (such as polyethylene film) during dry weather. Slit or 

puncture individual wrappings full length on the lower side to allow water drainage. 

Store and protect glued laminated timber according to AITC 111, Recommended Practice for Protection

of Structural Glued Laminated Timber During Transit, Storage and Erection. 

557.05 Holes for Drift Pins, Dowels, Bolts, and Lag Screws. Bore holes before preservative treatment.

Bore holes for round drift pins and dowels to a diameter 1⁄16 inch less than the diameter of the pin or dowel. 

Bore holes for square drift pins and dowels to a diameter equal to the side dimension of the pin or dowel. 

Bore holes for galvanized bolts to a diameter 1⁄16 inch larger than the diameter of the bolt.
Section 557

528

Bore holes for lag screws to a bit not larger than the body of the screw at the base of the thread. 

557.06 Treating Timber. Indicate the preservative used, penetration in inches, and the retention in pounds 

per cubic foot (assay method). 

Cut, frame, and bore timbers before treatment. Do not cut or bore timber below the high-water mark in 

coastal waters.

Handle treated timber according to AWPA M4, Standard for the Handling, Storage, Field Fabrication, 

and Field Treatment of Preservative-Treated Wood Products. Do not drip or spill preservative into an 

aquatic environment or onto the ground. Handle treated timbers to prevent damage to their surfaces. Do 

not use cant hooks or pike poles. 

Field treat cuts or abrasions with preservative. Dip, soak, spray, or apply three brush coats of the same 

preservative according to AWPA M4.

Impregnate holes bored after treatment with the same preservative using tools suitable for proper 

application. Plug unused holes with the same treated timber. 

557.07 Hardware. Galvanize hardware and fasteners, including nails, spikes, bolts, washers, and timber 

connectors according to AASHTO M 232.

Use washers under bolt heads and nuts in contact with wood. Fabricate washers from gray iron or 

malleable iron castings. Use malleable iron washers with a diameter approximately three times the bolt 

diameter. Use steel washers only when specified.

Use cut or round wire nails of standard form. Use cut, round, or boat spikes as specified. 

Cut off excess bolt lengths of more than 1 inch. After final tightening, check or burr bolts with a pointing 

tool to prevent loosening of the nuts. 

Use split-ring or shear-plate timber connectors conforming to Section 16.2.6 of AASHTO, LRFD Bridge 

Construction Specifications. 

For fasteners in contact with wood treated with copper-based preservatives, use Type 316 stainless steel 

or hot-dipped galvanized steel that conforms to ASTM A153 or A653, Class G185. For wood structures 

immersed in or within one mile of salt or brackish water, use Type 316 stainless steel fasteners and 

hardware.

557.08 Countersinking. Countersink screws, bolts, and nuts where required. Treat countersunk recesses 

with an approved preservative before filling, except in railings. Fill the recess with hot pitch or other 

approved filler after bolts, screws, and nuts are in place.

557.09 Framing. Do not slab or trim treated piles when fitting sway or sash braces. Securely fasten braces 

to smaller piles using treated blocks to fill the gaps.

557.10 Framed Bents. For mud sills, firmly and evenly bed mud blocks to solid bearing. Tamp in place. 
Section 557

529

Finish concrete pedestals supporting framed bents so that sills or posts bear evenly on the pedestals. When 

concrete is cast, set dowels for anchoring sills and posts to project at least 6 inches above the tops of the 

pedestals.

Make sills bear evenly and true on mud blocks, piles, or pedestals. Bolt sills into place with drift bolts that 

extend into the mud blocks or piles for at least 6 inches. Where possible, remove material in contact with 

sills for circulation of air around the sills.

557.11 Bent Caps. Make timber caps bear evenly and uniformly over the tops of aligned supporting posts 

or piles. Secure caps with drift bolts extending at least 9 inches into the approximate center of each post 

or pile. 

557.12 Bracing. Bolt the ends of bracing through the pile, post, cap, or sill. Bolt intermediate intersections 

and spike with wire or boat spikes. Use galvanized spikes in addition to bolts. 

Make bracing bear firmly against the pile or cap to which it is bolted. Provide and place shims as necessary 

to prevent bending of the bracing more than 1 inch out of true when bracing bolts are tightened. 

Shim based on the spacing between the bracing and cap or pile as follows: 

(a) Less than 1 inch, shims are not needed; 

(b) From 1 to 2 inches, place two ogee washers with their narrow faces together or other approved 

washers on each bolt that passes through the space; or

(c) Over 2 inches, use wooden shims of the proper thickness. 

Fabricate the wooden shims from the same treated wood used in the structure. Do not use built-up wooden 

shims. Make wooden shims from a single piece of lumber with the width at least 4 inches and the length 

at least the width of the bracing measured along the cap or pile. Do not adze, trim, or cut treated members 

to avoid the use of shims. 

557.13 Stringers. Size stringers at bearings. Position stringers so knots near edges are in the top portion 

of the stringer.

Outside stringers may have butt joints with ends cut on a taper. Lap interior stringers so both stringer ends 

have full length bearing on a floor beam or cap. Stagger joints where stringers are two panels in length. 

Separate lapped ends of untreated stringers by at least 1⁄2 inch for air circulation. Use drift bolts to securely 

fasten the lapped ends.

Place cross-bridging at the center of each span. Cut cross-bridging members to provide full bearing on the 

stinger sides at each end. Securely toenail the cross-bridging with at least two nails in each end. If blocking 

is used, make it fit snugly and securely. 

557.14 Plank Decks. Use planks that are surfaced on four sides (S4S).

Grade plank thickness so no two adjacent planks vary in thickness by more than 1⁄8 inch. Lay the planks 

heart side down with 1⁄4 inch space between them for dry, seasoned material and with no joint space for 

unseasoned material. Spike each plank securely to each stringer.
Section 557

530

For two-layer timber plank decks, treat the lower layer according to Subsection 557.06. Lay the top layer 

either diagonally or parallel to the roadway centerline. Stagger joints at least 36 inches. Securely fasten 

each top layer member to the lower layer. Where the top layer is placed parallel to the centerline of the 

roadway, use special care to securely fasten the ends of the flooring. Bevel the ends of top layer members 

at each end of the structure. 

557.15 Transversely Nail Laminated Decks. Use 2-inch nominal thickness laminations, surfaced on one 

side and one edge. 

Place the laminations on edge parallel to the skew as shown in plans with the surfaced edge facing 

downwards. Attach each piece to the preceding piece using spikes of sufficient length to pass through two 

pieces and at least halfway through the third piece. Drive spikes at each end and at approximately 18-inch 

intervals alternately driving near the top and bottom edges. 

Securely attach the deck to stringers using approved galvanized metal clips. 

Use pieces of sufficient length to bear on at least four stringers. Do not splice pieces between stringers. 

Space end joints on a stringer no closer than every third piece. Space end joints in adjoining pieces no 

closer than every second stringer.

557.16 Glue Laminated Panel Decks. When handling and transporting, avoid bending panels, especially 

transverse to the laminated pieces. When lifting a panel, support it at a sufficient number of points to 

prevent damage and distortion. Do not drag or skid panels. Protect the panel edges from damage. 

When dowels are used between panels, use a template or drilling jig to properly space dowel holes. Drill 

holes the same diameter as the dowel and 1⁄4 inch deeper than one-half of the dowel length. Slightly taper 

or round dowel tips and lubricate dowels to facilitate the connection process. 

Start the tips of the dowels partially and equally in the holes of the panels to be joined. Draw the panels 

together, keeping the edges parallel, until the panels abut tightly. Securely fasten each panel to each 

stringer.

557.17 Wheel Guards and Railings. Use S4S timber for wheel guards, rails, and posts. Place wheel 

guards in at least 12-foot lengths. Squarely butt-joint rails at posts.

557.18 Trusses. Avoid irregularities in alignment. In horizontal projection, fabricate chords straight and 

true from end-to-end. In vertical projection, fabricate chords to a smooth, corded curve through panel 

points conforming to the correct camber. Make bearing surfaces fit accurately. Do not make uneven or 

rough cuts at the points of bearing. 

557.19 Coating. If required, coat according to Section 563. 

557.20 Acceptance Material for timber structures will be evaluated under Subsections 106.02 and 106.03. 

Submit a production certification with each shipment of structural timber and lumber. If treated, indicate 

the preservative used, penetration inches, retention in pounds per cubic foot (assay method), and the BMP 

used in treating timber members.

Construction of timber structures will be evaluated under Subsections 106.02 and 106.04. 

Coatings will be evaluated under Section 563. 
Section 557

531

Excavation and backfill will be evaluated under Section 208. 

Measurement

557.21 Measure the Section 557 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring untreated and treated structural timber and lumber by the thousand board feet measure, 

measure in the structure.

Compute the quantities from nominal dimensions and actual lengths, except for transversely nail 

laminated decks and glue laminated panel decks. Measure transversely nail laminated decks and glue 

laminated panel decks in place after dressing.

Payment

557.22 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 557 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 558

532

Section 558. — DAMPPROOFING

Description

558.01 This work consists of dampproofing concrete and masonry surfaces. 

Material 

558.02 Conform to the following Subsection: 

Dampproofing material 723.01

Construction Requirements

558.03 Dampproofing. Cure the concrete or masonry surface according to Subsection 552.13, except do 

not use liquid membrane curing compound. Allow concrete surface to dry at least 10 days after completion 

of curing. 

Apply dampproofing to a dry, clean, and reasonably smooth surface that is free of dust and loose material. 

Apply dampproofing in dry weather when the air and surface temperatures are 45 °F or higher. 

Apply primer to the surface and allow it to dry. Apply two coats of asphalt at the rate of approximately 

25 pounds per 100 square feet of surface per coat. Apply prime coat and asphalt coats uniformly, covering 

the surface, and work them into the surface. Allow first coat to dry before second coat is applied. Make 

the total of the final two asphalt coats approximately 3⁄32 inch thick. Allow asphalt coats to harden before 

allowing contact with water or backfill material.

558.04 Acceptance. Material for dampproofing will be evaluated under Subsections 106.02 and 106.03. 

Applying dampproofing will be evaluated under Subsections 106.02 and 106.04. 

Measurement

558.05 Measure the Section 558 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

558.06 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 558 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 559

533

Section 559. — WATERPROOFING AND SEALING

Description

559.01 This work consists of providing and installing waterproofing systems on concrete surfaces and 

sealing concrete surfaces.

Material 

559.02 Conform to the following Subsections: 

Blotter 703.12

Penetrating sealant 725.20

Sealants, fillers, and seals 712.01

Waterproofing material 723.02

Construction Requirements

559.03 Qualifications. At least 30 days before starting waterproofing work, submit the following for 

approval: 

(a) Waterproofing systems. Provide an on-site supervisor, waterproofing system provider, on-site 

technical representative, and membrane applicator with experience installing waterproofing systems 

on concrete surfaces. 

(1) On-site supervisor. A résumé describing experience on at least three concrete bridge 

waterproofing projects within the past 5 years. Include project names, a brief description of each 

project, construction dates and quantities, locations, and contact information for project owners; 

(2) Waterproofing system provider. Documentation from the waterproofing system provider 

describing experience on at least five concrete bridge waterproofing projects within the past

5 years. Include project names, a brief description of each project, construction dates and 

quantities, locations, and contact information for project owners; 

(3) On-site technical representative. A résumé describing experience on at least three bridge 

deck waterproofing projects within the past 3 years. Include project names, a brief description of 

each project, construction dates and quantities, locations, and contact information for project 

owners; and 

(4) Membrane applicator. Manufacturer certification documenting that the membrane applicator 

is an approved applicator with the required training. 

(b) Concrete sealer. A résumé describing experience on at least three concrete bridge sealing 

operations within the past 5 years. Include project names, a brief description of each project, 

construction dates and quantities, locations, and contact information for project owners. 

559.04 General. Conduct a preapplication preparatory phase meeting according to Subsection 153.06(a)

at least 7 days before the start of operations. Review QCP procedures with personnel performing the work 

before start of installation.
Section 559

534

Store sealers and waterproofing materials in a dry, protected, climate-controlled location, and according 

to the manufacturer’s recommendations. Do not store rolls standing on end. Protect materials from sparks 

or flames.

Provide accessory materials that are compatible with membrane according to the membrane 

manufacturer’s recommendations. 

Protect surfaces, including scuppers, drains, dams, and headers, that will not be waterproofed by masking 

with oil-resistant, adhesive-backed construction paper. Prevent materials from coating surfaces not 

receiving or immediately receiving the waterproofing. Upon completion, remove the adhesive-backed 

construction paper from all surfaces. 

Provide certification from the waterproofing system provider’s on-site technical representative that the 

membrane installation complies with the manufacturer’s recommendations. 

559.05 Substrate Preparation. 

(a) Waterproofing membrane. Before waterproofing installation, sound the entire bridge deck in the 

presence of the CO according to ASTM D4580 to identify unsound substrate concrete. Submit repair 

areas, method, and materials for approval. Repair concrete according to Section 572. 

Ensure the concrete surface is free of projections or depressions that might cause puncture of the 

membrane. Provide a substrate surface profile with less than 1⁄4-inch projections or depressions or 

according to the manufacturer’s recommendations. Provide a clean concrete surface free of 

contaminants that could interfere with the proper function of the waterproofing system. Do not place 

membranes on damp or wet concrete. Do not place membranes on new concrete until at least 10 days 

after completion of the concrete curing process according to Subsection 552.13. Apply waterproofing 

in dry weather when the concrete substrate and ambient temperatures are at least 40 °F and are 

expected to remain above 40 °F during application. 

Do not expose cleaned surfaces to vehicles or equipment other than required by the waterproofing 

operation. If the deck becomes contaminated before installation, clean the contaminated areas. 

Before waterproofing placement, ensure that the substrate concrete is clean and dry with a moisture 

content in the deck substrate less than 5.0 percent as determined by an approved electronic moisture 

meter. Ensure that the concrete substrate is 5 °F above the dew point according to ASTM D4230 before 

applying the waterproofing system. 

(b) Sealers. Clean concrete surface according to manufacturer’s recommendations before application. 

Do not place sealer on damp or wet concrete. Do not place sealer on new concrete until at least 10 days 

after completion of the concrete curing process according to Subsection 552.13. Apply sealer in dry 

weather when the concrete substrate and ambient temperatures are at least 40 °F and are expected to 

remain above 40 °F during application. Ensure that the concrete substrate is 5 °F above the dew point 

according to ASTM D4230 before applying the sealer. 

559.06 Primer Application for Waterproofing Membrane Systems. Review QCP procedures with 

personnel performing the work before starting the primer application. Prevent primer from coating 

surfaces not receiving or immediately receiving the waterproofing.
Section 559

535

Monitor ambient temperature, surface temperature, moisture content of concrete, and dew point during 

primer application according to Subsection 559.05. 

Mix and apply primer according to the manufacturer’s recommendations. Continuously agitate the primer 

during application. Apply primer starting at the lowest point on bridge deck and work upwards. Work 

primer up the grade and up the cross slope during application. Overlap start of new day of primer 

installation over previous day’s primer according to the manufacturer’s recommendations.

Apply primer to ensure complete coverage. Prevent and remove puddling and excess buildup. If the 

primed surface becomes contaminated, clean and reapply primer.

Cure primer according to the manufacturer’s recommendations. Break bubbles in the primer according to 

the manufacturer’s recommendations before testing primer bond strength.

559.07 Waterproofing Systems. Provide one of the following waterproofing systems: 

(a) Seamless spray-applied system. A seamless spray-applied waterproofing system consists of a 

seamless, cold liquid applied multi-component polymer. The seamless spray-applied system includes 

primer, elastomeric spray-applied membrane, and an elastomeric membrane topcoat containing 

broadcast aggregate for the placement of an asphalt concrete pavement wearing course.

Monitor ambient temperature, surface temperature, moisture content of concrete, and dew point during 

spray membrane application according to Subsection 559.05. Provide wind breaks to minimize 

overspray. Do not apply spray membrane when wind speeds measured 2 feet above the deck exceed 

10 miles per hour with windbreaks in place. 

(1) Primer bond strength test. Verify bond strength of primer to concrete substrate by attaching 

a metal dolly to the primed area of concrete. Test for bond strength according to ASTM D7234. 

Perform at least one test per 2500 square feet of primed deck or one per day. Consider the bond 

strength of primer sufficient if the bond pull-off test exceeds 150 pounds per square inch. If the 

bond pull-off fails, establish adequate bond according to the manufacturer’s representative 

recommendations. Repair test areas according to the manufacturer’s recommendations.

(2) Membrane installation. When the primer has been accepted, start membrane installation.

Mix and apply spray membrane according to the manufacturer’s recommendations. Continuously 

agitate the liquid spray membrane during application. Apply spray membrane starting at the lowest 

point on bridge deck and work up the grade and up the cross slope during application. Lap spray 

membrane up curb 2 inches or the thickness of the asphalt pavement overlay. At the start of each 

day’s operations, overlap the previously applied spray membrane according to the manufacturer’s 

recommendations.

Apply membrane at a thickness of 80 mils. 

Prevent and remove puddling and excess buildup. If the spray membrane becomes contaminated, 

clean and reapply the membrane.

Cure spray membrane according to the manufacturer’s recommendations. Break bubbles in the 

spray membrane according to the manufacturer’s recommendations before testing the bond 

strength of the membrane.
Section 559

536

Verify bond strength of spray membrane to primed concrete by attaching a metal dolly to the 

waterproofed area. Test for bond strength according to ASTM D7234. Perform at least one test per 

2500 square feet of waterproofed deck or one per day. Consider the bond strength of the membrane 

sufficient if the bond pull-off test exceeds 150 pounds per square inch. If bond pull-off fails, 

establish adequate bond according to the manufacturer’s representative recommendations. Repair 

test areas according to the manufacturer’s recommendations.

(3) Elastomeric membrane topcoat with broadcast aggregate. Review QCP procedures with 

personnel performing the work before start of elastomer membrane topcoat installation.

When the waterproofing membrane has been accepted, start elastomeric membrane topcoat 

installation.

Apply elastomeric membrane topcoat according to the manufacturer’s recommendations. Apply 

elastomeric membrane topcoat at a thickness of 40 mils. Use approved aggregate source and 

gradation to broadcast into elastomeric topcoat. Broadcast aggregate uniformly according to the 

manufacturer’s recommendations. Apply elastomer aggregate broadcast topcoat starting at the 

lowest point on bridge deck and work up the grade and up the cross slope during application. 

Overlap start of a new day of elastomer aggregate broadcast topcoat construction over previous 

day’s work according to the manufacturer’s recommendations.

Cure topcoat according to the manufacturer’s recommendations. 

Lightly vacuum sweep excess aggregate from cured topcoat. Dispose of excess aggregate 

according to Subsection 203.07. 

(b) Preformed membrane system. A preformed membrane system consists of a primer applied to 

the prepared surface and a single layer of adhering preformed membrane sheet. The preformed 

membrane system includes primer, bituminous polymer or asphalt rubberized preformed membrane 

sheet with self-adhering backing, and materials for sealing of joints and around inlets, curbs, or other 

features.

Place the waterproofing membrane continuously within the masked areas within the time frame 

recommended by the manufacturer. If this time is exceeded, reapply the primer. Do not apply 

waterproofing membrane over wet primer.

Lap membrane sheets in the direction of water flow. Stagger membrane overlaps in the transverse 

direction so that transverse seams do not line up.

(1) Bridge decks.

(a) Install a 12-inch minimum width strip along the juncture of deck and base of barrier railing 

or curb face at the low side of the deck with the sheet extending up the face 3 inches; 

(b) Starting at the gutter line, lay sheets longitudinally and side lapped with adjacent sheets by 

at least 21⁄2 inches and end lapped by at least 6 inches;

(c) Place a 12-inch minimum width strip at the juncture of deck and base of curb or railing at 

the high side of the deck extending up the face 3 inches; 
Section 559

537

(d) Cut the membrane sheet and turn into the joint or bleeder as the sheet is being laid at open 

joints, deck bleeder pipes, and other locations as needed; 

(e) For rubberized asphalt sheets and modified bitumen sheets, apply mastic as a bead along 

the exposed edge of the membrane sheet that extends up the barrier railing or curb face and 

that ends in the high-side gutter. Seal terminations with mastic compatible with waterproofing 

system according to the manufacturer’s recommendations; and 

(f) Leave 12 inches of membrane to tie into if waterproofing one side of a deck at a time.

(2) Surfaces other than bridge decks. Install according to Subsection 559.07(b)(1) and the 

following:

(a) Place membrane vertically. Lap successive sheets at least 3 inches over the previous sheet;

(b) Lap horizontal splices by at least 6 inches;

(c) Place a troweled bead of manufacturer’s recommended mastic or sealing tape along 

exposed edges of the installed membrane;

(d) Flash projecting pipe, conduits, sleeves, or other facilities passing through the preformed 

membrane waterproofing;

(e) Use prefabricated or field-fabricated boots, fitted coverings, or other devices as necessary 

to provide watertight construction; and

(f) Make a seal with the curb up to the depth of the overlay. 

Roll the surface with hand rollers or other apparatus as necessary to develop a firm and uniform bond 

to the primer and minimize wrinkles and air bubbles.

Patch tears, cuts, or narrow overlaps by placing sections of membrane sheet over the defective area so 

that the patch extends at least 6 inches beyond the defect. Seal edges of patches with a mastic 

recommended by the manufacturer. On modified bitumen sheets with a permanent polyester film, use 

a propane torch to melt the polyester film on the section to be patched, then place the patch over the 

heated surface. Press or roll patches firmly onto the surface.

559.08 Concrete Sealers. Protect all surfaces, including scuppers, drains, dams, and headers, that will not 

be sealed by masking with materials that are non-reactive to the sealer. Remove the masking material from 

all surfaces after completion of sealer application.

Monitor ambient temperature, surface temperature, moisture content of concrete, and dew point during 

sealer application according to Subsection 559.05. Provide wind breaks to minimize overspray if using a 

sprayer system to apply sealer. Do not apply sealer with sprayer systems when wind speeds measured 

2 feet above the deck exceed 10 miles per hour with windbreaks in place. 

Apply sealer according to manufacturer’s recommendations. Do not allow puddles to occur on low spots 

for horizontal surface applications. Do not allow puddling at curb lines on bridge deck applications. Do 

not allow excessive dripping to occur during application on vertical surfaces.
Section 559

538

Do not allow any pedestrian or vehicular traffic until sealer has sufficiently cured. Provide blotter for 

newly cured sealed horizontal surfaces subject to traffic. Remove blotter 72 hours after opening to traffic 

and dispose of blotter according to Subsection 203.07.

559.09 Protective Covering. Install a protective covering immediately after waterproofing that prevents 

damage to the membrane from sunlight, weather, traffic, and construction operations. 

If backfill will be placed against waterproofed surfaces, cover the membrane with 1⁄8-inch thick hardboard 

or other approved material. 

559.10 Asphalt Concrete Pavement Overlay Placement. Do not place the overlay until the CO has 

accepted the waterproofing. Protect the waterproofing from damage. Limit traffic on the waterproofing 

system to necessary construction equipment and emergency vehicles before overlay placement. Do not 

turn vehicles or equipment on the membrane. Avoid abrupt starts and stops. 

Sweep the membrane surface before placing the overlay. Repair damaged areas on the membrane before 

starting overlay placement. If recommended by the manufacturer, apply an asphalt tack coat according to 

Section 412 before placing the overlay. 

Place the overlay continuously over waterproofed and masked areas according to the applicable asphalt 

concrete pavement Section, as soon as possible and within 48 hours after placing the membrane. Limit the 

lay-down temperature of the asphalt concrete mix according to the manufacturer’s recommendations. Do 

not windrow asphalt concrete on the waterproofing membrane ahead of the paving machine. Do not use 

an asphalt concrete pickup machine. Make subsequently asphalt pavement cuts at or near the expansion 

joint after the overlay is in place.

559.11 Acceptance. Material for waterproofing systems and sealing concrete surfaces will be evaluated 

under Subsections 106.02 and 106.03. 

Installation of waterproofing systems will be evaluated under Subsections 106.02, 106.03, and 106.04. 

Sealing concrete surfaces will be evaluated under Subsections 106.02, 106.03, and 106.04. 

Asphalt tack coat will be evaluated under Section 412. 

Concrete repairs will be evaluated under Section 572. 

Measurement

559.12 Measure the Section 559 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

559.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 559 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 560

539

Section 560. — REMOVAL OF CONCRETE BY HYDRODEMOLITION

Description

560.01 This work consists of removing concrete with high-pressure water jets.

Material 

560.02 Conform to the following Subsection: 

Water for construction 725.01(c)

Construction Requirements

560.03 Submittals. At least 30 days before starting hydrodemolition work, submit the following 

according to Subsection 104.06: 

(a) Sequence and schedule of work; 

(b) Concrete removal procedures; and 

(c) List of equipment to be used. 

560.04 General. Provide water required to operate the hydrodemolition equipment.

Protect adjacent property from dislodged concrete during operations. Construct debris shields to prevent 

debris and wastewater from entering waterways, travel lanes open to public traffic, or areas designated 

not to be disturbed. 

Dispose of wastewater and debris according to Subsection 203.07. 

560.05 Equipment. 

(a) Hydrodemolition system. Provide a self-propelled and completely programmable 

hydrodemolition system designed for concrete removal.

(b) Vacuum system. Provide a vacuum system equipped with: 

(1) Fugitive dust control devices that can remove wet debris and water in the same pass; and

(2) A pressurized washing system that can clean the concrete surface during the vacuum operation 

to dislodge debris and slurry.

560.06 Calibration. Calibrate equipment to remove concrete to the required dimensions before starting 

hydrodemolition production work. If hydrodemolition equipment cannot remove concrete to the required 

dimensions, remove equipment and provide another hydrodemolition system. Verify operation of 

equipment at the start of each day on an area of representative concrete designated by the CO before 

starting operations. Recalibrate during the work if concrete conditions, including degree of deterioration 

and strength, or dimensions change. 
Section 560

540

Record the following settings at each calibration and notify the CO: 

(a) Water pressure gauge; 

(b) Water usage in gallons per minute; 

(c) Machine staging control (step) – feet per minute forward travel;

(d) Nozzle size;

(e) Nozzle speed (revolutions per minute); 

(f) Transverse nozzle travel speed. Only applicable if hydrodemolition nozzle is not fixed and moves 

transversely on a track between stops before staging to the next step. Report transverse nozzle travel 

speed in feet per second; and

(g) Effective pass width of hydrodemolition unit. Effective pass width is defined as the width of 

hydrodemolition that has uniform pressure, water, and dwell time per machine staging control (step). 

Report effective width in feet.

560.07 Concrete Removal. Remove concrete as follows:

(a) Concrete scarification. Scarify to the depth shown in the plans. If no depth is shown, remove at 

least 1⁄4 inch of material. Clean the surface by an approved method of water blasting with 7000 pounds 

per square inch minimum pressure until sound concrete is exposed.

(b) Concrete removal. Remove concrete to the depth shown in the plans or down to sound concrete. 

Provide at least 1 inch below the bottom of the exposed reinforcing steel. Do not damage remaining 

sound concrete or reinforcing steel. If the bond between existing concrete and reinforcing steel is 

destroyed, remove the concrete adjacent to the reinforcing steel to a depth that allows new concrete to 

bond to the reinforcing steel.

Remove loose and unsound concrete resulting from the hydrodemolition operations below the 

minimum depth. 

Verify depth of concrete removal at least every 30 feet along the cutting path.

In areas inaccessible to the hydrodemolition equipment, use approved hand-held water blasting equipment 

or power-driven hand tools such as jackhammers, mechanical chipping tools, or chipping hammers. Do 

not use jackhammers heavier than nominal 30-pound class or chipping hammers heavier than 15-pound 

class. Operate mechanically driven tools at a maximum angle of 45 degrees from the concrete surface.

If necessary, use hand tools such as hammers and chisels to remove the final particles of concrete to 

achieve the required depth. Leave a rough surface after the concrete is removed. Immediately remove 

residue, water, dust, and concrete to prevent rebonding to the surface or reinforcing steel. 

560.08 Reinforcing Steel. Do not cut or damage reinforcing steel designated to remain. 

Inspect the reinforcing steel with the CO after the concrete has been removed. Clean exposed reinforcing 

steel of rust, loose and rebounded material, and other contaminants that may inhibit bonding to new 

concrete. Tie new reinforcing steel to the existing reinforcing steel if more than 10 percent of its section 
Section 560

541

is lost. If the deteriorated portion of the reinforcing steel is closer to the edge of the patch than the overlap 

distance designated in the plans, extend the limits of the patch to provide the required overlap distance 

with acceptable reinforcing steel. Provide a minimum 2-inch clearance between the ends of new 

reinforcing steel and the existing slab face. Match the number, type, and spacing of the new reinforcing 

steel to the existing reinforcing steel.

560.09 Acceptance. Removal of concrete by hydrodemolition will be evaluated under Subsections 106.02

and 106.04. 

Measurement

560.10 Measure the Section 560 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

560.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 560 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 561

542

Section 561. — CONCRETE CRACK REPAIR BY EPOXY INJECTION

Description

561.01 This work consists of repairing cracks in concrete by injecting epoxy into the cracks. 

Material 

561.02 Conform to the following Subsections: 

Epoxy resin adhesives 725.12

Latex-modified mortar 701.05(c)

Construction Requirements

561.03 General. At least 14 days before starting concrete crack repair work, submit the following 

according to Subsection 104.06: 

(a) Personnel qualifications;

(b) Manufacturer’s SDS and product data sheets; 

(c) Manufacturer’s installation recommendations; and

(d) Work plan for performing the work. 

Conduct a pre-injection preparatory phase meeting at least 7 days before the start of injection operations 

according to Subsection 153.06(a). 

561.04 Crack Preparation. Identify work areas and mark the cracks to be repaired for approval. Prepare 

cracks according to the manufacturer’s recommendations. Remove dirt, laitance, and other debris from 

the exterior and interior of the crack. Apply a temporary surface seal material with sufficient strength and 

adhesion to confine the injected epoxy resin adhesive within the crack until cured.

Provide openings (entry ports) in the surface seal along the crack. Make the distance between entry ports 

at least the thickness of the concrete member being repaired.

561.05 Injection Procedure. Maintain the epoxy resin adhesive component mix ratio within 5 percent by 

volume as recommended by the manufacturer. Do not use solvents to thin the epoxy. 

Use positive inline displacement type equipment to meter, mix, and inject the epoxy at pressures no more 

than 200 pounds per square inch. Inject epoxy into cracks according to the manufacturer’s 

recommendations until the entire crack is filled.

Perform the following tests for each injection unit at the start and at the end of each day.

(a) Ratio check test. Disconnect the mixing head of the injection equipment. Pump the two adhesive 

components through a ratio check device having two independent valved nozzles that can control the 

flow rate and back pressure by opening or closing the valves. Use a pressure gauge that can sense back 

pressure behind each valve. Adjust the discharge pressure to 200 pounds per square inch for both 
Section 561

543

epoxy components. Simultaneously discharge both epoxy components into separate calibrated 

containers. Compare the discharged quantities to determine the mix ratio.

After the test is completed at 200 pounds per square inch discharge pressure, repeat the procedures for 

0 pounds per square inch discharge pressure. 

(b) Pressure check test. Disconnect the mixing head of the injection equipment. Attach the two 

adhesive component delivery lines to a pressure check device having two independent valved nozzles 

that can control the flow rate and pressure by opening or closing the valves. Use a pressure gauge that 

can sense the pressure build-up behind each valve. Close the valves on the pressure-check device and 

operate the equipment until the gauge pressure on each line reads 200 pounds per square inch. Stop 

the pumps and check that the gauge pressure does not drop below 190 pounds per square inch within

3 minutes. 

(c) Records. Maintain and make available complete and accurate records of the ratio and pressure 

check tests. Additional ratio and pressure check tests may be required.

561.06 Coring. Take one 2-inch diameter test core according to AASHTO T 24 for every 50 feet of 

repaired crack at designated locations. The crack repair is acceptable when the epoxy bonding has 

penetrated at least 90 percent of the crack volume within the core sample.

If a test core is unacceptable, redo that 50-foot crack segment or the segment that the core represents and 

resample. Repeat this procedure until acceptable crack repair is achieved.

561.07 Finishing. Remove the surface seal and fill sample core holes with polymer concrete and mortar 

according to the manufacturer’s recommendations. Finish the face of the crack, the entry ports, and the 

core holes flush with the adjacent surface and finish the surface to match the adjacent concrete.

561.08 Opening to Traffic. Do not allow traffic on crack injection work for 6 hours after completion of 

the crack injection work or until the injected epoxy resin has attained a compressive strength of at least 

1450 pounds per square inch, whichever is less. For bridge deck repairs, stage traffic so that the edge of 

the nearest travel lane to the repair area is no closer than the center of the adjacent girder.

561.09 Acceptance. See Table 561-1 for sampling, testing, and acceptance requirements.

Material for concrete crack repair will be evaluated under Subsections 106.02 and 106.03. 

Concrete crack repair work will be evaluated under Subsections 106.02 and 106.04. 

Measurement

561.10 Measure the Section 561 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

561.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 561 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 561-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Daily Start-up & Shutdown Testing

Epoxy resin

adhesive

Process

control

(153.03) 

Ratio

check

(Mix)

− Subsection

561.05(a)

Daily before 

starting 

work & 

after

ending work

Injection

unit No Subsection

561.05

Pressure

check − Subsection

561.05(b) " " " " 

Production

Epoxy resin

adhesive

Measured &

tested for

conformance

(106.04) 

Penetration

of material

into crack

− Subsection

561.06

1 core for 

every

50 ft

of repaired

crack length

In-place

after epoxy

resin

injection

completed

No

Upon

completion

of test
Section 562

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Section 562. — TEMPORARY WORKS

Description

562.01 This work consists of the design, construction, inspection, maintenance, and removal of temporary 

works (such as shoring, bracing, cofferdams, falsework, forms, and formwork) for the construction and 

repair of permanent structures. This work also includes temporary facilities used in construction that do 

not become part of the permanent structure.

Material 

562.02 Select material consistent with the safety and quality required by the design assumptions. 

Provide factory fabricated components of vertical shoring towers according to FHWA-RD-93-033, 

Certification Program for Bridge Temporary Works. 

Design Requirements

562.03 Design. Design temporary works that will support loads imposed and provide the necessary 

rigidity to produce the lines and grades shown in the plans for the final structure. Design temporary works 

according to the AASHTO, LRFD Bridge Design Specifications or AASHTO, Guide Design 

Specifications for Bridge Temporary Works. Ensure the design load on manufactured devices is within 

the load rating recommended by the manufacturer. 

Design falsework and forms that support deck slabs and overhangs on girder bridges to ensure no 

differential settlement between the girders and the deck forms during placement of deck concrete.

Limit the calculated deflections of falsework and formwork members for cast-in-place concrete structures 

as follows:

(a) Falsework member vertical deflection. 1

⁄360 of the span under the dead load of the concrete only, 

regardless of the fact that deflection may be compensated for by camber strips;

(b) Formwork (other than sheathing). 1⁄360 of the span under the dead load of the concrete only or 

the lateral pressure of fluid concrete only; and

(c) Formwork (sheathing). 1⁄8 inch or 1

⁄270 of the center-to-center distance between studs, joists, form 

stiffeners, form fasteners, or wales.

Design falsework and forms for concrete supported on steel structures to ensure loads are applied to girder 

webs within 6 inches of a flange or stiffener. Distribute the loads to avoid producing local distortion of 

the web. Brace or tie exterior girders, upon which overhanging bridge deck falsework brackets are hung, 

to the adjacent interior girders as necessary to prevent rotation of exterior girders or overstressing the 

exterior girder web.

Do not use deck overhang form brackets that require holes to be cast or drilled into the bridge girders.

Do not apply loads to existing, new, or partially completed structures more than the load carrying capacity 

of any part of the structure as determined according to AASHTO, LRFD Bridge Design Specifications. 
Section 562

546

Do not use permanent or stay-in-place deck forms.

562.04 Drawings. Submit drawings according to Subsection 104.06. Provide design calculations and 

supporting data in sufficient detail to allow a structural and safety review of the proposed design. Show 

information to allow the design of components to be checked independently. Provide catalog or equivalent 

data indicating a manufactured device’s recommended safe load capacity.

Indicate the proposed sequence, rate of placement, direction of placement, and location of construction 

joints when concrete placement is involved. Show anticipated total settlements and deflections of the 

falsework and forms. Include falsework footing settlements, joint take-up, and deflection of beams or 

girders. 

Submit the erection procedure and temporary support system for girder erection. Include calculations in 

sufficient detail to substantiate that the girder geometry is correct. Provide supporting calculations 

showing the falsework design accommodates the erection procedure without overstressing the girder and 

produces the required final structural geometry, intended continuity, and structural action. 

Submit foundation design calculations and other relevant foundation design data for approval. 

Construction Requirements

562.05 Foundations. Determine the allowable bearing capacity of the foundation material that supports 

the temporary works. Perform load tests to verify proposed bearing capacity values that are in doubt, 

marginal or in other high-risk situations.

Specified foundation support values for the permanent structure may be used in the design of falsework 

foundations if foundations are at the same elevation and on the same soil as those of the permanent 

structure. If temporary works are to be supported on temporary fill, construct the fill according to 

Section 204 and verify the bearing capacity of the placed material.

Locate the edge of footings at least 12 inches from the intersection of the bench and the top of the slope. 

Locate the edge of the footings at least 48 inches or the depth of excavation, whichever is greater from the 

edge of excavation, unless shoring adequately supports the footing excavation. 

Provide adequate site drainage and erosion control protection. 

If piles are used, capacities may be estimated and later confirmed during construction using standard 

procedures based on the driving characteristics of the pile. Determine ultimate pile capacity according to 

Section 551. The Contractor may use load tests to confirm the estimated capacities. Perform load tests to 

verify proposed bearing capacity values that are in doubt, marginal, or in other high-risk situations.

562.06 Construction. Construct temporary works according to the approved drawings and the AASHTO,

Construction Handbook for Bridge Temporary Works. Use material and workmanship consistent with that 

assumed in the approved drawings. 

Do not weld or use driven devices to fasten temporary works to portions of the permanent structure unless 

shown in the approved drawings. 

Place form panels for exposed surfaces in uniform widths of at least 36 inches and in uniform lengths of 

at least 6 feet, except where the width of the member formed is at least 36 inches. Arrange panels in 
Section 562

547

symmetrical patterns conforming to the general lines of the structure. Place panels for vertical surfaces 

with the long dimension horizontal and with horizontal joints level and continuous. Place panels with the 

long dimension parallel to the footing for walls with sloping footings and that do not abut other walls. 

Align form panels on each side of the panel joint by supports or fasteners common to both panels. 

Devices may be cast into the concrete for later use in supporting forms or for lifting precast members. Do 

not use driven devices for fastening forms or form supports to concrete. Use form ties consisting of form 

bolts, clamps, or other devices necessary to prevent spreading of the forms during concrete placement. Do 

not use form ties consisting of twisted wire loops. 

Make the angle points for chords in wall stems fall at vertical rustication joints when architectural 

treatment is required. Form exposed curved surfaces to follow the shape of the curve, except on retaining 

walls that follow a horizontal curve. The wall stems may be a series of short chords if the following apply:

(a) Chords within the panel are the same length;

(b) Chords do not vary from a true curve by more than 1⁄2 inch at any point; and 

(c) All panel points are on the true curve. 

Provide tell-tales with surveyed measurements, or other acceptable means, for accurate measurement of 

falsework settlement. Do not use the ground surface near falsework supports as a reference elevation. 

Record settlement to the nearest 1⁄8 inch during concrete placement.

Discontinue concrete placement and take corrective action if settlement or deflections occur that deviate 

more than 3⁄8 inch from those shown on the approved drawings. If satisfactory corrective action is not 

taken before initial set, remove unacceptable concrete.

562.07 Maintenance and Inspection. Inspect and maintain temporary works in an acceptable condition. 

Clearly mark the capacity on each manufactured component according to FHWA-RD-93-033. 

Perform an in-depth inspection of the temporary works in the presence of the CO no more than 24 hours 

before starting each concrete placement, or before allowing people to enter a cofferdam or excavation 

support structure. Perform inspections and provide certifications according to FHWA-RD-93-033. Submit 

written results of the inspections before:

(a) Placing concrete;

(b) Allowing people to enter a cofferdam or excavation support structure; or 

(c) Loading temporary works. 

Inspect other temporary works at least once a month to ensure they are functioning properly. Use a 

professional engineer to inspect cofferdams, shoring, support of excavation structures, and support 

systems for load tests before loading.

For structures that qualify as bridges, perform an initial safety inspection for the temporary bridge structure 

according to the National Bridge Inspection Standards (NBIS) before opening the bridge to public traffic. 

Submit the initial bridge inspection report before opening the bridge to public traffic.
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548

Perform other safety inspections according to the NBIS. Maintain the in-service temporary bridge 

structure throughout its service life. Submit bridge inspection reports within 7 days after completing the 

inspection. 

562.08 Removal. Remove temporary works, except as follows:

(a) Portions of driven falsework piles that are at least 36 inches below subgrade within roadbeds, 

24 inches below the original ground or finished grade outside of roadbeds, or 24 inches below the 

established limits of a navigation channel; 

(b) Footing forms where their removal would damage the structural integrity of the cofferdams or 

other work; or

(c) Forms from enclosed cells where access is not provided.

Remove temporary works to allow the structure to take the stresses of its own dead load uniformly and 

gradually. 

Remove temporary works upon completion of the work unless approved to remain. Do not disturb or 

damage the finished work. Remove debris and restore the area to its original or planned condition. The 

removed temporary works remain the property of the Contractor. 

After the concrete has been in place for 24 hours, removal of railing and barrier forms and forms that do 

not support the dead load of concrete members is allowed. Do not remove forms until the concrete has 

attained at least 500 pounds per square inch strength. Do not damage the surface when removing forms. 

Cure concrete according to Subsection 552.13 when forms are removed less than 7 days after concrete 

placement.

Do not remove forms supporting the dead load of concrete members until the concrete has attained

90 percent of the design compressive strength and has been in place for at least 7 days.

Do not remove falsework supporting any span of a simple span bridge until the concrete, excluding 

concrete above the bridge deck, has attained 90 percent of the design compressive strength and has been 

in-place at least 10 days. 

Do not remove falsework supporting any span of a continuous or rigid frame bridge until the concrete in 

that span and in the adjacent portions of each adjoining span for a length equal to at least one-half of the 

length of the span where the falsework is to be released meets the requirements for simple span bridges.

Do not release falsework for post-tensioned portions of structures until the prestressing steel has been 

tensioned. 

Remove falsework for arch bridges uniformly and gradually. Start at the crown and work toward the 

springing points. Remove falsework for adjacent arch spans simultaneously. 

Install a reshoring system if falsework supporting the sides of girder stems with slopes steeper than 1V:1H 

are removed before placing deck slab concrete. Design the reshoring system with lateral supports, which 

resist rotational forces acting on the stem, including those caused by the placement of deck slab concrete. 

Install the lateral supports immediately after each form panel is removed and before release of supports 

for the adjacent form panel.
Section 562

549

562.09 Acceptance. Temporary works will be evaluated under Subsections 106.02, 106.03, and 106.04. 

Construction of temporary fill will be evaluated under Section 204.

Measurement and Payment

562.10 Do not measure temporary works for payment. See Subsection 109.05. 
Section 563

550

Section 563. — COATING

Description

563.01 This work consists of removing and applying coatings. 

Material 

563.02 Conform to the following Section and Subsection: 

Coating material 719

Water for cementitious materials 725.01(a)

Construction Requirements

563.03 Qualifications. At least 30 days before starting coating work, submit the following for approval: 

(a) Coating contractors. Coating contractors certified according to the following, as appropriate for 

the work: 

(1) SSPC-QP1, Certification (Field Application to Complex Industrial and Marine Structures); 

(2) SSPC-QP2, Certification Program (Field Removal of Hazardous Coatings); or 

(3) SSPC-QP3, Certification Program (Shop Painting Certification Program).

(b) Personnel. Personnel with the following qualifications:

(1) SSPC Competent Person Certificate;

(2) Certificate of completion of lead exposure training according to 29 CFR 1926.62; 

(3) Minimum of 2 years’ industrial field coating experience; and

(4) Minimum of 1 year’s field supervisory or management experience in coating removal projects.

563.04 Submittals. At least 30 days before starting coating work, submit the following according to 

Subsection 104.06: 

(a) A coating plan conforming to Subsection 563.05. Indicate which products will be used, methods 

of application, and schedule of application, including hold points. 

(b) SDS and product data sheets (PDS) for cleaning and coating products. 

(c) A containment system, coating removal, and waste disposal plan conforming to Subsection 563.07. 

(d) A worker protection plan conforming to Subsection 563.08. 

(e) Specific safety measures to comply with 29 CFR 1926.62, 40 CFR 50.6, 40 CFR 50.12, and 

40 CFR Parts 260-268, if coating being removed is a hazardous material. 
Section 563

551

(f) Emergency spill procedures.

(g) Site-specific plan for maintenance and protection of traffic.

(h) A topcoat coating sample at least 1 foot by 1 foot, using the same coating system to be used on the 

surface to be coated.

563.05 General. Perform work according to the approved Coating Plan. Stop work and take corrective 

action if the measures fail to perform as intended.

(a) Hold points. Specific inspection items are designated as hold points. Notify the CO at least four 

hours before reaching a hold point. If the four-hour notification is provided and the work is ready for 

inspection at that time, the CO will conduct the necessary inspection, testing, and validation. If the 

work is not ready at the appointed time and unless other arrangements are made, an additional fourhour notification is required. Do not proceed beyond a hold point until approved. 

(b) QC. Provide equipment to perform the QC inspections. At a minimum, provide the following: 

(1) Psychrometer or comparable equipment for the measurement of dew point and relative 

humidity, together with weather bureau tables or psychrometric charts;

(2) Surface temperature thermometer;

(3) Bresle Kits or equivalent for chloride determinations;

(4) Wet film thickness gauge;

(5) Blotter paper for compressed air cleanliness checks;

(6) Type 2 magnetic dry film thickness gauge according to SSPC-PA 2, Procedure for 

Determining Conformance to Dry Coating Thickness Requirements; 

(7) Calibration standards for dry film thickness gauge;

(8) Light meter for measuring light intensity during cleaning, coating, and inspection activities; 

(9) Applicable ASTM and SSPC Standards used for the work; 

(10) Putty knife of a minimum thickness of 40 mils and a width from 1 to 3 inches if there are 

touch-up areas where the coating is being feathered and tested with a dull putty knife; and

(11) Procedures for chloride remediation and frequency of testing. 

Calibrate instruments according to the QC process and the equipment manufacturer’s 

recommendations. Make inspection equipment and calibration charts available to the CO for 

inspection and testing. 

(c) Lighting. Inspection of lighting is designated as a hold point defined in Subsection 563.05(a). 

Provide artificial lighting both inside and outside the containment system where natural light is 

inadequate, as determined by the CO, to allow proper cleaning, inspection, and coating. Provide 
Section 563

552

illumination for inspection of at least 30 foot-candles. Provide illumination for cleaning and coating, 

including the working platforms, access, and entryways, of at least 20 foot-candles. Provide general 

work area illumination outside the containment of at least 5 foot-candles. Design and operate the 

lighting system to avoid glare that interferes with traffic, workers, and inspection personnel.

(d) Inspection access. Facilitate the CO’s inspections as needed, including allowing ample time to 

view the work. Provide and erect equipment to allow close observation of surfaces to be cleaned and 

coated. Provide this equipment during all phases of the work. 

(e) Protection of the work. Use tarps, screens, paper, cloth, or other suitable means to protect adjacent 

surfaces that are not to be coated. Prevent contamination of freshly coated surfaces by dust, oil, grease, 

or other harmful or deleterious material.

Repair damage caused to the bridge structure during construction. 

(f) Coating material. Provide new coating material applied to a single structural component from the 

same coating manufacturer and coating system. Include both shop and field coating applications and 

components. 

Use safe handling practices conforming to the manufacturer’s SDS and PDS. Store coating material 

in original unopened containers with labels intact and in weather-tight spaces where temperature is 

maintained between 40 and 100 °F. Do not open coating material containers until required for 

application that day. Do not use coating material from a punctured container or from a container with 

its lid seal broken. Do not use coating material with an expired shelf life.

Mix coating material according to the manufacturer’s recommendations. Mix coating material with

mechanical mixers for sufficient time to thoroughly blend the pigment and solvent together. Continue 

the mixing during application. Do not thin coating material that is formulated ready for application. 

Strain coating material after mixing, except where application equipment is provided with strainers. 

Use strainers of a size to remove only skins and undesirable matter, but not to remove the pigment. 

Where a skin has formed in the container, cut the skin loose from the sides of the container and discard 

it. If the volume of the skin is visually estimated to be more than 2 percent of the remaining coating 

material, discard the coating material.

(g) Surface preparation and weather limitations. Remove dirt, dust, and other contaminants from 

the surface according to the coating manufacturer’s recommendations. Clean the surface to the 

specified cleanliness level. Thoroughly dry the surface to be coated. 

Apply coating when the following conditions are met or according to the manufacturer’s 

recommendations, whichever is more restrictive:

(1) The surface temperature is between 50 and 100 oF;

(2) The surface temperature is 5 oF or more above the dew point measured according to 

ASTM D4230; and 

(3) The humidity is 85 percent or less, unless otherwise specified on the manufacturer’s PDS.
Section 563

553

Continuously monitor, record, and provide temperatures and humidity at least every 15 minutes while 

coating. Check the dew point immediately before each coating, at least every 4 hours during coating, 

and as conditions change. 

Provide a controlled environment to meet weather limitations if necessary.

(h) Application. Apply coating material according to the manufacturer’s recommendations. Apply 

coating material by brush, sprayer, roller, or combination of methods recommended by the 

manufacturer’s PDS.

(1) Brushes. Use brushes with sufficient bristle body and length to spread the coating material in 

a uniform film. Use round, oval shaped brushes, or flat brushes no wider than 41⁄2 inches. Evenly 

spread and thoroughly brush out the coating material as it is applied.

(2) Sprayers. Use airless or conventional spray equipment with suitable traps, filters, or separators 

to exclude oil and water from the compressed air. Use compressed air that does not show black or 

wet spots when tested according to ASTM D4285. Use the spray gun tip sizes and pressures 

recommended by the manufacturer. 

(3) Rollers. Select rollers and covers suitable for the surface and coating material to be applied. 

Use rollers only on flat, even surfaces. Do not use rollers that leave a stippled texture in the coating 

film.

Use sheepskin daubers, bottle brushes, or other coating methods recommended by the manufacturer 

to coat surfaces that are inaccessible for coating by regular means.

Coat surfaces in a manner that does not produce excessive coating build-up, runs, sags, skips, holidays, 

or thin areas in the coating film. Correct thin areas, skips, holidays, and other deficiencies before the 

next application of coating material. 

Tint succeeding applications of coating material to contrast with the coating being covered. Obtain 

color approval for the finish coat before application.

Coat surfaces that will be inaccessible after erection with the full number of undercoats required before 

erection. After erection, clean areas where the undercoating is damaged or deteriorated, and spot coat 

with the specified undercoats to the required thickness before applying the final coat. 

Measure the wet film thickness during application and adjust the application rate to obtain the required 

dry film thickness.

(i) Curing. Cure each coat according to the manufacturer’s recommendations, increasing cure times 

as needed for changes in surface and ambient temperatures, and humidity. Maintain a surface 

temperature of at least 5 oF above the dew point measured according to ASTM D4230 for at least 

12 hours after coating is finished. 

Continuously monitor, record, and provide temperatures and humidity at least every 15 minutes while 

curing. Maintain the coating manufacturer’s curing requirements for each coating application for the 

entire curing duration. 
Section 563

554

Protect coated surfaces from direct exposure to rain for the time interval recommended by the coating 

manufacturer for proper cure.

563.06 Protection of Public, Property, and Workers. Comply with SSPC-PA, Guide 10, Guide to Safety 

and Health Requirements for Industrial Painting Projects and OSHA standards.

Handle all waste as hazardous material until tested and proven to be non-hazardous. If a hazardous 

material is removed, comply with the following:

(a) SSPC Guide 6, Guide for Containing Surface Preparation Debris Generated During Paint 

Removal Operations; 

(b) SSPC Guide 7, Guide to the Disposal of Lead-Contaminated Surface Preparation Debris; 

(c) 29 CFR 1926.62, Lead (Safety and Health Regulations for Construction); 

(d) 40 CFR 50.6, National Primary and Secondary Ambient Air Quality Standards for PM10; 

(e) 40 CFR 50.12, National Primary and Secondary Ambient Air Quality Standards for Lead; and 

(f) 42 U.S.C. §6901, Resource Conservation and Recovery Act. 

Collect and dispose of material including wastewater that is used in preparing, cleaning, or coating. 

563.07 Containment System, Coating Removal, and Waste Disposal. Design and construct safe 

containment systems to support the loads imposed. Do not apply loads to the existing structure more than 

the load carrying capacity of any part of the structure. Include details of attachment. Include connections 

with clamps or other approved devices that do not require welding or drilling holes in the existing 

structure. Include working drawings and construction details. 

Provide design calculations, manufacturer’s specifications, and certifications for the containment system’s 

working platform. Provide a platform that is firm and stable, designed to support workers, authorized 

persons, spent abrasive material, and equipment during all phases of construction. Provide calculations 

and specifications stating the proposed containment system’s load bearing capacity and show that the 

system will support imposed loads. Maintain minimum vertical and horizontal clearances for construction 

operations as approved. 

Fully enclose surface preparation and coating application operations to eliminate the emission of airborne 

blast debris, dust, and coatings from the containment, and ensure that no dust, debris, or coatings enter the 

water below. Comply with SSPC Guide 6, Class 2. Provide a containment system with air impenetrable 

walls, a negative air pressure environment within the containment, and fresh air flow through the 

containment. Maintain an average negative pressure of 0.03-inch water column inside the enclosure (as 

measured by manometer or differential pressure gauge) during blasting and blow down operations. 

Maintain a safe and uncluttered passageway for foot traffic in the containment system, and between 

staging and work areas.

Design air flow inside the enclosure to meet OSHA standards. Provide containment design and ventilation 

to allow for the maximum practical reduction in exposure of workers to airborne contaminants inside the 

containment system. Submit a list of the equipment, including operating capacities and manufacturer’s 

instructions.
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Prevent release of accumulated debris into the environment. Protect workers from exposure to hazardous 

materials. Immediately correct visible emissions from the containment enclosure. Ensure emissions from 

the containment enclosure conform to Federal and state air quality standards.

Take at least eight representative soil samples, including at least one at each corner of the work site 

according to SSPC Guide 6. Take samples and perform test analysis for toxic metals on samples before 

work start-up, during surface preparation and coating application operations, and after work operations 

are completed. If elevated levels of toxic heavy metals are found in baseline soil samples, obtain additional 

samples and retain for future analysis.

Take water samples and perform test analysis for toxic metal content downstream before work start-up, 

every two weeks during work, and after work operations are completed, to demonstrate water purity. 

Clean up spilled waste materials immediately and take necessary actions to remedy resulting soil and 

water contamination.

Comply with SSPC Guide 7. Seal collected waste materials in leak-proof drums. Place only spent 

abrasives, coating particles, and blast debris in the drums. Provide drums that are in new condition and 

approved for use. Clearly identify each drum according to EPA and state rules and regulations, with the 

bridge number, contract number, Contractor’s name, contents, and the date waste material accumulation 

started.

Obtain necessary permits for storage, transport, characterization, and disposal of waste. 

Store contaminated debris according to Federal and state rules and regulations. Store drums containing 

contaminated debris in a locked sea cargo trailer within a secured staging area.

Remove the contaminated debris from the site within 30 days of collection. Obtain approval before storing 

drums in the trailer. Prevent the entry of unauthorized persons, livestock, or wildlife into the staging area 

and the lead work area. Post warning signs with clearly visible legends, "DANGER - AUTHORIZED 

PERSONNEL ONLY", easily visible from routinely used approaches to the staging area and the work 

area.

Sample and test the waste material according to EPA, SW-846 Test Method 1311, Toxicity Characteristic

Leaching Procedure. Test waste for lead and other elements shown in SSPC Guide 7, Table 1. 

If waste material is determined to be hazardous, obtain an EPA Identification Number and prepare a 

manifest of hazardous waste to be transported to an approved waste storage site. Prepare the manifest 

according to Federal and state rules and regulations. Provide a certificate or manifest indicating the weight 

and the number of drums of waste to be disposed. Provide a testing manifest for hazardous waste and EPA 

Identification Number to the bridge owner before the material is transported. Provide proof of acceptance 

from an approved disposal site, including information required by state and local rules and regulations. 

Ensure that the hazardous waste hauler is licensed and has an EPA Identification Number. Conform to 

Federal and state rules and regulations regarding the maximum volume of hazardous waste which may be 

stored on the site. Do not store the waste materials on the site for more than 90 days. Do not treat hazardous 

waste on site.

If lead or any element shown in SSPC Guide 7, Table 1 does not meet or exceed the permissible level of 

concentration as measured by the Toxicity Characteristic Leaching Procedure (TCLP), dispose of the 
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waste material as an industrial solid waste according to Federal and state rules and regulations. Dispose 

of waste at an approved facility. Provide the CO with an authorization before disposal. 

If waste material is transported outside the state for disposal, comply with Federal, state, and local rules 

and regulations. 

563.08 Worker Protection Plan. 

(a) Submit a worker health and protection plan that has been prepared by a Certified Industrial 

Hygienist who is certified by the American Industrial Hygienist Association, and according to Federal 

rules and state regulations. Include the following: 

(1) Work practices;

(2) Engineering controls;

(3) Administrative controls;

(4) Training;

(5) Medical surveillance;

(6) Hazard identification;

(7) Protective clothing and respirator selection;

(8) Handling containers;

(9) Emergency responses;

(10) Decontamination;

(11) Illumination;

(12) Sanitation; and

(13) Site control.

(b) Train workers and persons exposed to coating or cleaning operations according to the approved 

worker protection plan. 

Provide documentation of workers’ safety training and education that requires instruction in 

recognizing and avoiding unsafe conditions and hazards, complying with OSHA 29 CFR 1910 and 

OSHA 29 CFR 1926, with emphasis on beryllium, cadmium, chromium, lead, and respirable 

crystalline silica. 

(c) Require workers scheduled to receive lead exposure at or above the action level on any day during 

the project duration to have the following:

(1) An initial medical surveillance consisting of blood sampling and analysis for lead and zinc 

protoporphyrin levels (an indicator of lead levels in the blood).
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(2) Follow-up blood tests for any worker whose initial medical surveillance results were at the 

permissible exposure limit or more.

(3) Thorough medical examinations for workers who are or may be exposed at or above the action 

level for 30 or more days in any 12-month period. 

Use OSHA-approved laboratories to perform blood analyses. Provide initial and follow-up medical 

surveillance to workers and the CO within 48 hours of a worker’s exposure. Do not use prophylactic 

or preventive chelation to keep blood lead levels down while workers are on the job. 

(d) Designate a competent person who is knowledgeable about protection of workers from the hazards 

of lead exposure to be the Worker Health and Safety Officer and responsible for ensuring worker 

safety and remedying any hazardous situation. Submit certification signed by the Worker Health and 

Safety Officer at completion of the project that the worker health and protection plan complied with 

all regulations and was fully implemented. 

563.09 Structural Iron and Steel. Provide the topcoat of coating material to match existing coating on 

structural iron and steel or as directed. Conform to SAE-AMS-STD-595. 

Comply with SSPC-VIS Standards or NACE Comparators for surface conditions and finished surface 

profile visual standards. 

(a) Test blast. This Subsection is designated as a hold point defined in Subsection 563.05(a). 

Perform a test blast on a portable steel plate, measuring approximately 1 foot by 1 foot, representative 

of those steel surfaces cleaned throughout the structure, and according to Subsection 563.09(c). 

Produce an anchor profile height within the range recommended by the coating system manufacturer’s 

PDS. Measure anchor profile according to Subsection 563.09(c). 

Start blast cleaning only after the CO has inspected and approved the test blast plate. Preserve and 

protect the test blast plate as a job standard with a clear sealer, and photograph for documentation and 

project QC. 

(b) Compatibility test. This Subsection is designated as a hold point defined in Subsection 563.05(a). 

Select a test area of at least 30 square feet in a condition representative of the condition of the structure. 

Perform surface preparation according to Subsection 563.09(c) and apply the proposed system 

according to Subsection 563.09(f). Perform tests according to ASTM D5064. Observe for lifting, 

bleeding, blistering, wrinkling, cracking, flaking, or other evidence of incompatibility. 

Verify that no indication of incompatibility exists at least 14 days after the application of each product. 

Perform adhesion tests according to ASTM D4541, Methods C through F. 

Notify the CO if failure is due to adhesion (between coating and substrate or between applied coats) 

or cohesion (failure within a coating layer). If failure occurs, provide a compatible coating system and 

repeat the compatibility process.

Remove dirt, dust, and other debris from the surface by vacuuming or other approved methods. 
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558

(c) Surface preparation. Prepare surfaces by removing the existing coating, which may contain lead 

and other contaminants, according to Subsection 563.07. 

Remove dirt, mill scale, rust, and other foreign material from exposed surfaces by blast cleaning to 

near-white metal according to SSPC-SP 10/NACE No. 2, Near-White Blast Cleaning. Prepare surfaces 

inaccessible to near-white metal blast cleaning according to SSPC-SP 11, Power Tool Cleaning to 

Bare Metal. 

Blast clean with clean dry slag, mineral grit, steel shot, angular steel grit, or chilled iron grit abrasives. 

Use a suitable gradation to produce a dense, uniform anchor pattern. Produce an anchor profile within 

the range recommended by the coating system manufacturer’s PDS. Measure anchor profile height 

according to ASTM D4417, Method C or Method D, or ASTM D7127. Follow SSPC-PA 17, 

Procedure for Determining Conformance to Steel Profile/Surface Roughness/Peak Count 

Requirements. 

(d) Chloride testing. This Subsection is designated as a hold point defined in Subsection 563.05(a). 

Test bare metal surfaces for the presence of chlorides. If chlorides are present, clean surfaces to remove 

chlorides. Methods of chloride removal may include, but are not limited to, steam cleaning, pressure 

washing (with or without the addition of a chemical soluble salt remover according to the coating 

manufacturer), and scrubbing. 

After completing the chloride remediation steps, use approved cell methods of field chloride extraction 

and test procedures to test representative surfaces for the presence of remaining chlorides. Test at 

frequencies shown in the approved QCP. Maintain remaining chloride levels less than 5 μg/sq cm as 

read directly from the surface without any multiplier applied to the results.

Repeat solvent and surface cleaning if surfaces rust or become contaminated before coating. Repeat 

blast cleaning if surface cannot be made free of rust or contamination by other methods. Repeat blast 

cleaning on areas that have flash rusted from the chloride testing.

(e) Primer application. Apply primer to bare metal surfaces within 3 days of cleaning, and before the 

steel flash rusts. Repeat blast cleaning on areas that have flash rusted before applying primer. 

(f) Application. Use sheepskin daubers, bottle brushes, or other acceptable methods to coat surfaces 

that are inaccessible for coating by regular means. Coat in a manner that does not produce excessive 

coating build-up, runs, sags, skips, holidays, or thin areas in the coating film. Correct thin areas, skips, 

holidays, and other deficiencies before the next application of coating material.

Apply coating material in the following order: primer, primer stripe, intermediate, intermediate stripe, 

and finish coat. Extend stripe coats at least 1 inch beyond welds, rivets, bolts, nuts, edges of plates and 

structural members, angles, bearings, lattice pieces or other shapes, corners, crevices, and any area in 

which full coverage and film thickness are difficult to achieve.

Provide a different color for each coat with substantial contrast to the underlying substrate and 

previous coats to verify complete coverage. Submit colors for the primer, stripe coat, and intermediate 

coat to the CO for approval. 

Apply according to the manufacturer’s recommendations. 
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559

Do not use accelerator additives.

Apply subsequent coats of coating material only when the receiving surface is dry and fully cured 

according to the manufacturer’s recommendations.

Determine the dry coating thickness on steel structures using a Type 2 (electronic) film thickness 

gauge according to SSPC-PA 2. 

Repair minor coating defects, handling damage, and other occasional non-conformances, according to 

SSPC-PA 1, Shop, Field, and Maintenance Coating of Metals and the manufacturer’s 

recommendations. Submit repair procedures for substantial damage, significant defects, or widespread 

(gross) non-conformances in the coated surface. Ensure that repairs to the topcoat of coating material 

result in an acceptable, uniform color, gloss, and texture on visible surfaces. 

(g) Curing. Cure according to Subsection 563.05(i). 

563.10 Lumber and Timber. Dry timber to a moisture content of 15 percent or less.

Remove cracked or peeled coating, loose chalky coating, dirt, and other foreign material on previously 

coated timber. Use wire brushing, scraping, or other approved methods.

If timber is treated with a waterborne preservative, wash and brush away visible salt crystals on the wood 

surface. Allow wood to dry before coating. 

Remove dust and other foreign material from the surface fed before coating.

The primer may be applied before erection. After the primer dries and the timber is in place, fill cracks, 

checks, nail holes, and other depressions flush with the surface using an approved putty. After the putty 

has dried, evenly spread and thoroughly work the coating material into corners and recesses. Allow the 

full thickness of the applied coating material to dry before applying the next coat.

563.11 Masonry Block and Concrete Structures. Remove laitance, dust, and other deleterious material 

from the concrete surface. Give the cleaned surface a light abrasive sweep blast to remove mortar wash 

and other contaminants. Remove residue and dust by vacuuming or other approved methods. 

Evenly spread and thoroughly work the coating material into corners and recesses. Allow the full thickness 

of the applied coating material to dry before applying the next coat. 

563.12 Other Metals. 

(a) Aluminum. Prepare aluminum surfaces to be coated according to ASTM D1730. Use the type of 

treatment and method of preparation appropriate to the condition of the surface and coating to be 

applied. 

(b) Galvanized surfaces. Prepare galvanized surfaces to be coated according to ASTM D6386. Use 

the type of treatment and method of preparation appropriate to the condition of the surface and coating 

to be applied. Use zinc-rich coating material conforming to SSPC Paint 20 to treat galvanized steel 

field cuts and damaged galvanizing according to the applicable requirements of ASTM A780. 
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563.13 Acceptance. Coating material will be evaluated under Subsections 106.02 and 106.03. Sample 

coating material according to ASTM D3925. Test coating properties according to FED-STD-141D, Paint, 

Varnish, Lacquer and Related Materials: Methods of Inspection, Sampling and Testing, if required.

Coatings will be evaluated under Subsections 106.02 and 106.04. 

Containment systems will be evaluated under Subsections 106.02 and 106.03. 

Surface preparation will be evaluated under Subsection 106.02. 

Treating galvanized steel field cuts and repairing damaged galvanizing will be evaluated under 

Subsection 106.02. 

Measurement

563.14 Measure the Section 563 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

563.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 563 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 564

561

Section 564. — BEARING DEVICES

Description

564.01 This work consists of providing and installing bridge bearing devices.

Material 

564.02 Conform to the following Subsections: 

Bearings 717.09

Bolts and nuts 717.01(d)

Galvanized coatings 717.07

Non-shrink grout 701.04(b)(1)

Construction Requirements

564.03 General. Provide elastomeric, rocker, roller, sliding plate, and disc bearing devices. 

(a) Drawings. Submit drawings according to Subsection 104.06 and Section 18 of the AASHTO,

LRFD Bridge Construction Specifications. Show details of bearings including material proposed for 

use. Do not start fabrication until drawings are approved. 

(b) Fabrication. Fabricate bearings according to Section 18 of AASHTO, LRFD Bridge Construction 

Specifications. Finish bearing components surfaces in contact with each other or in contact with 

concrete according to Subsection 555.07(e). 

Preassemble bearing assemblies and check for proper completeness and geometry. Galvanize steel 

bearing components and anchor bolts. Do not galvanize stainless steel bearing components or anchor 

bolts. 

Packaging, handling, and storing material.

Clearly identify each bearing component and mark on its top the location and orientation in the 

structure before shipping. Securely bolt, strap, or otherwise fasten bearings to prevent relative 

movement.

Package bearings to prevent damage during shipping, handling, or storing. 

Do not dismantle bearing assemblies on site unless necessary for inspection or installation. Dismantle 

under the direct supervision or approval of the manufacturer. 

Provide a listing of individual bearing numbers. 

Store bearing devices to prevent damage from weather or other hazards.

(c) Construction and installation. Clean bearings of deleterious material. Install and set bearings to 

the dimensions shown in the plans or according to the manufacturer’s recommendations. Adjust

bearings according to the manufacturer’s recommendations to compensate for installation temperature 

and future movements. 
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Set bearings level, at the elevation, and position shown in the plans. Provide full and even bearing on 

external bearing contact surfaces. Notify the CO if bearing surfaces are at improper elevations, not 

level, or if bearings cannot be set properly. Submit a written proposal to modify the installation.

Bed metallic bearing assemblies on concrete with an approved filler or fabric material when not 

embedded in concrete.

Set elastomeric bearing pads directly on properly prepared concrete surfaces without bedding material.

Machine bearing surfaces seated directly on steel to provide a level and planar bearing surface.

564.04 Elastomeric Bearings. Fabricate, comply with testing and acceptance criteria, and mark 

elastomeric bearings according to AASHTO M 251. Test and accept bearings specified by hardness and 

designed according to Method A of AASHTO, LRFD Bridge Design Specifications according to 

Section 8.8.4 of AASHTO M 251. 

Place bearings on a level surface. Correct misalignments in the support to form a level surface. Do not 

weld steel girders or base plates to the exterior plates of the bearing unless there is more than 11⁄2 inches 

of steel between the weld and elastomer. Do not expose the elastomer or elastomer bond to instantaneous 

temperatures greater than 400 °F. Do not design or fabricate elastomeric bearings with holes. 

564.05 Rocker, Roller, and Sliding Plate Bearings. Fabricate pins, rollers, and rockers according to 

Subsection 555.10. Remove burrs, rough and sharp edges, and other flaws. Stress relieve rocker, roller, 

and other bearings that are built up by welding sections of plate together before boring, straightening, or 

final machining.

Thoroughly coat contact surfaces with oil and graphite before placing roller bearings. Install rocker, roller, 

and sliding bearings vertically at the specified mean temperature after release of falsework and after 

shortening due to prestressing forces. Account for variations from mean temperature of the supported span 

at time of installation and other anticipated changes in length of the supported span. 

Ensure the superstructure has full and free movement at movable bearings. Position roller bearings so their 

axes of rotation align and coincide with the axis of rotation of the superstructure.

564.06 Disc Bearings. Use structural steel plates conforming to AASHTO M 270, Grade 50. Equip disc 

bearings with a shear restriction mechanism to prevent movement of the disc. Use disc bearings produced 

by the same manufacturer. 

For guided bearings, use either a guide bar or keyway system to restrict transverse movement. Face the 

sliding surfaces of the guide bar or keyway systems with either PTFE sheets or stainless steel.

Provide polyether urethane rotational elements molded as a single piece.

Design the disc bearings for the loads and movements shown in the plans according to AASHTO, LRFD 

Bridge Design Specifications. Install according to the manufacturer’s recommendations.

Submit manufacturer’s test results to the CO certifying that the completed bearings and their components 

comply with the proof load test and sliding coefficient of friction test, according to Subsection 18.3.4 of 

AASHTO, LRFD Bridge Construction Specifications. 
Section 564

563

Bearings represented by test specimens passing the requirements are approved for use in the structure 

subject to on-site inspection for visible defects. Bearing devices showing visual defects will be rejected. 

Visual defects include extruded or deformed elastomer or PTFE, damaged seals or rings, and cracked 

steel.

564.07 Masonry, Sole, and Shim Plates for Bearings. Provide metal plates conforming to AASHTO 

M 270, Grade 36. 

Fabricate and finish steel according to Subsection 555.07. Form holes in bearing plates by drilling, 

punching, or controlled oxygen cutting. Remove burrs by grinding. 

Set bearing plates in a level position and provide a uniform bearing over the bearing contact area. If plates 

are embedded in concrete, make provisions to keep them in correct position as the concrete is placed. 

564.08 Polytetrafluoroethylene Surfaces for Bearings. Provide PTFE material that is factory-bonded, 

mechanically connected, or recessed into the backup material.

Bond or mechanically attach the fabric containing PTFE fibers to a rigid substrate. Use a fabric that can 

carry unit loads of 10,000 pounds per square inch without cold flow. Use a fabric-substrate bond that can

withstand a shear force equal to 10 percent of the perpendicular or normal application loading plus other 

bearing shear forces without delamination.

Use approved test methods and procedures according to Section 18 of AASHTO, LRFD Bridge 

Construction Specifications. Perform at least one material test on the material used in the sliding surface 

for each lot of bearings. If required by the contract, test complete bearings for complete bearing friction. 

If the test facility does not allow testing of completed bearings, manufacture extra bearings and prepare 

samples of at least 100-kip capacity at normal working stresses by sectioning the bearing. 

Measure the coefficient of friction between two mating surfaces. Submit test results showing the static 

and dynamic coefficients of friction meet the requirements for the design coefficient of friction specified 

in the contract or by the manufacturer for approved material.

564.09 Anchor Bolts. Provide threaded anchor bolts.

Adjust bolt locations for superstructure temperature and anticipated lengthening of bottom chord or 

bottom flange due to dead load after setting as required. Do not restrict free movement of the 

superstructure at movable bearings.

Preset anchor bolts before concrete placement or install anchor bolts in drilled holes after concrete 

placement. Drill holes 1 inch in diameter greater than the bolt if non-shrink cement grout is used to secure 

the bolts. Follow the adhesive manufacturer’s recommendations for hole diameter if an approved chemical 

adhesive is used to secure the bolts.

564.10 Bedding of Masonry Plates. Clean the contact surfaces of the concrete and steel before placing 

the bedding material and installing bearings or masonry plates. If bedding is specified, place filler or fabric 

as bedding material under masonry plates and install it to provide full bearing on contact areas. If bedding 

material is not specified, comply with Subsection 18.10.2 of AASHTO, LRFD Bridge Construction 

Specifications as directed.

564.11 Acceptance. Material for bearing devices will be evaluated under Subsections 106.02 and 106.03. 
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564

Submit a production certification with each shipment of bearing devices. 

Bearing device installation will be evaluated under Subsections 106.02 and 106.04. 

Measurement

564.12 Measure the Section 564 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Do not measure bearing devices for prefabricated steel bridges and fiber-reinforced polymer bridges.

Payment

564.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 564 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 565

565

Section 565. — DRILLED SHAFTS

Description

565.01 This work consists of providing and constructing reinforced concrete drilled shafts. 

Material 

565.02 Conform to the following Subsections: 

Neat hydraulic cement grout 701.04(a)(2)

Reinforcing steel 709.01

Slurry (drilling fluids) 725.13

Steel pipes 717.06

Structural carbon steel 717.01(a)

Water for cementitious materials 725.01(a)

Construction Requirements

565.03 Qualifications. At least 30 days before starting drilled shaft work, submit the following for 

approval: 

(a) On-site supervisor. A résumé for the on-site supervisor describing at least 5 years’ experience 

supervising construction of drilled shafts of similar lengths and scope to those shown in the plans and 

in similar geotechnical conditions described in the geotechnical report. Include experience as the direct 

supervisor responsible for on-site construction operations; 

(b) Drill operator. A résumé for each drill operator describing at least 2 years’ experience in the 

construction of drilled shafts; 

(c) Professional engineer or geologist. A résumé for a professional engineer or professional geologist 

with at least 5 years’ experience in the design and construction of drilled shafts and logging shaft 

excavations; 

(d) Geotechnical engineer or geologist. If applicable, a résumé for a geotechnical engineer or 

engineering geologist working under the direct supervision of the professional engineer or professional 

geologist described in Subsection 565.03(c), to maintain the boring log. Show at least 2 years’ 

experience in the design and construction of drilled shafts and logging shaft excavations; and 

(e) Crosshole sonic logging (CSL) engineer. A résumé for a CSL engineer describing at least 5 years’ 

experience in the testing of drilled shafts.

565.04 Construction Plan. At least 30 days before starting drilled shaft work, submit the following 

according to Subsection 104.06: 

(a) Proposed drilled shaft construction schedule and sequence. Schedule shaft installation to avoid 

interconnection or damage to shafts in which placed concrete has not attained final set.
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566

(b) Proposed drilling, hole cleaning, hole preparation, and bottom inspection method; and 

reinforcement and concrete placement equipment and procedures for the ground conditions expected 

to be encountered. Provide specific shaft drilling and concreting procedures to mitigate problems 

associated with ground water, surface water bodies, or both. Demonstrate an understanding of the 

subsurface conditions at the site by referencing available subsurface data shown in the boring logs. 

Indicate procedures to minimize disturbance to the construction site or overlaying or adjacent structure 

or services. Discuss potential drilling difficulties and indicate means and methods that will be used to 

remove obstructions from the excavation. 

(c) Proposed drilled shaft excavation and construction methods used to ensure shaft stability during 

construction and reinforcement and concrete placement. Include proposed shaft drilling procedures 

for maintaining required horizontal and vertical shaft alignment. Include disposal plan for excavated 

material. If shaft casing is required, provide casing dimensions and detailed procedures for permanent 

casing installation or temporary casing installation and removal.

(d) Proposed methods for mixing, testing, circulating, using, maintaining, and disposing of slurry, if 

used. Provide a detailed slurry mix design and its suitability to the subsurface conditions. Include the 

name and telephone number of the slurry manufacturer’s representative.

(e) Details of reinforcement placement. Include bracing, centering, centralizers, and lifting and support 

methods. 

(f) Proposed structural concrete mix design conforming to Section 552, except as shown in Table 565-

4. 

(g) Concrete placement methods. Include proposed operational procedures for free-fall, tremie, or 

pumping methods. 

(h) The method used to form an emergency horizontal construction joint during concrete placement. 

(i) Inspection forms and charts for logging subsurface conditions during excavation and concrete 

volume placement. Include examples of populated forms. 

Conform to the installation and construction plan requirements for drilled shafts in FHWA-NHI-18-024, 

Drilled Shafts: Construction Procedures and LRFD Design Methods. 

565.05 Trial Drilled Shafts. If trial drilled shafts are required, perform the work according to the 

applicable requirements of Subsection 565.06. 

Before drilling holes for production shafts, demonstrate that the proposed methods and equipment are 

adequate by drilling a trial drilled shaft adjacent to the production shafts at an approved location. Make 

the center-to-center spacing between the trial shaft and production shafts at least three shaft diameters or 

two bell diameters, whichever is larger.

Construct the trial drilled shaft to the same size and to the tip elevation of the deepest production shaft 

shown in the plans. When bells are specified for production shafts, include a bell in the final trial shaft to 

verify the feasibility of belling in the specified bearing stratum.

Install casing if caving occurs or the hole deforms sufficient to encroach upon the planned placement of 

the reinforcement cage with specified minimum concrete cover. Seat the casing to prevent caving and to 
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567

allow dewatering of the hole when required. Remove material from inside the hole. Keep casing in place 

at least 4 hours while attempting to remove water in the hole. Record the rate of groundwater seepage into 

the hole. After this 4-hour period, fill the hole with saturated sand while the casing is removed to simulate 

the concreting operation and casing removal for the production drilled shafts. 

Concrete or reinforcing steel is not required in the trial drilled shaft.

Modify methods and equipment if the trial drilled shaft does not meet performance requirements. Submit 

a new installation plan and drill a new trial shaft for approval.

565.06 Shaft Drilling. 

(a) Drilling. Drill holes according to the approved construction plan. Excavate structural footings 

supported on drilled shafts and construct fills before initiating shaft drilling.

Provide equipment and tooling able to drill shafts of the specified diameter and lengths 20 percent 

longer than those specified. Comply with tolerances shown in Table 565-1. 

(1) Boring log. Provide a geologist or an engineer to maintain a boring log of material excavated 

from the drilled shaft. Include the following information:

(a) Description and approximate top and bottom elevation of each type of soil or rock material 

encountered and the date and time the soil or rock material was encountered; 

(b) Elevation and approximate rate of seepage or groundwater encountered; 

(c) Equipment used to drill the shaft, time required to complete the shaft, bit changes, 

breakdowns, and other drilling difficulties encountered; and 

(d) Remarks.

(2) Drilling methods. Use the uncased dry construction method where groundwater level and soil 

conditions are suitable to construct the shaft in a relatively dry-stable excavation and may be 

visually inspected before placing concrete. Use casing construction method, wet construction 

method, or both for shafts that do not meet the requirements for the dry construction method. 

(a) Dry construction method. Drill the shaft, remove accumulated water and loose material 

from the excavation, place the reinforcing cage, and concrete the shaft in a relatively dry 

excavation. 

The dry construction method may be used when the excavation meets the following: 

(1) Less than 12 inches of water accumulates above the base of the hole during a 1-hour 

period without pumping; 

(2) The sides and bottom of the hole remain stable without caving, sloughing, or swelling 

for 4 hours after excavation or over-reaming; and

(3) Loose material and water can be satisfactorily removed before inspection and before 

reinforcement and concrete placement.
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568

(b) Wet construction method. Use water or slurry to maintain shaft stability with a fluid head 

inside the shaft excavation higher than the on-site static water elevation while advancing the 

excavation to final depth, placing the reinforcing cage, and concreting the shaft. Perform the 

following:

(1) Desand and clean drilling slurry;

(2) Final cleaning of the excavation using a bailing bucket, submersible pump, or other 

approved devices; 

(3) Place shaft concrete with a tremie or concrete pump, starting at the shaft bottom; and

(4) Maintain pressure inside the shaft higher than outside at all times. Maintain inside fluid 

head elevation at least 5 feet higher than outside water head elevation.

Table 565-1

Drilled Shaft Construction Tolerances

Drilled Shaft Attribute Allowable Variance

Top elevation 1 in above to 3 in below the elevation shown in the 

plans

Axial alignment Within 1.5% of plumb in soil

Within 2.0% of plumb in rock

Rebar stick-up 

6 in above to 3 in below the elevation shown in the 

plans

Diameter At least the diameter shown in the plans

Horizontal location at top-of-shaft elevation

 Shaft diameter less than or equal to 2.0 ft 3 in

 Shaft diameter greater than 2.0 ft and less than 5.0 ft 4 in

 Shaft diameter 5.0 ft or larger 6 in

If drilled shaft excavations and completed drilled shafts are out of tolerance or defective, submit 

correction procedures for approval before correcting the deficiencies. Correct unacceptable shaft 

excavations and completed shafts to the satisfaction of the CO.

Maintain the drilled hole to the specified nominal diameter before placing reinforcement elements and 

concrete. Increase the hole diameter at least 1⁄2 inch to a maximum of 3 inches when approved if ground 

softening, swelling or slurry cake buildup occurs. Case the hole, use a slurry during drilling, or both if 

the drilled hole continues to degrade and encroach upon the planned placement of the reinforcement 

cage with specified minimum concrete cover.

Extend exterior casings from above the waterline to a subsurface elevation to protect against water 

action during placement and curing of the concrete when drilled shafts are located in open waters. 

Install the exterior casing to provide a positive seal at the bottom of the casing and prevent piping of 

water or entry of other material from the shaft excavation behind the casing. 

Remove drill cuttings and other loose debris from the bottom of the hole upon completion of drilling. 

Clean the drilled hole leaving no more than 2 inches of sediment on the bottom of the hole. Reduce 

the depth of accumulated water to less than 3 inches before placing concrete in shafts constructed 

using the dry method. Use a Shaft Inspection Device (SID) to visually verify that the magnitude of 

sediment is within tolerance unless otherwise specified. Provide a SID for the inspection that is 

equipped with a high-resolution video camera with recording capability. Use the SID to measure the 
Section 565

569

amount of sediment in the bottom of the drill hole in multiple locations totaling no less than 1 location 

per foot of drilled shaft diameter. Provide 3 days' notice before performing the SID camera work and 

provide live video feed. Provide video recordings within 1 week. 

Do not drill additional shafts, allow wheel loads, vibration-inducing equipment, or other construction 

activities within 15 feet or 3 shaft diameters, whichever is greater, of a newly constructed shaft for at 

least 20 hours. 

Fill rejected drill holes with flowable backfill.

(b) Slurry. Premix slurry with potable water according to the slurry manufacturer’s instructions to 

allow for hydration before introduction into the shaft excavation. Use slurry tanks of adequate capacity 

for slurry circulation, storage, and treatment. Do not use excavated slurry pits or the shaft excavation 

to mix the slurry. Do not add slurry component directly into the shaft excavation. 

Provide desanding equipment to limit slurry sand content as shown in Tables 565-2 and 565-3, at any 

point within the shaft. Verify sand content immediately before placing concrete. Desanding is not 

required for setting temporary casings, sign posts, or lighting mast foundations. 

Maintain the level of slurry in the excavation at least 5 feet above the highest expected adjacent 

piezometric water pressure head for mineral slurry, or 10 feet above the highest expected piezometric 

water pressure head for polymer or water slurry.

Stop drilling and take corrective measures when there is a sudden loss of slurry from the hole. Prevent 

the slurry from setting up in the shaft. Discontinue the use of slurry and use an approved alternative 

method if the slurry construction method fails to produce the desired results. 

Maintain density, viscosity, and pH of the mineral or polymer slurry throughout shaft excavation and 

concrete placement according to Tables 565-2 and 565-3. Take slurry samples using an approved 

sampling tool. Extract slurry samples from the base of the shaft and 10 feet up from the base of the 

shaft. Perform 4 sets of tests during the first 8 hours of slurry use. The testing frequency may be 

decreased to one test set for every 4 hours of slurry use when results are acceptable and consistent.

Comply with the manufacturer’s recommendations and Table 565-3 for polymer slurry.
Section 565

570

Table 565-2 

Acceptable Range of Values for Mineral Slurry

Property

In Hole at

Time of Test

Concreting

Method

Density, pounds per cubic foot(1) 64 to 72 Density balance

API 13B-1, Section 1(2)

Viscosity, seconds per quart 28 to 50 Marsh Funnel

AP 13B-1, Section 2.2(2)

pH 8 to 11 pH paper or meter

Sand content, % 4.0 maximum API 13B-1, Section 5(2)

(1) Density values shown are for fresh water. Increase density values 2 pounds per cubic foot for saltwater. 

Perform tests when slurry temperature is above 40 °F.

(2) American Petroleum Institute, API 13B-1, Recommended Practice for Field Testing Water-based 

Drilling Fluids.

Table 565-3 

Acceptable Range of Values for Polymer Slurry

Property

In Hole at

Time of Test

Concreting

Method

Density, pounds per cubic foot(1) 64 maximum Density balance

API 13B-1, Section 1(2)

Viscosity, seconds per quart 32 to 135 Marsh Funnel

AP 13B-1, Section 2.2(2)

pH 8 to 11 pH paper or meter

Sand content, % 1.0 maximum API 13B-1, Section 5(2)

(1) Density values shown are for fresh water. Increase density values 2 pounds per cubic foot for saltwater. 

Perform tests when slurry temperature is above 40 °F.

(2) American Petroleum Institute, API 13B-1, Recommended Practice for Field Testing Water-based 

Drilling Fluids. 

Correct slurry if sample does not meet the requirements shown in Table 565-2 or 565-3. Do not place 

concrete until the results of the resampling and retesting are approved. 

(c) Casings. Install temporary casing to prevent sloughing of the top of the shaft excavation, unless it 

can be satisfactorily demonstrated to the CO that surface casing is not required. Install temporary 

casing regardless of excavation method when sidewall conditions warrant additional stabilization or 

mitigation of excessive groundwater infiltration. 

Use smooth, clean, watertight, steel casings of sufficient strength to withstand handling, installation 

stresses, concrete placement, and surrounding earth pressures. Casing diameters are outside diameters 

when shown in the plans. Comply with American Petroleum Institute tolerances applicable to regular 

steel pipe for permanent casing diameter. Provide casings with the outside diameter at least the 

specified size of the shaft.

Install casings to produce a positive seal at the bottom of the shaft to prevent piping of water or other 

material into or out of the excavated hole. Stabilize the excavation with slurry, backfill, or other 

approved methods if it becomes necessary to remove a casing. Maintain an adequate head of water or 
Section 565

571

slurry inside the casing to prevent piping or sloughing of material at the bottom of the hole when 

drilling below the water table.

Subsurface casings are to be considered temporary unless designated as permanent casing. Remove 

temporary casing concurrent with concrete placement. Maintain the concrete within the casing so fluid 

trapped behind the casing is displaced upward and discharged at the ground surface without 

contaminating or displacing the shaft concrete. 

Temporary casings that have become bound or fouled during shaft construction and cannot be 

practically removed are considered to be a defect in the drilled shaft. Correct defective shafts using 

approved methods. Corrective action may consist of, but is not limited to, the following: 

(1) Removing the shaft concrete and extending the shaft deeper to compensate for loss of frictional 

capacity in the cased zone;

(2) Providing straddle shafts to compensate for capacity loss; or

(3) Providing a replacement shaft.

Cut permanent casing off at the required elevation and leave in place.

(d) Obstructions. If obstructions, such as boulders, logs, or man-made objects are encountered during 

shaft excavation, notify the CO. Remove, bypass, or break-up obstructions according to the approved 

construction plan and Section 203. If methods in the approved construction plan are not effective, 

submit alternative plans for approval.

Drilling tools and other construction material and equipment lost in the excavation will not be 

considered as obstructions. Promptly remove tools, material, or equipment from the excavation and 

repair degradation of the shaft.

565.07 Reinforcing Steel and Crosshole Sonic Logging Access Tubes Placement. Perform reinforcing 

steel work according to Section 554. Securely wire together contact reinforcing steel lap splices. Tie and 

support the reinforcing steel so it remains within the required tolerances. Securely tie concrete spacers or 

other approved spacing devices at fifth points around the cage perimeter and space at intervals no more 

than 10 feet along the length of the cage. Use spacers of approved material at least equal in quality and 

durability to the shaft concrete.

Install steel CSL access tubes for each drilled shaft at locations specified and according to ASTM D6760. 

Extend access tubes at least 24 inches above shaft top and no more than 3 inches above shaft bottom. Use 

11⁄2-inch nominal diameter, Schedule 40, standard black pipe conforming to ASTM A53 for CSL access 

tubes. Provide a watertight end plug at the lower end of the pipe and make joints watertight. Fill the CSL 

access tubes with potable water before placing concrete in the drilled shaft. Temporarily cap the top of the 

tubes to prevent debris or concrete from entering the tubes. 

Place the reinforcing steel cage as a unit immediately after the drilled hole is inspected, accepted, and 

before concrete placement. Remove cage when directed for re-inspection if concrete is not placed 

immediately. Avoid distortion or racking of the steel when handling reinforcing cages. 

Provide positive support at the top for the reinforcing steel cage during concrete placement. 
Section 565

572

Do not proceed with installation of subsequent shafts until CSL testing has been completed on the first 

drilled shaft and the results have been approved in writing. Approval to proceed with the construction of 

subsequent shafts, before receiving approval of the first shaft will be based on observations of 

workmanship during construction of the first shaft and the following: 

(a) Compliance with the approved shaft installation plan; 

(b) Contractor’s daily reports and inspector’s daily logs of excavation, reinforcement, and concrete 

placement; and 

(c) Concrete placement logs and volume curves.

The CO will furnish written notification to proceed with subsequent shaft construction within 24 hours 

after completion of the first shaft. If the CO determines the first shaft to be of questionable quality, 

discontinue all shaft construction until the CSL test results of the first shaft are received and reviewed and 

the shaft accepted in writing. 

After the first drilled shaft has been accepted, do not change construction methods, equipment, or material 

used to construct subsequent shafts, unless otherwise approved. 

565.08 Concrete for Drilled Shafts. Use a removable form or other approved means to form the shaft to 

at least 24 inches below finished ground when the top of shaft is above ground. Forms may be removed 

according to Subsection 562.08 if the shaft concrete has not been exposed to saltwater or moving water 

for 7 days. Strip the forms without damaging the concrete. 

Remove the top portion of the drilled shaft concrete before continuing with column construction when it 

is determined the concrete has been affected by underwater placement. 

Place concrete immediately after excavation is complete and the reinforcing steel cage with CSL access 

tubes is in place. Provide concrete conforming to Section 552, except as shown in Table 565-4. 

Table 565-4 

Concrete for Drilled Shafts

Method Class Slump

Shafts constructed without 

drilling fluid A(1) 7±1 inches

Shafts constructed with 

drilling fluid A(1) 8±1 inches

Shafts for underwater 

placement S – 

(1) Use Class A(AE) concrete on portions of the drilled shaft above the finished ground-line unless 

otherwise noted.

Do not use seal concrete above the freeze-thaw or wet-dry zone of the hole. Place underwater concrete 

according to Subsection 552.08(d), except as modified in this Section and as approved. 

Adjust approved admixtures for project conditions to ensure that the concrete has the minimum required 

slump for at least 2 hours. Submit trial mix and slump loss test results for concrete at ambient temperatures 

appropriate for site conditions. 
Section 565

573

Place each load of concrete within 2 hours of batching. Longer placement time may be allowed if the 

concrete mix maintains the minimum required slump for longer than 2 hours. Do not retemper concrete 

that has developed its initial set.

Place concrete in one continuous operation from bottom to top of the shaft. 

Continue placing concrete after the shaft excavation is full and until acceptable quality concrete is evident 

at the top of shaft. Consolidate the top 10 feet of the shaft concrete using acceptable vibratory equipment 

before initial concrete set. Finish the top of the shaft to the required elevation shown in Table 565-1. 

Consolidate shaft concrete only when water or slurry above the finish concrete level has been removed.

Place concrete using the following methods:

(a) Free-fall. Use free-fall placement only in dry holes. Ensure the concrete falls directly to the shaft 

base without contacting either the rebar cage or shaft sidewall.

Drop chutes may be used to direct placement of free-fall concrete. Drop chutes consist of a smooth 

tube of either one-piece construction or sections that can be added and removed. Support the drop 

chute so that the maximum height of free-fall of the concrete measured from the bottom of the chute 

is 25 feet. Reduce the height of free-fall or rate of concrete flow into the excavation if concrete 

placement causes the shaft excavation to cave or slough or strikes the rebar cage or sidewall. Use 

tremie or pumping to place the concrete if placement cannot be satisfactorily accomplished by freefall placement.

(b) Tremies. Use tremies for concrete placement in either wet or dry holes. A tremie consists of a 

hopper and tube of sufficient length, mass, and diameter to discharge concrete at the shaft base. Do 

not use tremies that contain aluminum parts that will come in contact with the concrete. Provide a 

tremie tube with clean and smooth inside and outside surfaces and sufficient wall thickness to prevent 

crimping or sharp bends. Provide tubes with an inside diameter at least six times the maximum size of 

aggregate used in the concrete mix, but at least 10 inches. Use a watertight tremie according to 

Subsection 552.08(d) for wet holes. Construct the discharge end of the tremie to allow free radial flow 

of concrete during placement. Place the tremie discharge at the shaft base elevation. Place the concrete 

in a continuous flow. Keep the tremie discharge immersed at least 10 feet below the surface of the 

fluid concrete. Maintain a positive head of concrete in the tremie at all times. If the tremie discharge 

is removed from the fluid concrete column and discharges concrete above the rising concrete surface 

into displaced water; remove the reinforcing cage and concrete, complete necessary sidewall removal 

as directed, and reconstruct the shaft.

(c) Pumps. Use pumped concrete placement in either wet or dry holes. Use a 4-inch minimum 

diameter discharge tube with watertight joints. Place the discharge tube at the shaft base elevation.

Use a sealed discharge tube according to Subsection 552.08(d) for wet holes. If a plug is used, remove 

it from the hole or use a plug made from approved material that will prevent a defect in the shaft if not 

removed. 

Place the concrete in a continuous flow. Keep the pump discharge tube immersed at least 10 feet below 

the surface of the fluid concrete. Remove the reinforcing cage and concrete if the discharge tube is 

removed from the fluid concrete column and discharges concrete into displaced water. Complete 

necessary sidewall removal as directed and reconstruct the shaft.
Section 565

574

565.09 Crosshole Sonic Logging Integrity Testing. Provide an on-site CSL engineer during testing. 

(a) Testing. Perform integrity testing on production drilled shafts according to ASTM D6760. Test 

drilled shafts between 4 and 14 days after concrete placement. Submit drilled shaft bottom and tip 

elevations, access tube lengths, surveyed tube positions, and date of concrete placement before testing 

to the CO. Perform tests between all tube pairings in the shaft, including adjacent perimeter access 

tubes and diagonally between tubes. 

If an access tube is unacceptable for testing, drill a plumb core hole to the appropriate depth and install 

a fully-grouted replacement tube or propose an alternative integrity test method that is acceptable to 

the CO.

Tremie fill access tubes with neat hydraulic cement grout after integrity testing, inspection and data 

analysis are completed and accepted.

(b) Test results and reporting. Submit preliminary results for each shaft tested before CSL test 

personnel leave the site. Submit a detailed CSL report within 5 days of testing. Allow 5 days for review 

of the data before continuing construction on the tested shaft. Include the following in the CSL report:

(1) Project identification and dates of CSL testing;

(2) Table and a schematic showing shafts tested with identification of tube coordinates and collar 

elevation; 

(3) Names and affiliations of personnel who performed the CSL tests and interpretations;

(4) Type of equipment used for testing; 

(5) Data logs and waterfall diagrams;

(6) X-Y plots of first arrival times, amplitude, and velocity versus shaft depth; and

(7) Interpretations, analyses, and results.

Identify and provide detailed discussion of each anomalous zone detected by the CSL. Anomalous 

zones are zones where velocity reduction exceeds 15 percent of the average velocity of properly placed 

and cured shaft concrete at the time of testing or reductions in measured relative energy are greater 

than 9 dB of the local average value of relative energy. Collect and process additional data sufficient 

to construct 3D color-coded tomographic images with two-dimensional cross-sections between tubes 

within identified anomalous zones. 

565.10 Acceptance. Material for drilled shafts will be evaluated under Subsections 106.02 and 106.03. 

Construction of drilled shafts will be evaluated under Subsections 106.02, 106.03, and 106.04 as follows:

(a) Drilled shafts exhibiting velocity reductions less than or equal to 15 percent of the average velocity 

of properly placed and cured shaft concrete at the time of testing and reductions in measured relative 

energy less than 9 dB of the local average value of relative energy are acceptable.

(b) Where velocity reductions exceed 15 percent of the average velocity of properly placed and cured 

shaft concrete at the time of testing or reductions in measured relative energy are greater than 9 dB of 
Section 565

575

the local average value of relative energy, provide additional imaging and other data required in 

Subsection 565.09(b) to enable further evaluation of the shaft. Drill at least two core holes to intercept 

the anomalous zone and obtain core samples from the suspect area when required. The CO will 

evaluate the crosshole sonic logging data, the tomographic imaging data, and the retrieved core data 

and determine if substantive defects are present. 

(c) Removal of obstructions will be evaluated under Subsection 106.02. 

Concrete will be evaluated under Section 552, except concrete will be sampled at the point of discharge 

from the truck.

Reinforcing steel will be evaluated under Section 554. 

Measurement

565.11 Measure the Section 565 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring drilled shafts by the linear foot, measure from the plan top elevation to the approved tip. 

Do not measure portions of shafts extending deeper than approved. 

When measuring trial drilled shafts by the linear foot, measure from the approved tip elevation to the 

ground surface at the center of the shaft.

Payment

565.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 565 pay items listed in the bid schedule, except the drilled shaft contract price will be adjusted 

according to Subsection 106.05. Payment will be full compensation for the work prescribed in this 

Section. See Subsection 109.05. 

Payment for drilled shafts will be made at a price determined by multiplying the contract price by the 

structural concrete compressive strength pay factor.
Section 566

576

Section 566. — SHOTCRETE

Description

566.01 This work consists of constructing shotcrete on a prepared surface. This work also consists of 

installing shotcrete drainage systems.

Material 

566.02 Conform to the following Section and Subsections: 

Concrete curing material and additives 711

Geocomposite drain 714.02

Hydraulic cement 701.01

Pozzolans 701.03

Reinforcing steel 709.01

Shotcrete aggregate 703.16

Water for cementitious materials 725.01(a)

Construction Requirements

566.03 Qualifications. Provide an on-site supervisor and nozzle operators with experience placing 

shotcrete. At least 30 days before starting shotcrete work, submit the following for approval:

(a) On-site supervisor. A résumé describing experience on at least five shotcrete projects of similar 

complexity within the past 5 years. Include project names, locations, and contact information for 

project owners; and 

(b) Nozzle operator. A résumé describing experience in shotcrete construction on at least three 

projects with similar complexity within the past 3 years. Include an ACI nozzle operator certification 

in the processes and orientations in which shotcrete will be applied. 

566.04 Composition (Shotcrete Mix Design). Design and produce shotcrete mixtures that conform to 

Table 566-1 and ACI 506.2, Specification for Shotcrete. 

Submit the following for approval at least 30 days before preconstruction testing: 

(a) Proposed shotcrete mix design with mix proportions and aggregate grading; 

(b) Dosage of admixtures. Do not mix chemical admixtures together in a mix unless they are 

compatible. Provide supporting documentation of compatibility from the manufacturers; 

(1) Air-entraining admixtures. Entrained air may be obtained with either air-entraining hydraulic 

cement or air-entraining admixture.

(2) Set accelerating admixtures. Do not use chloride accelerators. Do not use set accelerating 

admixtures in prestressed concrete applications.

(3) Hydration stabilizing admixtures. Hydration stabilizing admixtures may be used to extend 

the allowable delivery time for concrete. Determine dosage required to stabilize shotcrete using 
Section 566

577

job site material, field trial mixtures, and admixture manufacturer’s recommendations. Changes to 

dosage rates to meet changing job site conditions is allowed. Include the design discharge time 

limit. The maximum allowable design discharge time is 31⁄2 hours;

(c) Representative samples of shotcrete material, if requested;

(d) Test results conforming with Table 566-1; 

(e) Material certifications;

(f) Fiber samples and method for adding the fibers to the shotcrete, if used; 

(g) When an integral color admixture is specified, prepare five 2- by 2-foot test panels. Construct the 

test panels using the proposed mix design. Determine coloring agent batch amounts by weight. Provide 

color charts representing available color selections for shotcrete material in a range of dark, earth-tone 

colors representative of natural features found in the local landscape. Provide additional mixing time 

according to the manufacturer’s recommendations. Cure the test panels similar to the structure. 

Transport the panels to an approved location. Provide at least 2 weeks outside exposure. The CO will 

select the acceptable test panel. Use the same rate of integral color admixture for the item of work;

(h) Proposed equipment and method for applying shotcrete. Conform to the equipment requirements 

in ACI 506R, Guide to Shotcrete; 

(i) Proposed methods of shotcrete placement, installing depth gauges for maintaining shotcrete 

thickness, and for properly curing the applied shotcrete layers;

(j) If applicable, the proposed construction method, sequence, and schedule for shotcrete drainage 

system elements. Include the following: 

(1) Proposed weep hole drilling methods and equipment. Include drill rod sizes and bit diameters; 

(2) Catalog cuts, brochures, or other descriptive literature describing the materials and equipment 

to be used in the installation of shotcrete drainage system elements; 

(3) Proposed method to access the weep hole locations with the drill equipment; and 

(4) Proposed methods for cleaning weep holes, protecting them during shotcrete applications, and 

reopening them after shotcrete has set.

(k) Other information necessary to verify compliance with ACI 506.2, including steel reinforcement 

plan for each area, when applicable.
Table 566-1 

Composition and Property Requirements of Shotcrete Mixtures

Type of

Shotcrete

Mixture

Maximum

WaterCementitious

Material

Ratio

Air

Content 

AASHTO T 152

Minimum

28-Day

Compressive

Strength, f'c, 

ASTM C1604, 

pounds per 

square inch,

(1)

Maximum

Boiling

Absorption, 

ASTM

C642, 

percent

Maximum

Permeable

Void

Volume,

ASTM C642, 

percent

Minimum Core 

Quality 

Evaluation

ACI 506.6T(2)

Maximum

Water-Soluble

Chloride Ion

Content,

ASTM C1218, percent by 

mass of cement

Wet 0.50 – 4000 9 17 Satisfactory 0.15

Wet (AE) 0.45

Grading A

7±1.5%

Grading B

6±1.5%

4000 9 17 Satisfactory 0.15

Dry 0.40 – 4000 9 17 Satisfactory 0.15

(1) Calculate mean compressive core strength as the average strength of at least three individual cores taken from the same nonreinforced test panel. 

Provide a minimum mean core strength of 0.85 f'c for the arithmetic average of any three consecutive cores with no individual core less than 0.75 f'c. 

(2) Use a group of at least three cores taken from the same reinforced test panel to complete evaluation.
Section 566

579

566.05 Production Start-Up Procedures. Conduct preconstruction shotcrete field trials before starting 

shotcrete production. Preconstruction test panels are required for each production nozzle operator.

Prepare and cure test panels according to ASTM C1140. Construct steel or wood test panel forms 

containing no reinforcement with a width and length of at least 24 inches and a depth matching the design 

shotcrete thickness with either square or sloped sides. 

When shotcrete is to be applied over reinforcement or on natural ground and rock, construct additional 

steel or wood test panel forms containing reinforcement with a width and length of at least 30 inches and 

a depth of at least 3 inches with either square or sloped sides. Use reinforcement of the same size and 

spacing or include the fiber reinforcement required for the project. 

Demonstrate the procedure for adding fibers with uniform distribution to the shotcrete in the field for 

approval during preconstruction testing. 

Shoot test panels using the personnel, material, equipment, operating pressures, and mix designs approved 

for the project. Produce test panels for each approved mix proportion, each anticipated shooting 

orientation, and each proposed nozzle operator. 

When shotcrete is applied over reinforcement, or with reinforcing fibers, evaluate at least three cores from 

each reinforced test panel according to ACI 506.6T, Visual Shotcrete Core Quality Evaluation, between 

14 and 28 days after shooting. 

Repeat the preconstruction testing process until an acceptable test panel is produced. If a nozzle operator’s 

test panel is rejected due to quality evaluation, a second panel may be shot. If the nozzle operator’s second 

test panel is rejected due to quality evaluation, that nozzle operator is not allowed to shoot shotcrete on 

the project.

Sample material and test according to ACI 506.2 and Table 566-2. 

Submit reports with the test data and results. Include the following information in the reports:

(a) Date and time of test panel shooting. Include panel dimensions, size and spacing of reinforcement, 

when used, and type of curing; 

(b) Test panel identification. Include panel number, shooting orientation, mix proportions, and nozzle 

operator;

(c) Date, time, method of panel coring, number of test samples obtained from each panel and sample 

preparation methods;

(d) Test sample identification by panel number, sample number, and sample dimensions; and 

(e) Date, time, and types of tests performed. 

Approval of the nozzle operator and placement operations will be based on preconstruction field trials and 

test results. Start production only after the test panel is approved. 
Section 566

580

566.06 Shotcrete Construction. Produce shotcrete according to ACI 506.2 and the following: 

(a) Surface preparation. If shotcrete is to be placed over existing concrete or rock, remove loose or 

deteriorated material from the existing surface by chipping with pneumatic or hand tools. Cut 

shoulders approximately 1 inch deep along the perimeter of repair areas on existing concrete.

Remove curing compound on previously placed shotcrete surfaces by sandblasting or other approved 

method. Maintain prepared surfaces in a clean condition. Install approved depth gauges to indicate the 

thickness of the shotcrete layers. Install depth gauges on 3-foot centers longitudinally and transversely.

When applying shotcrete to soil, thoroughly clean the area of loose material with compressed air and 

compact the soil to provide a firm face for application. Apply water to surfaces 2 to 24 hours before 

application to provide a saturated surface dry condition. Remove surface water before placing 

shotcrete.

(b) Reinforcing. Install reinforcing steel as shown in the plans. Support the reinforcing steel by 

installing anchor studs or bolts in the existing surface. Do not displace reinforcing steel during 

shotcrete application. Space supports at no more than 12 inches on overhead surfaces, 18 inches on 

vertical surfaces, and 36 inches on top of horizontal surfaces. Use at least three supports in each area.

Reinforce areas where the planned shotcrete thickness exceeds 11⁄2 inches. Place reinforcement parallel 

to the proposed finished surface. Support reinforcement at least 1⁄2 inch from the existing surface. 

Provide at least 1 inch cover over steel items including anchors and reinforcement.

(c) Temperature and weather conditions. Conform to Subsection 552.07. Limit expected 

evaporation rate to less than 0.2 pound per square foot per hour as determined by Figure 552-1. If the 

ambient conditions (relative humidity, wind speed, air temperature and direct exposure to sunlight) 

cause the shotcrete to develop plastic shrinkage or early drying shrinkage cracking, suspend shotcrete 

application. Reschedule the work to a time when more favorable ambient conditions prevail; or adopt 

corrective measures as required by Subsection 552.07(c). 

Do not place shotcrete against frozen surfaces. Place shotcrete when the surface and ambient 

temperature is at least 40 °F and rising. 

(d) Shotcrete application. Apply shotcrete according to ACI 506.2 and the following: 

(1) Use the same nozzle operator that produced approved test panels.

(2) Apply shotcrete within 45 minutes of adding cement to the mixture unless an approved 

hydration stabilizer is used. If a hydration stabilizer is approved, deliver and place the shotcrete 

within the approved design discharge time limit, up to 31⁄2 hours maximum.

(3) If fibers are added at the nozzle, uniformly distribute the fibers throughout the shotcrete without 

isolated concentrations. If fibers are added to the dry or wet mix process, use a screen having a 

mesh of 11⁄2 inches to 21⁄2 inches to prevent any fiber balls from entering the shotcrete line unless 

it is demonstrated that fiber balls are not being formed without a screen. Do not add fibers to the 

dry or wet mix at a rate faster than can be blended with the other ingredients without forming balls 

or clumps. Pass bulk fibers that tend to tangle together through a vibrating screen or sift them into 

the mix, so they enter as individual elements and not as clumps.
Section 566

581

(4) Limit the thickness of each shotcrete layer to no more than 2 inches. Thicker layers may be 

approved if no sloughing or sagging is occurring. If additional thickness is required, broom or 

scarify the applied surface and allow the layer to harden. Provide a saturated surface dry condition 

before applying an additional layer. 

(5) Remove laitance, loose material, and rebound. Promptly remove rebound from the work area. 

Do not incorporate rebound or slumped shotcrete into final shotcrete. 

(6) Taper construction joints to a thin edge over a distance of at least 12 inches. Wet the joint 

surface before placing additional shotcrete on the joint. Do not use square construction joints. 

(7) Construct nonreinforced test panels for each mixture, each workday conforming to 

Table 566-2. Cure test panels according to ASTM C1140 for mixture properties testing. Construct 

steel or wood test panel forms to a minimum width and length of 24 inches and a depth matching 

the design shotcrete thickness with either square or sloped sides.

(8) Finish shotcrete as shown in the plans. If no method is specified, finish according to ACI 506.2. 

If penetrating stain is required, apply according to the manufacturer’s recommendations.

566.07 Curing Shotcrete. Cure shotcrete for at least 7 days. Do not use liquid membrane curing 

compounds for intermediate shotcrete surfaces or if a stained or finished final surface is required. Cure by 

one of the following methods: 

(a) Ponding or continuous sprinkling; 

(b) Covering with an absorptive mat or sand that is kept continuously wet; 

(c) Covering with impervious sheeting material; or

(d) Liquid membrane curing compound. Apply twice the rate for formed surfaces as recommended by 

manufacturer if the surface is a gun finish.

566.08 Production Report. Submit a written report within 24 hours of shotcrete work for each shift. 

Include the following information: 

(a) Quantity and location of shotcrete applied. Include photos of areas before and after the shotcrete 

was placed;

(b) Observations of success or problems of equipment operation, application, final product condition, 

and other relevant issues during production and application; 

(c) Batch tickets if applicable;

(d) Name of nozzle operator; and

(e) Name and signature of person performing the observation. 

566.09 Defective Shotcrete. Repair shotcrete surface defects as soon as possible after placement. Remove 

and replace shotcrete that exhibits segregation, honeycombing, lamination, voids, or sand pockets. 
Section 566

582

Make changes to the mix, crew, equipment, or procedures, as needed to obtain satisfactory results, before 

resuming work. Shoot additional test panels and demonstrate that the shotcrete in the panels satisfies the 

specified requirements.

566.10 Shotcrete Drainage Systems. Install strip drains, collector systems, and weep holes as shown in 

the plans.

Provide equipment that can drill straight, uniform-diameter weep holes to the diameter and length shown 

in the plans. Holes may be advanced by rotary, percussion, down-the-hole hammer, or using other drilling 

methods suitable for advancing the drill tools to the depth and at the alignment specified. Do not use water 

or drilling slurry. Drill weep holes to the minimum depths shown in the plans, and within 6 inches of the 

required location. Adjust weep hole lengths and locations as directed. Drill weep holes perpendicular to 

rock faces with a minimum inclination of 5 degrees upward unless otherwise shown in the plans, or as 

directed.

Do not drill weep holes within 15 feet (horizontal and vertical) of any grouted rock reinforcement elements 

until the grout has set at least 12 hours. 

Upon completion of drilling, clean drill holes of cuttings, sludge, and debris using compressed air. 

Drill weep holes after rock reinforcements are installed, if applicable, and before shotcrete is applied. 

Protect weep holes during application of shotcrete and reopen them after the shotcrete has set. Do not drill 

weep holes through shotcrete. 

Provide equipment that can install collector systems, including strip drains, as shown in the plans.

Install strip drains after installation of rock reinforcement and weep holes and before the application of 

shotcrete.

Provide additional drainage measures, as needed, in addition to the described pattern or adjust the spacing 

of the weep holes as directed to allow proper drainage of any observed springs or seeps exposed as surface 

preparation proceeds.

566.11 Acceptance. See Table 566-2 for sampling, testing, and acceptance requirements. 

Material for shotcrete will be evaluated under Subsections 106.02 and 106.03. Submit a production 

certification with each shipment of hydraulic cement.

The shotcrete mixture’s air content, density, boiling absorption, and permeable void volume will be 

evaluated under Subsections 106.02 and 106.04. 

Compressive strength will be evaluated under Subsection 106.05. 

Construction of shotcrete will be evaluated under Subsections 106.02 and 106.04. 

Shotcrete drainage system elements will be evaluated under Subsection 106.02. 

Measurement

566.12 Measure the Section 566 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:
Section 566

583

When measuring shotcrete by the cubic yard, measure in place.

When measuring shotcrete by the square yard, measure the plane parallel to the finished shotcrete surface.

Payment

566.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 566 pay items listed in the bid schedule, except the shotcrete contract price will be adjusted 

according to Subsection 106.05. Payment will be full compensation for the work prescribed in this 

Section. See Subsection 109.05. 

Payment for shotcrete will be made at a price determined by multiplying the contract price by the 

compressive strength pay factor.
Table 566-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sample

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

quality

(703.16) 

Measured &

tested for

conformance

(106.04 & 105) 

Quality – Subsection

703.16

1 per

material type

Source of

material Yes Beforeproducing – 

Mix Design

Shotcrete

composition

Measured &

tested for

conformance

(106.04) 

All – Subsection

566.04

1 per

mix design

Source of 

material No Beforeproducing – 

Production Start-up (Test Panels)

Shotcrete

composition

Measured &

tested for

conformance

(106.04) 

Boiling

absorption

& permeable

void volume(2)

– ASTM

C642(1),(2)

1 set per test 

panel 

(unreinforced)

Test panels No Before

producing – 

Density – AASHTO T 

121 1 per load Shotcrete machine(5) " " – 

Compressive

strength – ASTM C1604(1),(3)

1 set per test 

panel 

(unreinforced)

Test panels Yes 28 days – 

Core quality 

evaluation – ACI 506.6T

1 set per test 

panel(4)

(reinforced)

Test panels No

14 to 28 

days after 

shooting

– 
Table 566-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sample

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Aggregate

(fine & 

coarse)

Measured &

tested for

conformance

(106.04) 

Gradation – AASHTO

T 27 & T 11 1 per day

Flowing 

aggregate

stream

(bin, belt, 

discharge

conveyor 

belt, or 

stockpile)

Yes,

If 

requested

Before

batching – 

Moisture test – AASHTO T 

255 " " " " – 

Shotcrete

Measured &

tested for

conformance

(106.04) 

Boiling

absorption

& permeable

void volume(2)

– ASTM

C642(1),(2)

1 set per 50 yd3

but not less than 

1 per job

Production

test panels

Upon 

completing 

tests

– 

Density – AASHTO

T 121 1 per load

Per 

Shotcrete 

machine(5)

– " – 

Air content 

(wet mix only) – AASHTOT 152 " " – " – 

Statistical

(106.05) 

Compressive

strength II ASTM C1604(1),(3)

1 set per

30 yd3 but not 

less than

1 per day 

Production

test panels Yes 28 days – 

(1) Core 3-inch diameter samples at least 14 days after the field trial and moisture condition in sealed plastic bags or nonabsorbent containers according to ASTM 

C1604. As directed, deliver Government cores to the designated laboratory for testing.

(2) Test at least three samples from each nonreinforced test panel between 14 and 28 days after shooting. Samples may consist of cores or pieces of cores.

(3) Test at least three 3-inch diameter moisture conditioned cores from each nonreinforced test panel 28 days after shooting.

(4) Use a group of least three 3-inch diameter cores, taken from the same reinforced test panel at least 14 days after shooting, to complete evaluation.

(5) Obtain samples of shotcrete material according to ASTM C1385.
Section 567

586

Section 567. — MICROPILES

Description

567.01 This work consists of providing and installing micropiles. 

Material 

567.02 Conform to the following Subsections: 

Centralizers and spacers 722.02(e)

Chemical admixtures 711.03

Portland cement 701.01(a)

Neat hydraulic cement grout 701.04(a)(1)

Reinforcing bars 709.01(a)

Steel pipes 715.03

Micropile materials 722.06

Water for cementitious materials 725.01(a)

Construction Requirements

567.03 Qualifications. Provide a professional engineer, an on-site supervisor, and installation personnel 

with experience installing and testing micropiles. At least 30 days before starting micropile work, submit 

a résumé for each individual describing their experience on at least five micropile projects of similar 

complexity within the past 5 years for approval. Include project names, locations, and contact information 

for project owners.

567.04 Submittals. At least 30 days before starting micropile work, submit the following according to 

Subsection 104.06: 

(a) Start date;

(b) Micropile construction sequence;

(c) Micropile types, sizes, spacings, depths, installation angles, and ultimate strengths for range of 

material to be encountered;

(d) Tendons, full moment splices, permanent casing, and additional hardware with the manufacturer’s 

product data sheets, specifications, catalog cuts, and mill certificates;

(e) Manufacturer’s recommendations for tendon and hardware handling, storing, assembly, and 

working temperature ranges. Hollow bar micropiles are unacceptable unless shown in the plans or 

approved; 

(f) Grout type, mix design, mixing equipment, placement procedures, and 7- and 28-day grout 

compressive strengths test results;

(g) Grouting pressure, volume, and location, if post grouting system is used;
Section 567

587

(h) Procedures and material for repairing corrosion protection coatings in the field;

(i) Drilling methods and equipment; 

(j) Alternative drilling and grouting methods including grout additives;

(k) Additional material needed to achieve required bond capacities such as grout socks; 

(l) Methods to ensure borehole stability during excavation and grout placement; 

(m) Micropile testing methods and equipment. Include type and capacity of reaction load system, 

drawings, and supporting calculations for structural components of the micropile load test apparatus. 

Include locations for sacrificial micropiles for verification tests; and

(n) Identification number and calibration test certification for each jack, pressure gauge, and electronic 

load cell. Clearly indicate the serial number of each component of the testing assembly on calibration 

graphs. Submit results from calibration tests conducted by an independent testing laboratory within 

the previous 60 days. 

567.05 Installation. Stage micropile installation to avoid interconnection or damage to piles with uncured 

grout. 

Before drilling holes for constructing production micropiles, install verification micropiles for verification 

load tests. Install verification and production micropiles as follows:

(a) Drilling. Provide equipment that can drill soil, boulder colluvium and alluvium, and bedrock to 

anticipated depths. Drill micropile holes to the required diameter and length shown in Table 567-1 and 

the construction schedule and sequence. 

If an obstruction prevents the advancement of the pile, abandon the hole and fill the hole with grout. 

Drill a new hole at an approved location. 

Remove drill cuttings and other loose debris from the hole. 

(b) Casing, reinforcing bar, and splicing. Place reinforcing bars with centralizers shown in 

Table 567-1. Use centralizers sized to within 1⁄2 inch of the drill hole diameter.

Construct micropile splices to the required design strength. Align casing joints and reinforcing bar 

splices to avoid eccentricity or angles at splices. Locate threaded pipe casing joints at least two casing 

outer diameters from bar splices. When multiple bars are used, stagger the bar splices by at least 

12 inches. If shown in the plans or approved, weld according to Subsection 551.11(a). 

(c) Grouting. Use a positive displacement grout pump according to Subsection 256.07(b)(1). Place a 

neat hydraulic cement grout in one continuous operation. Mix admixtures according to the 

manufacturer’s recommendations. Do not use compressed air to directly pressurize the grout. 

Grout the micropile the same day the micropile hole is drilled. Inject grout from the lowest point of 

the drill hole until clean, pure grout flows from the top of the micropile. Grout may be pumped through 

tremie tubes, hollow stem augers, or drill rods. Ensure complete continuity of the grout column during 

all phases of grouting and casing extraction. Control the grout pressures and grout takes to prevent 
Section 567

588

excessive heave in cohesive soils or fractured formations. Grout the entire pile to the design cut-off 

level.

After grouting is complete, fill the grout tube with grout if the tube will remain in the hole. Ensure 

grout within the micropiles attains the minimum design strength before loading. 

Observe site conditions in the vicinity of the micropile construction daily. Stop operations and notify 

the CO if:

(1) Ground heave, subsidence, or grout leakage is observed; 

(2) Micropile structure is adversely affected; or

(3) Adjacent structures are damaged from drilling or grouting. 

Table 567-1 

Micropile Construction Tolerances

Micropile Attribute Allowable Variance

Center of micropile < 3 in from indicated plan location or pile spacing

Pile-hole alignment ±2% of design alignment

Top elevation 0 to 1 in above the design vertical elevation

Center of reinforcing bar < 0.75 in from pile center

567.06 Testing and Stressing. 

(a) Testing equipment. Conform to Subsection 256.08(a). 

(b) Stressing. Place testing equipment over the micropile so that the jack, bearing plates, load cells, 

and stressing assembly are axially aligned with the micropile and the micropile is centered within the 

equipment. Do not apply loads greater 80 percent of the structural capacity of the micropile.

Place the reference pressure gauge in series with the pressure gauge and jack so they need not be 

unloaded and repositioned during a test. Raise the load from one increment to another. Hold the load 

just long enough to measure and record the micropile top movement to the nearest 0.001 inch with 

respect to an independent fixed reference point. Repump the jack as necessary to maintain a constant 

load. Monitor the load with a pressure gauge. If the load measured by the pressure gauge and the load 

measured by the reference pressure gauge differ by more than 10 percent, recalibrate the jack, pressure 

gauge, and reference pressure gauge.

(1) Verification tests. Perform verification tests at the approved locations. Test under tension 

according to Tables 567-2 and 567-4 consistent with AASHTO, LRFD Bridge Design 

Specifications. 
Section 567

589

Table 567-2

Verification Test Load Schedule

Cycle Load Hold Time (Minutes)

1 

AL(1) – 

0.075 Factored Design Load (FDL) 4 

0.15 FDL 4 

0.225 FDL 4 

0.30 FDL 4 

0.375 FDL 4 

2 

AL(1) 1 

0.15 FDL 1 

0.30 FDL 1 

0.375 FDL 1 

0.45 FDL 4 

0.525 FDL 4 

0.60 FDL 4 

0.675 FDL 4 

0.75 FDL 4 

3 

AL(1) 1 

0.30 FDL 1 

0.60 FDL 1 

0.675 FDL 1 

0.75 FDL 1 

0.825 FDL 4 

0.90 FDL 4 

0.975 FDL 60(2)

4 

AL(1) 1 

0.30 FDL 1 

0.60 FDL 1 

0.90 FDL 1 

0.975 FDL 1 

1.05 FDL 4 

1.125 FDL 4 

1.20 FDL 4 

1.275 FDL 4 

1.35 FDL 4 

1.425 FDL 4 

1.50 FDL

(Maximum test load) 4 

1.20 FDL 4 

0.90 FDL 4 

0.60 FDL 4 

0.30 FDL 4 

AL(1) 15

(1) No greater than 4 percent of FDL (0.04 FDL) applied to the pile before setting 

the movement recording devices. Zero dial gauges after the first setting of AL.

(2) Hold the load to within 2 percent and measure and record pile top movement at 

1, 2, 3, 4, 5, 6, 10, 20, 30, 50, and 60 minutes.
Section 567

590

A verification test is acceptable based on one of the following results:

(a) Total vertical movement does not exceed 3⁄8 inch under 0.75 FDL. If an AL is used, reduce 

the allowable movement by multiplying by a factor of (0.75 FDL-AL)/0.75 FDL; 

(b) Deflection rate is linear or decreasing and does not exceed 0.040 inch per log cycle time 

from 1 to 10 minutes or 0.080 inch per log cycle time from 6 to 60 minutes under 0.975 times 

the FDL; or

(c) Slope of the load versus deflection (at end of increment) curve does not exceed 0.025 inch 

per kip at each test load increment. 

If the micropile verification is unacceptable, perform another verification test to establish the cause 

and make design or construction modifications. These modifications may include installing 

replacement test micropiles, modifying the installation methods, increasing the bond length, 

regrouting with pre-placed re-grout tubes, or changing the micropile type. Submit structure 

modifications requiring changes and retest the new system as directed.

Submit micropile geometry, construction, testing details, and verification test results for approval 

before installing production micropiles. 

Remove verification test micropiles to an elevation 24 inches below finished ground level. 

If construction methods or foundation material change, perform additional verification tests.

(2) Proof tests. The CO will designate production micropiles for proof testing. Test according to 

Tables 567-3 and 567-4. 

A proof test is acceptable based on one of the following results: 

(a) Total vertical movement does not exceed 1⁄2 inch under 0.75 FDL. If an AL is used, reduce 

the allowable movement by multiplying by a factor of (0.75 FDL-AL)/0.75 FDL; 

(b) Deflection rate is linear or decreasing and does not exceed 0.040 inch per log cycle time 

from 1 to 10 minutes or 0.080 inch per log cycle time from 6 to 60 minutes under 1.00 times 

the FDL; or

(c) Slope of the load versus deflection (at end of increment) curve does not exceed 0.025 inch 

per kip under the maximum test load (1.00 FDL.) 

If a proof-tested micropile is unacceptable, proof test another micropile in the immediate vicinity. 

Establish the cause and make design or construction modifications for future piles. Submit 

structure modifications requiring changes for approval. 
Section 567

591

Table 567-3 

Proof Test Load Schedule

Load Minimum Hold Time (Minutes)

AL(1) – 

0.10 Factored design load (FDL) 4 

0.20 FDL 4 

0.30 FDL 4 

0.40 FDL 4 

0.50 FDL 4 

0.60 FDL 4 

0.70 FDL 4 

0.80 FDL 4 

0.90 FDL 4 

1.00 FDL (Load-hold test) 10(2)

0.75 FDL 4 

0.50 FDL 4 

0.25 FDL 4 

AL(1) 4 

(1) No greater than 4 percent of FDL (0.04 FDL) applied to the pile before setting the 

movement recording devices. Zero dial gauges after the first setting of AL.

(2) Hold the load to within 2 percent and measure and record pile top movement at 

1, 2, 3, 4, 5, 6, and 10 minutes. If the movement measured between 1 and 10 minutes 

exceeds 0.04 inch, continue holding the load and measure and record pile movement 

at 20, 30, 50, and 60 minutes.

567.07 Test Results and Reporting. Submit preliminary results to the CO for each micropile tested before 

testing personnel leave the site at the end of each testing day. Submit detailed verification and proof test 

load and deflection data in a tabular format within 5 days. Submit a graph that plots total micropile top 

movement versus load, the A-line, and the B-line. The A-line is defined as 0.8 multiplied by the theoretical 

free test length elastic elongation. The B-line is defined as the theoretical free test length elastic elongation 

plus 0.50 multiplied by the theoretical bond length elastic elongation. Allow 5 days for the CO to conduct 

a review of the data and approve micropile installation.

567.08 Acceptance. See Table 567-4 for sampling, testing, and acceptance requirements.

Material for micropiles will be evaluated under Subsections 106.02 and 106.03. Submit a production 

certification with each shipment of structural steel and casing.

Construction of micropiles will be evaluated under Subsections 106.02 and 106.04. 

Reinforcing steel will be evaluated under Section 554. 

Measurement

567.09 Measure the Section 567 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring production micropiles by the linear foot, measure from the plan top elevation to the 

approved tip elevation. Do not measure linear footage for verification test piles. Do not measure failed 

verification or proof tests or additional tests to verify alternative micropile installation methods proposed 

by the Contractor. 
Section 567

592

Payment

567.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 567 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 567-4 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

Neat hydraulic

cement grout

(701.04(a)(1)) 

Measured &

tested for

conformance

(106.04) 

All − Subsection

567.04(f)

1 per

mix

design

Source of

material

If

requested

Before

producing −

Production

Neat hydraulic

cement grout

(701.04(a)(1)) 

Measured &

tested for

conformance

(106.04) 

Density – AASHTO

T 121

1 per

5 piles Mixer No

Upon 

completion 

of test

−

Flow – ASTM

C939 " Point ofdischarge " " −

Compressive

strength – ASTMC109

1 set of 

3 sample(1)

Grout

plant " " −

Verification test

micropile " Performance – Subsection

567.06(b)(1) All Installation No 5 days −

Proof test

micropile " Performance – Subsection

567.06(b)(2)

1 in 20 & 

1 min per 

substructure 

unit

" " " −

(1) From each grout plant per day of operation or per five micropiles, whichever occurs more frequently.
Section 568

594

Section 568. — SERVICE LIFE DESIGN CONCRETE

Description

568.01 This work consists of constructing Service Life Design Concrete (SLDC) for structural elements 

to meet the requirements of a stated service life in conditions subject to exposure to chloride ions. 

Material 

568.02 Conform to the following Section and Subsections: 

Coarse aggregate for concrete 703.02

Concrete curing material and additives 711

Fine aggregate for concrete 703.01

Hydraulic cement 701.01

Pozzolans 701.03

Structural steel 717.01

Water for cementitious materials 725.01(a)

Construction Requirements

568.03 Service Life Analysis to Determine Adequacy of Submitted Concrete Mixture. Provide 

concrete for service life design that is free of repairs from chloride intrusion and damage caused by 

corrosion of reinforcing steel for the stated service life of the structure. Use approved service life 

modelling software that models the ingress of chlorides into the structure. Use software that indicates the 

initiation of corrosion based on inputs of estimated chloride exposure, environmental conditions, steel 

type used, concrete cover depth, and element geometry, and provides the years from corrosion initiation 

to concrete damage caused by steel corrosion that requires repair to the structure. Provide results of 

modelling and the life cycle cost to meet the stated service life requirement for the structure.

Fabricate trial batches of concrete to verify that the mixture proposed for SLDC meets the requirements 

of the model. Fabricate and test specimens according to ASTM C1556 to determine apparent D28 chloride 

diffusion rate for the mixture. Input the D28 value into the model to confirm service life performance.

If a corrosion inhibitor is selected to meet service life requirements use a calcium nitrite based Corrosion

Inhibiting (CI) admixture. Report addition rate required to meet service life requirements.

For prestressed concrete elements that contain 270 kilopound per square inch low relaxation carbon steel 

strand provide a concrete mixture with minimum addition rate of 3 gallons per cubic yard of CI admixture 

regardless of level of chloride exposure. If necessary, increase the addition rate of CI to meet the service 

life requirements of the prestressed element based on exposure risk to chlorides. Provide documentation 

that calcium nitrite addition rates have been evaluated for the exposure risk for the concrete element with 

the use of the approved service life modeling software. If a proposed design alternative uses stainless steel 

secondary reinforcement and stainless steel prestressing strand, the inclusion of CI is not required unless 

warranted by the service life analysis.

568.04 Composition (Concrete Mix Design). Design and produce concrete mixtures that conform to 

Tables 568-1 and 568-2. 
Section 568

595

Table 568-1 

Performance Characteristics and Plastic Properties

of Service Life Design Concrete

Property Specification

Concrete resistivity, no corrosion inhibitor 

in mixture, AASHTO T 358, except as 

modified in Subsection 568.04(c) 

25 kΩ -cm minimum

Concrete resistivity, corrosion inhibitor in 

mixture, AASHTO T 358, except as 

modified in Subsection 568.04(c)

18 kΩ -cm minimum

Drying shrinkage, ASTM C157, except as 

modified in Subsection 568.04(g) 400 microstrains maximum

Apparent chloride diffusion Rate D28, as 

determined according to ASTM C1556 Subsection 568.03

Compressive strength, AASHTO T 22 4500 psi minimum at 56 days

Approved shrinkage reducing admixture 1.5 gal/yd3 addition rate

Water to cementitious material ratio 0.45 maximum

Plastic air content AASHTO T 152 5.5% to 8%

Super air meter (SAM) value 

AASHTO TP 118 0.20 minimum

Aggregate size(7) 1.5 in maximum

Total cementitious content(1) 750 lb/yd3 maximum

Slump,(2) AASHTO T 119 2 to 8 in

Sulfate resistance

AASHTO M 240, Type IP(MS) or Type IS(< 

70)(MS) (use Type II cement per 

AASHTO M 85)(4),(5)

Water-soluble chloride ion content,

ASTM C1218(6)

0.15% by mass of cement maximum for reinforced 

concrete

0.06% by mass of cement maximum for 

prestressed concrete

(1) The total cementitious content includes portland cement and all pozzolans added to the concrete 

mixture (such as ground granulated blast furnace slag, fly ash, and silica fume).

(2) Slump can be adjusted using a high-range water reducer (superplasticizer) if the maximum water

to cementitious material ratio is not exceeded. Include the water contained in the aggregates above 

the amount of absorbed water in the calculation of the water to cementitious material ratio.

(3) If the plastic air content is low when the concrete arrives on site, additional air-entraining agent 

may be added to the concrete and mixed provided that 300 revolutions of the mixer has not been 

exceeded.

(4) For seawater exposure, other portland cement types are allowed if the tricalcium aluminate (C3A) 

content is 10 percent or less and the water to cementitious material ratio is 0.40 or less.

(5) Other cement types are allowed if the C3A content is less than 8 percent.

(6) Determine the water-soluble chloride ion content contributed from the ingredients including 

water, aggregates, cementitious material, and admixtures between ages 28 and 42 days.

(7) Meet size number gradation and requirements from AASHTO M 43 for coarse aggregates. 

Blending of standard sizes to optimize gradation is allowed. 
Section 568

596

Table 568-2 

Cementitious Material Requirements for Concrete

Cementitious Material Maximum Percent of Total

Cementitious Material by Mass

Fly ash or other pozzolans, AASHTO M 295 25

Slag, AASHTO M 302 50

Silica fume, AASHTO M 307 10

Total fly ash or other pozzolans, slag, and silica fume 50(1)

Total fly ash or other pozzolans and silica fume 35(1)

(1) Limit fly ash or other pozzolans to no more than 25 percent of the total mass of cementitious material and 

limit silica fume to no more than 10 percent of the total mass of cementitious material.

Determine design strength values according to Section 4 of ACI 301, Specifications for Concrete 

Construction. 

Verify mixture design with trial mixes prepared according to Section 4 of ACI 301 from proposed sources 

or with previous concrete production data for the mixture design submitted from proposed sources. Verify 

the performance characteristics and plastic properties in Table 568-1. Submit written concrete mix designs 

for approval at least 36 days before production. 

Submit SLDC mix designs on Form FHWA 1608, 552 Structural Concrete Mix Design Submittal. 

Include the following in each mix design submittal: 

(a) Mix design information. Information listed in Subsections 552.03(a) except for 

Subsections 552.03(a)(23) and 552.03(a)(24).

(b) Shrinkage reducing admixture. Provide a shrinkage reducing admixture that conforms to the 

requirements of ASTM C494 Type S. 

(c) Corrosion inhibiting admixture. If required for meeting service life requirements, provide a 

calcium nitrite corrosion inhibiting admixture that conforms to ASTM C494 Type S. 

(d) Design strength. Specified design strength (f'c) and required average strength (f'cr) for the concrete 

mixture at 56 days as determined by the process described in Section 4 of ACI 301. This process and 

associated calculations are outlined on Form FHWA 1608, pages 4 and 5. Pending 56-day strength 

results, a mix design may be approved on the basis that 14-day compressive strength results meet or 

exceed 85 percent of the required average strength (f'cr) at 56 days. 

(e) Compressive strength. Compressive strengths test results at 1, 3, 7, 14, 28, and 56 days according 

to Table 552-10, Note (3). 

(f) Concrete resistivity. Report concrete resistivity according to AASHTO T 358 at 56 days of curing. 

(g) Drying shrinkage of concrete. Initial lime water curing is according to ASTM C157 for 14 days. 

Report Drying Shrinkage of Concrete after 28 days of air drying, that is 42 days from fabrication of 

test samples.

(h) Internally cured concrete (ICC). If used as part of the SLDC design, produce concrete mixtures 

that conform to Tables 568-1 and 552-2. Provide aggregate for the class specified, except substitute a 
Section 568

597

portion of the normal weight fine aggregate (on a cubic yard basis) for Lightweight Fine Aggregate 

(LWFA) conforming to AASHTO M 195. 

Determine the quantity of LWFA (pounds per cubic yard) by the following calculations: 

Cementitious Factor = Cementitious Content (lb/yd3

)/100 

where:

Cementitious Content is the inclusion of portland cement and any supplementary cementitious 

materials in the submitted concrete mixture;

 

 

Round calculated LWFA quantity to nearest pound per cubic yard.

Adjust the concrete mix design normal weight fine aggregate quantity after determining the saturated 

surface dry (SSD) volume of the LWFA. Subtract the SSD LWFA volume from the original volume 

of normal weight fine aggregate. Calculate new adjusted SSD weight of normal weight fine aggregate 

on a pound per cubic yard basis. 

Start production only after the mix design is approved. 

Provide a new mix design for approval if there is a change in a source of material source or when the 

fineness modulus of the fine aggregate changes by more than 0.20. 

568.05 Test Section for Cast-in-Place Bridge Deck and Cast-in-Place Structural Elements. For bridge 

decks, approach slabs, and other flatwork, construct a 9-foot by 9-foot by 8-inch test section. For other 

structural elements, construct a 3- by 3- by 3-foot test section. Use the approved concrete mix design and 

the same methods of handling, placing, monitoring, finishing, curing, and cleaning as intended for 

production placement. Sample and test according to Table 568-1. Monitor temperatures of the test 

placements according to Subsection 552.07.Start production only after the test section is approved. 

568.06 Delivery. Conform to Subsection 552.05. 

568.07 Quality Control of Mix. Conform to Subsection 552.06. 

568.08 Temperature, Weather, and Mass Concrete Conditions. Conform to Subsection 552.07. 

568.09 Handling and Placing Concrete. Conform to Subsection 552.08. Remove and replace concrete 

represented by cylinders having a compressive strength less than 90 percent of the minimum 56-day 

compressive strength (f'c).

568.10 Construction Joints. Conform to Subsection 552.09. 

568.11 Expansion and Contraction Joints. Conform to Subsections 552.10 and 552.11. 

568.12 Finishing Plastic Concrete. Conform to Subsection 552.12. 
Section 568

598

568.13 Concrete Curing. For cast-in-place structural elements, start curing immediately after the free 

surface water has evaporated and the finishing is complete. If the surface of the concrete starts to dry 

before the selected cure method can be implemented, keep concrete surface moist using a fog spray 

without damaging the surface. As soon as possible after completion of finishing operations, start selected 

curing method.

Keep surfaces to be rubbed moist after forms are removed. Cure immediately following the first rub.

Cure cast-in-place elements at least 14 days and until the summation of the product of concrete 

temperature (°F) and curing time (hours) for all the temperature sensors placed in the structural element 

meets a minimum value of 7000 degree-hours, as calculated using the Nurse Saul Method of ASTM 

C1074, with a datum temperature of 32 °F.

(a) Flatwork and bridge decks. Cure the top surfaces of bridge decks using the water method. Apply 

the water cure as soon as all finishing operations have been completed. Use water method for flatwork 

placements.

Keep the concrete surface continuously wet by ponding, spraying, or covering with material that is 

kept continuously and thoroughly wet. Covering material may consist of cotton mats, multiple layers 

of burlap, or other approved material that does not discolor or otherwise damage the concrete.

Cover the covering material with a waterproof sheet material that prevents moisture loss from the 

concrete. Use the widest sheets practical. Lap adjacent sheets at least 6 inches, and tightly seal seams 

with pressure sensitive tape, mastic, glue, or other approved methods. Secure material so that wind 

does not displace it. Immediately repair sheets that are broken or damaged. 

(b) Cast-in-place structural elements. Use a combination of the forms in-place method according to 

Subsection 552.13(a) and the water method according to Subsection 552.13(b). If forms are stripped 

or loosened before the end of the curing period, complete the remainder of the curing using the water 

method. 

(c) Prestressed elements. Cure according to Subsection 553.06. 

If directed after curing, clean staining or efflorescence to provide a uniform color to the concrete surface.

568.14 Finishing Cured Formed Structural Elements and Concrete Bridge Decks. Finish according 

to Subsection 552.14. 

568.15 Acceptance. See Table 568-4 for sampling, testing, and acceptance requirements.

Material for SLDC will be evaluated under Subsections 106.02 and 106.03. Submit a production 

certification with each shipment of cementitious material.

The concrete mixture’s slump, air content, density, and temperature will be evaluated under 

Subsections 106.02 and 106.04. 

Concrete compressive strength will be evaluated under Subsection 106.05. The lower specification limit 

is the minimum required compressive strength (f'c) at 56 days shown in Table 568-1. 
Section 568

599

Concrete resistivity will be evaluated under Subsection 106.04. Refer to Table 568-1 for Resistivity Lower 

Specification Limits.

Drying shrinkage will be evaluated under Subsection 106.04. 

Construction of SLDC structures will be evaluated under Subsections 106.02 and 106.04. 

Measurement

568.16 Measure the Section 568 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring SLDC by the cubic yard, measure in the structure. 

Payment

568.17 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 568 pay items listed in the bid schedule, except the SLDC contract price will be adjusted according 

to Subsection 106.05. Payment will be full compensation for the work prescribed in this Section. See 

Subsection 109.05. 

Payment for SLDC will be made at a price determined by multiplying the contract price by the lower of 

the two pay factors determined for compressive strength or chloride permeability.
Table 568-4 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

(fine & 

coarse) 

Measured & 

tested for

conformance

(106.04 & 

105) 

Quality −

Subsections

703.01 & 

703.02

including ASR

requirements

1 per

material

type

Source of

material Yes Beforeproducing −

Mix Design

Concrete

composition

Measured & 

tested for

conformance

(106.04) 

All − Subsection

568.04

1 per

mix

design

" Yes " −

Production Start-up (Test Section)

SLDC 

Measured & 

tested for

conformance

(106.04)

(1)

Concrete

resistivity(2) − AASHTO

T 358

1 set per

test

sextion

Discharge

stream at 

point of

placement

Yes

Upon

completing

tests

−

" Compressive

strength(3)

AASHTO

T 23 & 22 " " " " −

" Plastic air 

content − AASHTO T 152 " " No " −

For 

Informational

Purposes

SAM value − AASHTO TP 118 " " No " – 
Table 568-4 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

Produced

aggregate

(fine & 

coarse)

Measured & 

tested for

conformance

(106.04) 

Gradation −

AASHTO

T 27 & T 11 1 per

day

Flowing

aggregate

stream 

(bin, belt, 

discharge

conveyor 

belt, or 

stockpile)

Yes Before

batching

−

Fineness

modulus − AASHTOT 27 " " " " −

Moisture test − AASHTO 

T255 " " " " −

SLDC 

Measured & 

tested for

conformance

(106.04) 

Density − AASHTO

T 121

1 per

load

Point of

discharge No

Upon

completing

tests

−

Air content −

AASHTO

T 152 or

AASHTO

T 196

" " No " −

Slump(5) − AASHTO

T 119 " " No " −

Temperature − ASTM

C1064 " " No " −

Drying

shrinkage(4) − ASTM

C157

As 

directed " No " −

Concrete 

resistivity

− AASHTO

T 358

1 set per

30 yd3 but 

not less 

than

1 per day

" Yes " 
Table 568-4 (continued)

Sampling and Testing Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

SLDC Statistical

(106.05) 

Compressive

strength(6) II AASHTO

T 23 & T 22

1 set per

30 yd3

, but 

not less

than 1 per 

day

Discharge

stream at

point of

placement

Yes

Upon

completing

tests

−

SLDC 

For 

informational 

purposes

SAM value – AASHTO

TP 118

1 test per

30 yd3

, but 

not less

than 1 per 

day

Discharge

stream at

point of

placement

No

Upon

completing

tests

−

(1) Sample according to AASHTO R 60, except composite samples are not required.

(2) Cast at least three 4- by 8-inch for AASHTO T 358 testing cylinders per set and carefully transport the cylinders to the job site curing facility. Have 

the testing done at 56 days in an independent laboratory that is qualified to perform the testing and is approved. The set test result is the average of the 

measurements on three cylinders cast from the same load.

(3) Cast at least eighteen 4- by 8-inch compressive strength cylinders per set and carefully transport the cylinders to the job site curing facility. Have 

the testing done at 1, 7, 14, 28, and 56 days in an independent laboratory that is qualified to perform the testing and is approved. A single compressive 

strength test result is the average result from three cylinders cast from the same load.

(4) If testing is directed, use 3- by 3- by 11-inch prisms for drying shrinkage specimens. Cast at least three drying shrinkage prisms per set and carefully 

transport the prisms to the job site curing facility. Moist the prisms for the duration of the specified moist curing period for SLDC elements. Have the 

testing done in an independent laboratory that is qualified to perform the testing and is approved. The zero measurement for percent drying shrinkage 

is the initial measurement taken at demolding of the specimens at 231⁄2±1⁄2 hours after introduction of mixing water to the concrete mixture. Measure 

percent drying shrinkage at the end of specified moist curing period for the structural elements, 1, 4, 7, 14, 28, and 56 days after the end of the specified 

field moist curing period.

(5) If reinforcing fibers are used at an addition rate greater than 0.3 percent by volume, measure slump at the batch plant before the addition of fibers.

(6) Cast at least six 4- by 8-inch compressive strength cylinders per set and carefully transport the cylinders to the job site curing facility. Test three

cylinders at 56 days. Use the remainder of cylinders as designated by the CO.
Section 569

603

Section 569. — CONCRETE OVERLAYS FOR BRIDGE DECKS

Description

569.01 This work consists of providing, placing, finishing, and curing concrete for bridge deck overlays. 

Material 

569.02 Conform to the following Section and Subsections:

Coarse aggregate for concrete 703.02

Concrete curing material and additives 711

Fine aggregate for concrete 703.01

Hydraulic cement 701.01

Pozzolans 701.03

Water for cementitious materials 725.01(a)

Construction Requirements

569.03 Qualifications. Provide an on-site supervisor with experience placing concrete overlays on bridge 

decks. At least 30 days before starting concrete overlay work, submit a résumé for the on-site supervisor 

describing experience on at least two overlay projects with the specified overlay class within the past

3 years for approval. Include project names, locations, and contact information for project owners. 

569.04 Composition (Concrete Mix Design). Design and produce concrete overlay mixtures that 

conform to following:

(a) Table 569-1 for the class specified; and

(b) Section 4 of ACI 301, Specifications for Concrete Construction for determining required average 

compressive strength (f'cr).
Table 569-1 

Composition of Concrete

Concrete

Overlay

Class

Property Performance Characteristics

Total

Cementitious

Material

Content, 

pounds per 

cubic yard(1)

Maximum

Water/

Cementitious

Material

Ratio(4)

Slump,

inches

Air

Content, 

percent

Coarse

Aggregate

Size

Number

AASHTO

M 43(5)

Maximum

Chloride

Permeability,

AASHTO

T 277, 

coulombs

Average Bond 

Strength at

14 Days, 

ASTM C1583, 

pounds per square 

inch

Minimum

Compressive

Strength,

AASHTO T 22, pounds 

per square inch

HPC(O)(2) 564 to 750 0.45 2 to 8 Table 552-1 7, 78, 8 1500 150 4500

LMC(3) 564 to 750 0.45 2 to 8 3.0 to 10.0 7, 78, 8 1500 150 4000

(1) The total cementitious material content includes portland cement and pozzolans added to the concrete mixture (such as ground granulated blast furnace slag, 

fly ash, and silica fume). Meet the requirements shown in Table 552-2. 

(2) Add 1.5 gallons per cubic yard of concrete of an approved Shrinkage Reducing Admixture (SRA). 

(3) Add 3.5 gallons of latex emulsion admixture per 94 pounds of cement.

(4) Include the water contained in the aggregate above the amount of absorbed water in the calculation of the water-to-cementitious material ratio.

(5) Meet the processing requirements of AASHTO M 43, Table 1 – Standard Sizes of Processed Aggregate. Do not use gravel or alkali-silica reactive aggregates.
Section 569

605

Submit concrete overlay mix designs on Form FHWA 1608, 552 Structural Concrete Mix Design 

Submittal. 

Verify the mix designs with trial mixes prepared according to Section 4 of ACI 301 from proposed sources 

or with previous concrete production data for the mixture submitted from proposed sources. Verify the 

performance characteristics in Table 569-1. Submit written concrete mix designs for approval at least 

36 days before production. Include the items listed in Subsections 552.03(a)(1) through (28) in each mix 

design submittal. 

Provide a new mix design for approval if a source of material changes or if the fine aggregate fineness 

modulus changes by more than 0.20. 

569.05 Strength-Maturity Relationship. If used, submit strength-maturity relationships according to 

AASHTO T 325.

569.06 Surface Preparation. Remove asphalt, asphalt membranes, and concrete overlays without 

damaging the concrete bridge deck. Micro mill according to Section 413 to remove existing overlays. 

Sound the bridge deck according to ASTM D4580 to identify unsound concrete in the deck. Do not 

perform surface preparation within 6 feet of a new overlay until 48 hours after its placement. Submit a 

repair plan for approval that includes the following:

(a) Concrete repairs. Conform to Section 572. 

(b) Surface profiling. Provide a minimum profile of 1⁄16 inch and a maximum of 1⁄4 inch on the 

substrate concrete to bond to the concrete. Use hydrodemolition according to Section 560 or a micro 

milling machine.

After surface profiling approval and within 36 hours of expected overlay placement, shot blast and 

pressure wash the substrate concrete. Use a potable water source with a minimum water pressure of 

4000 pounds per square inch. Remove concrete laitances, oils, fuels, and other foreign and loose 

material detrimental to achieving a sufficient bond. Capture debris from shotblasting and pressure 

washing, and properly dispose of it off site. Cover the prepared surface with polyethylene sheeting to 

prevent contamination.

(c) Saturation. Thoroughly water-soak the clean concrete surface for at least 24 hours before placing 

the overlay concrete. Do not use burlap. Remove puddles of standing water using a vacuum or other 

approved equipment. Do not use a blower or compressed air to remove water. 

569.07 Test Section. Prepare the substrate concrete surface using the same methods intended for the 

overlay placement. Construct a 9- by 9-foot test section on the substrate concrete at the same thickness as 

the overlay. Use the approved concrete mix design and the same methods of handling, placing, finishing, 

and curing intended for actual placement. Sample and test according to in Table 569-2. 

Demonstrate the maturity meter operation. Use the strength-maturity relationship developed for the 

approved mix design to determine in-place compressive strength. Verify that the test section concrete has 

a similar time temperature relationship. Demonstrate methods for conforming to temperature requirements 

in Subsection 569.11. 

Demonstrate methods for cleaning stains or efflorescence to provide uniform color on the concrete surface.
Section 569

606

Start production only after the test panel is approved. 

569.08 Mixing. Conform to Subsection 552.04 and the following: 

(a) Class HPC(O). Provide ready-mixed concrete produced and delivered according to AASHTO 

M 157. 

(b) Class LMC. Provide volumetric proportioning and mixing equipment with an integral mobile unit 

with continuous mixing capability. Provide a mixer with the following: 

(1) Capable of producing at least 6.0 cubic yards of concrete without recharging; 

(2) Equipped with a cement metering device and recording meter accurate within a tolerance of 

minus 1 to plus 3 percent and with a device to record the cement quantity added to the mix; 

(3) Equipped with a latex tank with a standpipe marked in gallons and a latex metering device 

accurate within a tolerance of minus 1 to plus 2 percent;

(4) Equipped with a water flow control and flow indicator accurate within a tolerance of 2 percent 

in the range of expected use that is readily adjustable to provide for minor variations in aggregate 

moisture content;

(5) Equipped with controls to regulate the quantity of other components required to produce the 

specified mix; and

(6) Capable of discharging the mixture through a conventional chute directly in front of the 

finishing machine. 

Calibrate LMC equipment with material for the approved mix design within 6 months before the 

placement date. Keep the equipment maintained, calibrated, clean, and free of partially dried or 

hardened material.

Protect latex emulsion from freezing and prolonged exposure to temperatures more than 85 °F. Store 

containers of latex admixture at the bridge site for no more than 10 days. 

Add reinforcing fibers to the concrete mixture according to the manufacturer’s recommendations. Add 

fibers to the concrete mixture gradually to ensure the fibers are uniformly distributed throughout the 

concrete mixture. 

569.09 Delivery. Conform to Subsection 552.05, except do not use non-agitating equipment. 

(a) Class HPC(O). If reinforcing fibers reduce workability, do not add additional water to the concrete 

mixture. Adjust workability using admixtures from the approved mix design. 

If the air content is low when the concrete arrives on site, add air-entraining agent and mix. 

(b) Class LMC. Deliver concrete through the conventional chute of an integral mobile volumetric 

mixer directly in front of the finishing machine.
Section 569

607

569.10 Quality Control of Mix. Conform to Subsection 552.06, except as modified in Table 569-2. 

569.11 Temperature and Weather Conditions. Before placement, maintain the temperature of the 

overlay concrete mixture between 45 and 80 oF.

Install maturity meter probes and monitor concrete temperatures according to AASHTO T 325. Monitor 

the temperature differential from the center of the concrete mass to the surface. Provide internal cooling, 

external heating, or insulation to ensure the temperature differential is no more than 35 °F during placing, 

curing, and immediately after curing ends.

Using the strength-maturity relationship developed for the approved concrete mixture, determine in-place 

concrete compressive strength of the overlay. Measure concrete temperature and calculate in-place 

maturity.

(a) Cold weather. Conform to Subsection 552.07(a). 

(b) Hot weather. Conform to Subsection 552.07(b). 

(c) Evaporation. Conform to Subsection 552.07(c). 

(d) Precipitation. Conform to Subsection 552.07(d). 

569.12 Handling and Placing Concrete. Conform to Subsection 552.08 and the following: 

(a) Placing methods.

(1) Class HPC(O). Do not broom mortar from the concrete from the front edge of the placement.

(2) Class LMC. Immediately ahead of placing overlay mixture, broom a thin coat of the concrete 

overlay mixture and scrub it into the surface as a grout-bond coat at the front edge of the placement. 

Work evenly over the surface in front of the front edge of the placement.

(b) Consolidation. Use a self-propelled finishing machine capable of forward and reverse movement 

under positive control. Ensure the length of the screed is sufficient to extend at least 6 inches beyond 

the edge of both ends of the section being placed. Provide a finishing machine capable of consolidating 

the concrete by vibration and of raising screeds to clear the concrete for traveling in reverse. Provide 

either a rotating roller-type or an oscillating screed-type finishing machine. 

Use rotating roller-type machines with one or more rollers, augers, and 1500 to 2500 vibrations per 

minute vibratory pans. 

Use oscillating screed-type machines with vibrators on the screeds whose frequency of vibration can 

be varied between 3000 and 15,000 vibrations per minute. Use metal screeds with a bottom face of at 

least 4 inches wide. 

Use hand-held vibrators at the concrete edges and adjacent to expansion joints.

Remove and replace concrete represented by cylinders having a compressive strength less than 90 percent 

of the minimum 28-day strength (f'c).
Section 569

608

569.13 Construction Joints. Conform to Subsection 552.09. In addition, form the vertical edge at 

construction joints by bulkhead or saw cut. Make construction joints straight and vertical. 

569.14 Expansion and Contraction Joints. Conform to Subsection 552.10. 

569.15 Finishing Plastic Concrete. Conform to Subsection 552.12. 

Use a self-propelled rotating cylinder machine, either single or double roller that is capable of forward or 

reverse movement under positive control. Equip the machine with an oscillating screed and other devices 

required to continuously spread, consolidate, and finish the plastic concrete. Ensure the screed extends the 

full width of the deck. 

Produce a longitudinal troweled finish along the gutter line for a 12-inch width from the curb face.

Proceed at a constant rate so final finishing is complete before a plastic film forms on the concrete surface. 

Install a construction dam or bulkhead in case of delays over an hour. During delays of 1 hour or less, 

protect the end of the placement from drying with layers of wet burlap.

569.16 Concrete Curing. Prevent plastic shrinkage cracking and crusting of the surface. Use the water 

method of curing according to Subsection 552.13(b). Use washed burlap and apply soaker hoses or other 

approved methods to keep the coverings saturated at all times. 

Install maturity meter probes and monitor concrete temperatures according to AASHTO T 325. Maintain 

the concrete temperature of the outermost surfaces above 45 °F. Monitor the temperature differential from 

the center of the concrete mass to its surface. Using the strength-maturity relationship developed for the 

approved concrete mixture, determine the in-place concrete compressive strength.

(a) Class HPC(O). Wet cure the concrete for at least 14 days. Provide internal cooling, external 

heating, or insulation to ensure the temperature differential does not exceed 35 °F. Cure until the inplace concrete compressive strength of the overlay concrete attains at least 80 percent of the minimum 

compressive strength shown in Table 569-1. 

(b) Class LMC. Wet cure the concrete for at least 48 hours and until the maturity meter reading 

exceeds 48 maturity hours. Air cure the concrete for an additional 48 hours and until the maturity 

meter reading exceeds 96 maturity hours.

After curing, visually inspect the overlay for cracking or other damage and inspect for delamination. 

Perform bond test. Remove and replace delaminated or unbounded portions of the overlay or portions 

damaged by precipitation or freezing. Clean staining or efflorescence to provide a uniform color to the 

concrete overlay surface.

569.17 Texturing. After the bond strength shown in Table 569-1 is attained, groove surface according to 

Subsection 552.14(g). 

Continuously remove slurry and other residue from the overlay by vacuum pickup or other approved 

methods. Properly dispose of slurry and other residue off site. 
Section 569

609

569.18 Acceptance. See Table 569-2 for sampling, testing, and acceptance requirements.

Material for concrete overlays for bridge decks will be evaluated under Subsections 106.02 and 106.03. 

Submit a production certification with each shipment of cementitious material.

Bond strength will be evaluated under Subsection 106.05. The lower specification limit is the minimum 

required bond strength at 14 days shown in Table 569-1. 

Compressive strength will be evaluated under Subsection 106.05. The lower specification limit is the 

minimum required compressive strength at (f'c) 28 days shown in Table 569-1. 

Maximum chloride permeability will be evaluated under Subsection 106.05. The upper specification limit 

is the maximum specified chloride permeability value shown in Table 569-1. A single chloride 

permeability test result is the average result from 2 samples cast from the same load and tested.

Slump, air content, density, and temperature will be evaluated under Subsections 106.02 and 106.04. 

Construction of concrete overlays for bridge decks will be evaluated under Subsections 106.02 and 

106.04. 

Concrete repairs will be evaluated under Section 572. 

Hydrodemolition will be evaluated under Section 560. 

Micro milling will be evaluated under Section 413. 

Measurement

569.19 Measure the Section 569 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

569.20 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 569 pay items listed in the bid schedule, except the overlay concrete contract price will be adjusted 

according to Subsection 106.05. Payment will be full compensation for the work prescribed in this 

Section. See Subsection 109.05. 

Payment for overlay concrete will be made at a price determined by multiplying the contract price by the 

lower of the three pay factors determined for compressive strength, chloride permeability, or bond 

strength.
Table 569-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

(fine & 

coarse) 

Measured &

tested for

conformance

(106.04 & 

105) 

Quality −

Subsections

703.01 & 

703.02

1 per

material

type

Source

of material

Yes,

if

requested

Before 

producing

Date 

reports

within

1 year of

intended

use 

Mix Design

Concrete

composition

Measured &

tested for

conformance

(106.04 & 

105) 

All − Subsection

569.04

1 per

mix

design

Source

of material

Yes,

if

requested

Before

producing −

Production Start-up (Test Section) 

HPC(O)

Measured &

tested for

conformance

(106.04) 

Maximum

chloride

permeability(1)

− AASHTO

T 277

1 set

per test

placement

Discharge

stream at

point of

placement

(1)

Yes,

if

requested

Upon

completing

tests

−

Compressive

strength(2) − AASHTO

T 23 & 22 " " " " −

Tensile bond

strength − ASTMC1583

5 cores

per test

placement

In-place

after

curing is

complete

" " −
Table 569-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (Test Section) (continued)

LMC 

Measured &

tested for

conformance

(106.04) 

Maximum

chloride

permeability(1)

− AASHTO

T 277

1 set

per test

placement

Discharge

stream at

point of

placement

Yes

Upon

completing

tests

−

Compressive

strength(3) − AASHTO

T 23 & 22 " " " " −

Tensile bond

strength(7) − ASTM

C1583

5 cores

per test

placement

In-place

after

curing is

complete

" " −

HPC(O)

and

LMC 

" 

Density(4) − AASHTO

T 121

1 per

load

Point of

discharge No

Upon

completing

tests

−

Air content(4) −

AASHTO

T 152

or

AASHTO

T 196

" " " " −

Slump(4),(5) − AASHTO

T 119 " " " " −

Temperature − Field 

measured " " " " −
Table 569-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (Test Section) (continued)

Aggregate

(fine & 

coarse)

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11

1 per

day

Flowing

aggregate

stream

(bin, belt,

discharge

conveyor

belt, or

stockpile)

Yes Before

batching −

Fineness

modulus − AASHTOT 27 − " " " −

Moisture test − AASHTO

T 255 − " " " −

Production

HPC(O)

& LMC

Statistical

(106.05) 

Maximum

chloride

permeability(1)

II AASHTO

T 277

1 set per

30 yd3

but not 

less than

1 per day 

Discharge

stream

at point

of

placement

Yes

Upon

completing

tests

−

Compressive

strength(6) II AASHTO

T 23 & T 22 " " " " −

Tensile bond

strength(7) II ASTM

C1583

1 set per

3000 ft2

of overlay

but not 

less than

1 per day

In-place

after 

curing

is 

complete

No " −
Table 569-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production (continued)

HPC(O)

& 

LMC 

Measured &

tested for

conformance

(106.04) 

Density(4) − AASHTO

T 121

1 per

load

Point of

discharge No

Upon

completing

tests

−

Air content(4) −

AASHTO

T 152

or

AASHTO

T 196

" " No " −

Slump(4),(5) − AASHTO

T 119 " " " " −

Temperature − ASTM

C1064 " " " " −

Aggregate

(fine & 

coarse)

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11

1 per

day

Flowing

aggregate

stream

(bin, belt,

discharge

conveyor

belt, or

stockpile)

Yes,

if

requested

Before

batching −

Fineness

modulus − AASHTOT 27 − " " " −

Moisture test − AASHTO

T 255 − " " " −
Table 569-2 (continued)

Sampling, Testing, and Acceptance Requirements

(1) Cast at least three 4- by 8-inch maximum chloride permeability cylinders per set and carefully transport the cylinders to the job site curing 

facility. Cure the HPC(O) cylinders for 7 days and the LMC cylinders for 3 days according to AASHTO M 201. Then cure the HPC(O) cylinders 

at 100±10 °F in saturated lime water until AASHTO T 277 sample conditioning starts and air dry the LMC cylinders at 73±3 °F at 40 to 60 percent 

relative humidity. Test for chloride permeability at 28 days by measuring the total charge passed, in coulombs, over a specified period of time 

according to AASHTO T 277. The test result is the average of the measurements on three cylinders cast from the same load. If pigment is used 

in the concrete mixture, sample concrete at the batch plant before and after adding pigment. Test at least three specimens with and without 

pigment. Determine the average difference between the pigmented and non-pigmented test results. Adjust production test results by the average 

difference. Report both initial and adjusted test results.

(2) For HPC(O), cast at least fifteen 4- by 8-inch compressive strength cylinders per set and carefully transport the cylinders to the job site curing 

facility. Test three cylinders each at 1, 3, 7, 14 and 28 days. A single compressive strength test result is the average result from three cylinders 

cast from the same load.

(3) For LMC, cast at least eighteen 4- by 8-inch compressive strength cylinders per set and carefully transport the cylinders to the job site curing 

facility. Test three cylinders each at 1, 2, 4, 7, 14 and 28 days. A single compressive strength test result is the average result from three cylinders 

cast from the same load.

(4) For LMC, measure density, slump, and plastic air content 5 minutes after discharge from the mixer chute. Cover wheelbarrow or other 

receptacle used to hold sample with a sheet of plastic to prevent evaporation during the 5 minutes before sampling.

(5) If reinforcing fibers are used at an addition rate greater than 0.3 percent by volume, measure slump at the batch plant before adding fibers.

(6) Cast at least six 4- by 8-inch compressive strength cylinders per set and carefully transport the cylinders to the job site curing facility. Test 

three cylinders at 28 days. Use the remainder of cylinders as directed.

(7) At random locations determined by the CO, core 2-inch diameter specimens through the overlay and 1⁄2 inch into the substrate concrete. Cure 

the specimens in situ for the same length of time as the overlay. Test the specimens in situ by attaching a loading disk with fast setting, high 

strength epoxy. Measure the tensile pull-off bond strength in pounds per square inch according to ASTM C1583. The average bond strength is 

the average of the results from three test specimens adjusted as follows: For tests where failure occurs in the substrate concrete at a depth of at 

least 1⁄4 inch for more than 50 percent of the specimen, use 150 pounds per square inch for that specimen test result in the calculation of the 

average of the three test specimens. When two of the three test results have been adjusted, the average bond strength results use the greater of 

150 pounds per square inch or the calculated value.
Section 570

615

Section 570. — POLYESTER POLYMER CONCRETE OVERLAYS FOR 

BRIDGE DECKS

Description

570.01 This work consists of providing, placing, finishing, and curing a PPC overlay system on concrete 

surfaces.

Material 

570.02 Conform to the following Subsections: 

High molecular weight methacrylate 725.18

Polyester polymer concrete aggregate 703.19

Polyester resin binder 725.17

Sand 703.14

Sealants, fillers, and seals 712.01

Construction Requirements

570.03 Qualifications. Provide a system provider and system provider technical representative with 

experience placing PPC overlay systems. At least 30 days before starting PPC overlay work, submit the 

following for approval:

(a) System provider. Documentation from the system provider describing experience on at least five 

projects of similar size and scope within the past 5 years. Include project names, overlay system and 

quantities, construction dates, locations, and contact information for project owners; 

(b) System provider technical representative. A résumé describing at least 5 years’ experience with 

PPC overlay systems and at least five PPC overlay projects within the past 5 years. Include project 

names, overlay system and quantities, construction dates, locations, and contact information for 

project owners; and 

(c) Contractor experience. Documentation describing at least 5 years’ experience and five completed 

projects placing PPC overlay systems with similar equipment and scope. Include project names, 

construction date, overlay system and quantities, construction dates, and contact information for 

project owners. 

570.04 Submittals. At least 30 days before the PPC pre-paving meeting, submit the following according 

to Subsection 104.06: 

(a) Operations and placement plan. Include the following: 

(1) Schedule of surface preparation, overlay work, and testing; 

(2) Staging plan describing surface preparation and overlay placement sequence including: 

(a) Asphalt removal methods, and other surface preparation operations; 
Section 570

616

(b) Paving widths and anticipated paving lengths; 

(c) Paving directions with paving from high side of bridge to low side. Do not include gaps 

between passes;

(d) Joint locations placing cold joints within 1 foot of the lane lines or centered within a lane; 

and 

(e) Location of proposed test section. 

(3) Method for preventing leakage of primer onto areas of deck that have not received surface 

preparation; 

(4) Method for isolating expansion joints including pourable joints at abutment and piers; 

(5) Method for measuring and maintaining overlay thickness and profile; 

(6) Finishing and texturing plan describing methods that will be used to broadcast sand and saw 

grooves to produce a skid-resistant surface;

(7) Cure time for polyester concrete;

(8) Storage and handling of HMWM resin and polyester concrete components; 

(9) Procedure for disposal of excess HMWM resin, polyester concrete, and containers;

(10) Procedure for cleanup of mixing and placement equipment; and 

(11) Proposed schedule for closing and opening lanes during milling, surface preparation, and PPC 

overlay placement. Include estimated duration of lane closures.

(b) Polyester polymer concrete mix design and overlay system. Include a PPC mix design and 

overlay system conforming to Subsection 570.06. 

(c) Equipment. Include a list of equipment conforming to Subsection 570.07. 

570.05 General. Provide an on-site technical representative for the duration of bridge overlay placement 

including test strip, surface preparation, application, and cure. 

570.06 Composition (Polyester Polymer Concrete Mix Design and Overlay System). Design and 

produce a PPC mixture consisting of polyester resin and aggregate conforming to Table 570-1. Include a 

compatible primer with the overlay system.

Submit the system provider’s materials information, installation instructions, and independent test results 

for approval. 

If recommended by the overlay system provider, use accelerators or inhibitors to achieve proper setting 

time of the PPC.
Section 570

617

Verify mix design with trial mixes from proposed sources or with previous PPC production data for the 

mix design submitted from proposed sources. Verify the performance characteristics shown in 

Table 570-1. Include the following in each mix design submittal: 

(a) Project identification;

(b) Name and address of PPC system provider and suppliers; 

(c) Materials proportions; 

(d) Name and location of material sources for aggregate, binder resin, polymer, and admixtures;

(e) Type of binder resin proposed. Include content in pounds per cubic yard of mix; 

(f) The dry batch mass of the aggregate in pounds per cubic yard of mix; 

(g) Dosage of admixtures. Do not mix chemical admixtures together in a mix unless they are 

compatible. Provide supporting documentation of compatibility from the manufacturers; 

(h) Test results from aggregate sieve analysis, absorption, and other specified properties;

(i) Results from tests shown in Table 570-1; 

(j) Material certifications; and 

(k) Material samples if requested.

Table 570-1 

Composition of Polyester Polymer Concrete

PPC 

Property

Minimum 

Bond 

Strength, 

ASTM C1583, 

pounds per 

square inch(1)

Abrasion Resistance, 

Caltrans Test 550 or 

approved equivalent 

test, maximum weight 

loss, grams(2)

Modulus of 

Elasticity, 

Range, 

ASTM C469, 

pounds per 

square inch(3)

Initial Set Time

ASTM C266, 

minutes

Resin Content, 

by weight of the 

dry aggregate, 

percent

250 < 2 1,000,000 to 

2,000,000 30 to 120(4) 12±1

(1) After at least 24 hours cure time. Test on in-place material. Drill to at least 0.25 inch but no more than 0.50 inch below 

the bond line. An acceptable test will demonstrate that the overlay bond strength is sufficient by producing a concrete 

subsurface failure area greater than 50 percent of the test surface area. Repair bond test locations with polymer overlay.

(2) At 12 percent resin content by weight of dry aggregate. Provide test results that are less than 1 year old.

(3) At 12 percent resin content by weight of dry aggregate, and after at least 24 hours cure time. Provide test results that 

are less than 1 year old.

(4) Initial set times less than 30 minutes may be proposed by the system provider. Initial set time may also be defined as 

the point at which the in-place PPC cannot be deformed by pressing with a finger.

570.07 Equipment. Provide equipment to be used to prepare the surface, and to mix, place, finish, and 

cure the PPC. Provide equipment according to the system provider’s recommendations.

(a) Mobile mixing equipment. Keep the equipment maintained, calibrated, clean, and free of partially 

dried or hardened material.
Section 570

618

(1) Use certified scales, with certification less than one month old, to calibrate mobile mixing 

equipment. Submit scale certification within 1 month before production. If any adjustments are 

made to the scales, submit a new certification.

Complete on-site calibration by demonstrating that the computer tickets are within 2 percent of the 

actual material weights. Produce three consecutive batches of aggregate that have batch tickets and 

actual materials weights that are within 2 percent of each other. Produce three consecutive batches 

of resin that have batch weights and actual material weights that are within 2 percent of each other.

(2) Use a continuous mixer with the following capabilities:

(a) Employs an auger screw and chute device; 

(b) Measures and records aggregate and resin volumes automatically with a metering device 

at least every 5 minutes, including time and date. Equipped with controls to regulate the 

quantity of components required to produce the approved mix; 

(c) Displays volumes of aggregate and resin on a visible readout gauge;

(d) Produces a satisfactory mix consistency; and 

(e) Measures the resin levels in the tank of the mobile mixer during paving operations and 

allows access to the resin tank.

A portable mechanical mixer of appropriate size for the proposed batches and recommended by the 

system provider may be used.

(b) Paving machine. Submit documentation of the proposed paving machine that establishes its 

successful use to place PPC overlays on bridge projects. Use a self-propelled slip-form paving machine 

that is modified or built to place PPC overlay and has the follow capabilities:

(1) Employs a vibrating pan to consolidate and finish the PPC, and is fitted with hydraulically 

controlled grade automation using substrate grade averaging devices on both sides of the new 

placement to establish the finished profile. Use devices that average 15 feet in front and behind 

the automation sensors. Use sensors compatible with string-line control; 

(2) Equipped with controls capable of maintaining the screed at the specified transverse slope; 

(3) Sufficient engine power and weight to provide adequate vibration of the finishing pan while 

maintaining consistent forward placement speed. Capable of forward or reverse motion; and

As an alternative to using a paving machine, an approved self-propelled rotating cylinder machine, 

either single or double roller, that is capable of forward or reverse movement under positive control 

may be used. Conform to Subsection 552.12. Equip the machine with an oscillating screed and other 

devices required to continuously spread, consolidate, and finish the plastic PPC. Ensure the screed 

extends the full width of the placement.

(c) Other equipment. Include descriptions of equipment used for the following:

(1) Preparing the surface including grinding and shotblasting; 
Section 570

619

(2) Applying HMWM resin; 

(3) Finishing and curing the polyester concrete overlay;

(4) Applying sand; 

(5) Texturing and grooving the PPC surface; and 

(6) Protecting and finishing inlets and bridge drains. 

570.08 Production Start-Up Procedures.

(a) Preparatory phase meeting. Conduct a pre-paving preparatory phase meeting according to 

Subsection 153.06(a) at least 7 days before the start of PPC overlay operations. 

(b) Test section. Submit a proposed location of previously constructed concrete to complete a test 

section. Provide at least 7 days’ notice before placing the test section. Prepare the substrate concrete 

surface using the same methods intended for the overlay placement. Construct a test section at least 

20 feet long at the same thickness and paving width as the overlay. Use the approved mix design and 

the same methods of handling, placing, finishing, texturing, and curing intended for actual placement. 

Determine the initial set time. Complete one or more bond strength tests. See Table 570-1 for 

requirements. Demonstrate the ability to construct an acceptable test section and competency to 

perform the work.

Repeat the test section process until an acceptable test section is produced. If required, remove and dispose 

of the test section materials off site according to Subsections 203.05 and 203.07. 

Start production only after the test section is evaluated and accepted.

570.09 Surface Preparation. Do not perform surface preparation within 6 feet of a new overlay until 

48 hours after its placement.

(a) Removal of asphalt and membrane. Remove asphalt, asphalt membranes, and other deleterious 

material without damaging the concrete bridge deck. Micro mill according to Section 413 to remove 

the existing asphalt to a depth 1⁄2 inch away from the concrete deck surface. Use other approved 

methods to remove the remaining asphaltic material.

Repair concrete according to Section 572. Do not place PPC until concrete repair material has cured 

at least 5 days and there is no moisture in the repair areas. Test for moisture in concrete according to 

ASTM D4263 at locations as directed.

(b) Surface cleaning. Do not start cleaning operations until concrete repairs are complete and the deck 

is dry. Use equipment and procedures that do not obstruct the view or travel way of motorists in 

adjacent roadways. Do not power wash. 

Shot blast to remove grease, oil, asphalt, coating material, membrane, concrete laitance, and other 

contaminants that could interfere with the proper adhesion of the overlay system. Use steel shot 

conforming to SSPC-AB3, Ferrous Metallic Abrasive or recycled steel shot conforming to 

SSPC-AB2, Cleanliness of Recycled Ferrous Metallic Abrasives. Complete enough passes at a travel 

speed that results in loose surface concrete being removed, aggregates of the concrete being exposed, 
Section 570

620

and a visible change in concrete color occurring. Capture debris from shotblasting and dispose 

according to Subsection 203.07. 

Cover the prepared surface with polyethylene sheeting to prevent contamination. Do not expose 

cleaned surfaces to traffic.

Immediately before placing primer, remove loose particles by oil-free compressed air, magnets, or 

vacuuming. Make a final complete pass of the area to be overlaid with oil-free compressed air to clean 

and dry the concrete substrate. 

570.10 Handling and Storing Material. Prevent segregation, contamination, or other harmful effects

during handling and storage of material. Provide aggregate with uniform moisture content at the time of 

batching. Submit and follow the system provider’s recommendations.

570.11 Delivery. Produce and deliver PPC to allow a continuous placement with no PPC achieving initial 

set before the remaining PPC being placed adjacent to it. Deliver PPC through the conventional chute of 

a mobile mixer directly to the paving machine or use another approved delivery process. 

570.12 Quality Control of Mix. Conform to Subsection 552.06, except as modified in Table 570-2. 

570.13 Application of the Polyester Polymer Concrete Overlay. Application methods may be modified 

according to the system provider’s recommendations and as approved. 

(a) Moisture conditions. Do not start placement of HMWM primer and PPC overlay unless the 

concrete substrate is dry. Do not start placement of the PPC overlay if there is standing water, 

darkening of substrate surface due to moisture, or evidence of moisture in the substrate cracks. 

Artificial drying methods, such as using oil-free compressed air or a propane torch, may be applied as 

approved. 

Do not start placement of HMWM primer and PPC overlay if the relatively humidity is greater than 

85 percent or if precipitation is anticipated during the planned production and placement period for 

the PPC overlay. 

(b) Concrete surface temperature. Apply HMWM primer and PPC overlay when the concrete 

substrate is between 40 °F and 100 °F, unless otherwise recommended by the system provider. 

(c) HMWM primer. Apply primer according to the system provider’s recommendations. Mix all 

components of the HMWM resin. Place primer within 5 minutes of mixing and at a rate of 90 square 

feet per gallon, or at the rate recommended by the system provider.

Uniformly spread primer to completely cover the concrete substrate to be overlaid. Do not allow 

leakage of primer on unprepared areas and areas that will not receive an overlay. Apply primer with 

push brooms or rollers. Avoid excess application that results in puddling. Remove excess material to 

meet the required application rate. Reapply primer to areas that appear dry after 15 minutes of 

absorbing the material.

(d) PPC. Apply PPC within a timeframe of 15 minutes to 2 hours after the primer has been applied. 

Apply PPC before gelling or 15 minutes following addition of initiator, whichever occurs first.
Section 570

621

Completely blend and initiate the polyester resin binder. Add the aggregate and mix for at least 

2 minutes, or as recommended by the system provider. 

Remove and replace PPC that does not attain an initial set within the range shown in Table 570-1. 

Consolidate and finish the PPC to the required grade and cross-section. Control the profile and 

cross-section by a taut reference string line on both sides of the paving machine. Do not start placement 

operations until the reference elevation and string line are approved. 

Use the paving machine as the primary finishing device. Hand finish in areas that are inaccessible to 

the paving machine. Finish to produce a slight resin bleed. 

(e) Texturing. Produce a skid resistant surface texture using the following methods: 

(1) Sand friction finish. Completely cover the overlay by uniformly broadcasting at least 

2.2 pounds per square yard of sand onto the glossy PPC surface immediately after finishing and 

before resin gelling occurs.

Repair smooth or low friction areas from insufficient quantities of sand according to the system 

provider’s recommendations and as approved. 

(2) Grooving. After the bond strength as shown in Table 570-1 is attained, groove according to 

Subsection 552.14(g). Complete grooving within 7 days of completing PPC overlay placement. 

Limit traffic speeds to 25 miles per hour or less until grooving is complete.

Continuously remove slurry and other residue from the PPC overlay by vacuum pickup or other 

approved methods. Dispose of slurry and other residue according to Subsection 203.07. 

(f) Joints. Install construction joints and saw cut joint locations as shown in the plans. If no joint 

locations are shown in the plans, submit a jointing plan for approval. Form the vertical edge at 

construction joints by bulkhead or saw cut. Make construction joints straight and vertical. If 

uncontrolled cracking occurs, repair the crack according to the system provider’s recommendations 

and as approved. Seal joints according to the system provider’s recommendations and as approved.

(g) Curing. Protect the overlay from moisture for at least 4 hours. Do not open to traffic until at least 

4 hours of curing has been completed. 

(h) Roughness. Check PPC overlay surfaces with a 10-foot metal straightedge. Check the entire 

surface in both the longitudinal and transverse directions with the straightedge. Overlap the 

straightedge at least one-half of the length of the previous straightedge placement. 

Defective areas are deviations between the surface and the bottom of the straightedge more than 1⁄4 inch 

between the two contacts of the straightedge, or deviations more than 1⁄4 inch measured at the end of

the straightedge. Correct defective areas. Obtain approval for the method of correction. 

(i) Tapers. Complete one lane of PPC placement for the entire length of the bridge in one placement 

operation. If the need arises to suspend operations and complete a transverse taper, use a bond breaker 

and construct an asphalt taper with a 1V:10H slope. Completely remove the bond breaker and 

temporary asphalt taper and clean the surface according to Subsection 570.09(b) before resuming PPC 

placement. 
Section 570

622

570.14 Acceptance. See Table 570-2 for sampling, testing, and acceptance requirements.

Material for PCC overlays will be evaluated under Subsections 106.02 and 106.03. Submit a production 

certification with each shipment of cementitious material.

The PPC overlay mix will be evaluated under Subsections 106.02 and 106.04. 

Construction of PPC overlays for bridge decks will be evaluated under Subsections 106.02 and 106.04. 

Concrete repairs will be evaluated under Section 572. 

Micro milling will be evaluated under Section 413. 

Measurement

570.15 Measure the Section 570 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

570.16 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 570 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 570-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Mix Design

PPC

composition

Measured &

tested for

conformance

(106.04 & 

105) 

All − Subsection 

570.06

1 per mix

design

Source of 

material

Yes, if

requested

28 days 

minimum

before prepaving 

meeting

−

Production Start-up (Test Section)

PPC

Measured &

tested for

conformance

(106.04) 

Minimum 

bond strength, 

psi(1)

− ASTM

C1583

2 locations 

per test

section 

minimum

In-place

after

curing is

complete

No

Upon

completing

tests

−

Initial set time, 

minutes − ASTMC266(3)

1 per test 

section

In-place to 

measure 

initial set 

time

" " −
Table 570-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production

PPC

Measured &

tested for

conformance

(106.04) 

Minimum 

bond strength, 

psi(1)

− ASTM

C1583

1 per 300 yd2

but not less 

than one per 

day

In-place

after

curing is

complete

No

Upon

completing

tests

−

Surface 

tolerance 

(roughness)

− Subsection 

570.13(h)

Complete 

coverage, see 

Subsection 

570.13(h)

Finished 

PPC 

overlay 

surface

" " −

Process 

control 

(153.03) 

Initial set time, 

minutes − ASTMC266(3)

Continuously 

during 

production

In-place 

to 

measure 

initial set 

time

No

Upon

completing

tests

−

Yield(2) − (2) Daily (2) " 

Before 

starting the 

following 

day’s 

placement

−

(1) After at least 24 hours cure time. Tested on in-place material. Drill from 0.25 inch to 0.50 inch below the bond line. An acceptable test will 

demonstrate that the overlay bond strength is sufficient by producing a concrete subsurface failure area greater than 50 percent of the test surface 

area. Repair bond test locations with polymer overlay.

(2) Complete a comparison of the actual yield for each day’s placement to the theoretical yield. Theoretical yield is based on the actual area paved 

and the planned thickness of the mixture being placed. When the variance is greater than 5 percent include a written explanation and corrective 

measures, as appropriate.

(3) Initial set time may also be defined as the point at which the in-place PPC cannot be deformed by pressing with a finger.
Section 571

625

Section 571. — ULTRA-HIGH PERFORMANCE CONCRETE

Description

571.01 This work consists of providing, placing, finishing, and curing ultra-high performance concrete 

(UHPC).

Material 

571.02 Conform to the following Subsections: 

Curing material 711.01

Reinforcing fibers 711.06

Sealants, fillers, and seals 712.01

Water for cementitious materials 725.01(a)

Construction Requirements

571.03 Qualifications. At least 30 days before starting UHPC work, submit the following for approval: 

(a) On-site technical representative. A résumé describing experience supervising on-site UHPC 

related activities including mixing, placement, and process control of the UHPC test section and 

UHPC production pours; and 

(b) UHPC manufacturer. Documentation describing at least 3 years’ experience on UHPC projects 

of similar size and scope. Include project names, construction dates, locations, and contact information 

for the project owners.

571.04 Composition (Ultra-High Performance Concrete Mix Design). Submit written concrete mix 

design and test results at least 14 days before test section. Include the following: 

(a) Material certifications;

(b) Mass of mixing water per cubic yard of concrete; and

(c) Test results from within the last 12 months. 

Produce UHPC mixtures that conform to Table 571-1 and are suitable for the application shown in the 

plans. 
Section 571

626

Table 571-1 

Properties of UHPC

Property Test Method Performance

Compressive strength ASTM C1856 ≥ 13,000 psi at 4 days

≥ 18,000 psi at 28 days

Effective cracking strength AASHTO T 397 ≥ 1100 psi

Peak tensile strength AASHTO T 397 ≥ 1250 psi

Direct tension bond strength ASTM C1583 100% failure in substrate concrete

Modulus of elasticity ASTM C1856 ≥ 6500 ksi

Long-term drying shrinkage ASTM C1856 ≤ 800 microstrains at 28 days

Chloride ion penetrability ASTM C1856 ≤ 250 coulombs

Abrasion resistance ASTM C1856 < 0.025 oz. lost

Freeze thaw resistance ASTM C1856 RDME > 95%

Flow(1) ASTM C1856 Between 7 to 10 in

ASR(2) ASTM C1567 ≤ 0.10 percent at 16 days after casting

(1) Flow property is only applicable to closure pour application.

(2) Performed on approved mix design mass percent combinations.

571.05 Placement Plan. At least 14 days before starting the test section, submit the following according 

to Subsection 104.06: 

(a) Responsible personnel and hierarchy; 

(b) Type, size, location, and number of equipment;

(c) QC of batch proportions. Include dry ingredients, fibers, water, and admixtures; 

(d) QC of mixing time and batch times;

(e) Batch procedure sequence;

(f) Test section construction sequence and drawings;

(g) Form work including materials and removal;

(h) Placement procedure. Include surface preparation of existing concrete surfaces, prewetting of 

existing concrete surfaces to a saturated surface dry (SSD) condition before placement of UHPC, 

handling, transporting, placing, finishing, curing protection, and overall sequencing of placement 

procedure. Include provisions for acceptable ambient conditions and batch temperatures and corrective 

measures as required;

(i) Threshold limits for ambient temperature, ambient relative humidity, batch consistency, batch 

temperature, batch times, and relative corrective action;

(j) Spill prevention and cleanup plan; 

(k) Cold weather placement plan including if cold weather placement is expected during placement of 

UHPC;

(l) Contingency plan including contingency procedures for interruption of operations by weather, 

equipment malfunctions, or other issues; and 
Section 571

627

(m) Sampling and testing procedures. 

571.06 Production Start-up Procedures.

(a) Preparatory phase meeting. Conduct a pre-UHPC preparatory phase meeting according to 

Subsection 153.06(a) at least 7 days before the start of UHPC operations. In addition, be prepared to 

discuss the approved Placement Plan.

(b) Test section. Complete a test section at least 30 days before production according to the approved 

Placement Plan.

For overlays, bridge decks, and other flatwork, construct a 9- by 9-foot test section at the same 

thickness as the production placement. For closure pours, construct a 9-foot-long test section. For other 

structural elements, construct a 3- by 3- by 3-foot test section. Use the approved UHPC mix design 

and the same methods of handling, placing, finishing, and curing intended for production placement. 

Sample and test according to Table 571-2. 

Construct the test section formwork according to Subsection 571.14 and as shown in the plans. 

Construct the test section to represent prepared surfaces and reinforcement bars in the production 

placement and the steepest grade and cross slope of the finished surface. Complete the test section at 

the project site in a location that allows the CO access to all sides.

Construct the test section in the presence of the manufacturer’s technical representative and the CO. 

Use the same staff, equipment, forming, mixing, placing, and curing procedures as the production 

pour. Include all steps necessary to replicate a production UHPC pour. 

After the UHPC has taken its initial set, strip the forms to allow the CO to evaluate the test section.

Demonstrate the placement plan and methods for surface preparation and compliance with temperature 

and finishing requirements.

Verify fresh and hardened concrete properties. 

Repeat the test section process until an acceptable test section is produced.

If desired results are not achieved as determined by the CO, modify the process accordingly and 

complete another UHPC test section. Continue until a UHPC test section is completed successfully. 

Document the procedures, tools, forms, and any other equipment implemented in this successful 

completion. Use the same in completing production UHPC pours. Provide a revised Placement Plan 

as directed before production UHPC pours based on the test section results. 

571.07 Handling and Storing Material. Handle and store material to ensure uniformity of mixture at 

time of use and to prevent loss of physical and mechanical properties, according to the manufacturer’s 

recommendations. Do not use UHPC materials containing evidence of moisture contamination.

571.08 Batching. Batch the concrete according to the manufacturer’s recommendations.

571.09 Equipment. Do not use equipment with aluminum parts that contact the UHPC. 
Section 571

628

(a) Mixers. Provide mixers capable of uniformly mixing the UHPC, according to the manufacturer’s 

recommendations. Provide documentation that mixers are rated for use with UHPC mixtures. Provide 

at least two portable mixing units.

(b) Vibrating screed. When constructing UHPC overlays, use an approved power-driven finishing 

machine equipped with a screed that oscillates in a transverse direction.

571.10 Mixing. Ensure the manufacturer’s representative is present during all UHPC mixing. Maintain 

the mixture at an ambient temperature below 85 °F or according to the manufacturer’s recommendations. 

Ice may be added to the mix if recommended by the manufacturer’s representative.

Mix the concrete in a portable mixer according to the manufacturer’s recommendations. If multiple 

portable mixers are used, stagger the batching operations so that a constant supply of fresh concrete is 

available for placement. Operate equipment within the manufacturer’s recommended capacity. Add 

UHPC materials according to the manufacturer’s recommendations. Produce concrete of uniform 

consistency. Remove the contents of a mixed batch before a succeeding batch is charged into the mixer. 

Regulate the delivery of the UHPC to the site so that the placing and finishing operations can proceed at 

a uniform rate.

571.11 Quality Control of Mix. Submit and follow a QCP according to Section 153. 

Mix and place UHPC according to the manufacturer’s recommendations.

Designate at least one laborer to monitor the UHPC placement for concrete leakage. Identify materials to 

be kept on hand and procedures to be implemented to stop any UHPC leaking from forms.

571.12 Temperature and Weather Conditions. Protect the UHPC from precipitation during and after 

placement. Maintain the temperature of the UHPC mixture before placement according to the 

manufacturer’s recommendations. 

During curing, maintain the temperature of the UHPC’s outermost surfaces according to the 

manufacturer’s recommendations or the following: 

(a) Cold weather. Conform to Subsection 552.07(a), except as follows: 

(1) Place UHPC when the ambient air temperature is 45 °F and rising, and the substrate 

temperature is 40 °F and rising;

(2) Maintain a minimum concrete temperature of 50 °F during curing. Protect UHPC until the 

concrete minimum 4-day compressive strength is attained; and 

(3) Remove protection only when the average wind speed is less than 10 miles per hour as 

measured 3 feet from the UHPC surface.

(b) Hot weather. Conform to Subsection 552.07(b), except as follows:

(1) Place UHPC when the ambient air temperature is less than 85 °F, and the substrate temperature 

is less than 80 °F; and 
Section 571

629

(2) Do not remove curing material until the minimum 4-day compressive strength is attained and 

the average wind speed is less than 10 miles per hour as measured 3 feet from the UHPC surface.

(c) Evaporation. Conform to Subsection 552.07(c). 

(d) Precipitation. Protect UHPC from precipitation during and after placement.

571.13 Surface Preparation. 

(a) UHPC overlay. Conform to Subsection 569.06(b). 

(b) UHPC closure pour and other structural elements. Sandblast concrete surfaces to exposed 

aggregate surface finish. Clean concrete surfaces by flushing with clean water from a high-pressure 

water jet or compressed air. Clean exposed steel. Remove any dirt, rust, oil, grease, coating material, 

or other contaminants which may inhibit UHPC bonding. If compressed air is used, provide a filter to 

deliver oil-free compressed air.

571.14 Formwork. Design and construct falsework, shoring, and bracing according to Section 562. 

Provide watertight formwork with a non-absorbing finish. Use an approved form release agent to produce 

a minimum of staining, air holes, and hydration discoloration.

Fasten formwork to existing concrete using adhesives or other approved methods that do not damage the 

existing concrete. Do not use drilling, nailing, or post anchor systems to fasten temporary works or 

formwork to existing concrete. Provide formwork according to the manufacturer’s recommendations for 

construction of concrete elements.

571.15 Placing Ultra-High Performance Concrete.

(a) General. Ensure the manufacturer’s representative is present during handling and placing of the 

UHPC. Prepare surfaces according to Subsection 571.13. Monitor the UHPC handling and placement 

for concrete leakage.

(b) Sequence of placement. Sequence UHPC placement according to the construction stages shown 

in the plans. Finish placing UHPC in each overlay lane or closure pour before starting placement in 

successive overlay lanes or closure pours.

Thoroughly moisten the forms and wet existing concrete surfaces to an SSD condition immediately 

before placing UHPC. Remove excess water by approved methods before placing UHPC. 

Do not place concrete until the forms have been inspected and approved. 

(c) Placing methods. Place UHPC according to the manufacturer’s recommendations. Handle and 

place concrete by methods that do not cause segregation and results in dense homogenous concrete 

that is free of voids.

Do not pump UHPC unless it was demonstrated and approved in the test section. If ambient 

temperature during the UHPC placement is at least 7 °F greater than during the test section, perform 

another test section at the higher temperature according to Subsection 571.04. 

Cast UHPC continuously without interruption. Add UHPC behind the leading edge of the flow. Do 

not use cold joints unless shown in the plans. 
Section 571

630

For UHPC closure pours, place UHPC using chimneys, ports, or other approved equipment that 

maintain a positive head of material to the flowing UHPC, according to the manufacturer’s 

recommendations. Provide equipment with a minimum discharge opening of 3 inches. Install 

chimneys, ports, or other approved equipment at the highest point of each joint and at intervals no 

more than 10 feet.

Fill the joint from the low point. Maintain a continuous head of pressure sufficient to fill the joint to 

just beyond the next uphill chimney or port. Fill successive chimneys or ports in the same manner until 

UHPC emerges from the one placed at the highest point of the joint.

Monitor UHPC for subsidence and maintain a positive head of material to the UHPC in all chimney 

or ports until the UHPC has taken initial set.

(d) Consolidation. Consolidate UHPC according to the manufacturer’s recommendations.

(e) Compressive strength. Remove and replace concrete represented by cylinders having a 

compressive strength less than 90 percent of the minimum 28-day strength. 

571.16 Construction Joints. Do not use construction joints unless shown in the plans. 

571.17 Expansion and Contraction Joints. Provide expansion and contraction joints as shown in the 

plans. 

571.18 Curing Ultra-High Performance Concrete. Start curing immediately after consolidation during 

placement operations. Apply a curing compound to the UHPC surface and cover the UHPC surface with 

waterproof plastic sheeting. Ensure the UHPC surface is continuously covered by the waterproof sheeting 

until the UHPC has attained the 4-day minimum compressive strength shown in Table 571-1. Cure UHPC 

according to the manufacturer’s recommendations.

571.19 Finishing Ultra-High Performance Concrete. Overfill the UHPC at least 1⁄2 inch. Perform 

diamond grinding of UHPC surfaces after the UHPC has attained the 4-day minimum compressive 

strength shown in Table 571-1. 

(a) UHPC overlay. Where UHPC is the final riding surface, diamond grind the entire top surface of 

the overlay in the direction parallel with the centerline to provide a uniform longitudinal corduroy 

grooved texture. Space fins 1⁄2 to 3⁄4 inch on centers. Cut the grooves between 1⁄16 inch and 3/16 inch wide 

and 1⁄16 to 3/16 inch deep. 

Discontinue grooving 12 inches from curb face and provide a flat ground finish on the surface of 

gutters. For bridge decks, do not groove within 6 inches of joint blockouts and bridge ends. 

Check the entire surface parallel to the centerline with a 10-foot metal straightedge. Overlap the 

straightedge at least one-half of the length of the previous straight edge placement. 

Correct deviations more than 1⁄8 inch from the testing edge of the straightedge. 

(b) UHPC closure pour. Diamond grind the top surface of the UHPC closure pour to match the 

existing grade and cross slope within 1⁄4 inch. 
Section 571

631

571.20 Loads on New Ultra-High Performance Concrete Structures. Do not allow traffic or other 

loading, including construction loading, on UHPC decks until the deck concrete has attained the 4-day 

compressive design strength and the finished surface (and diamond grinding) has been approved to allow 

vehicular traffic.

571.21 Acceptance. See Table 571-2 for sampling, testing, and acceptance requirements.

Material for UHPC will be evaluated under Subsections 106.02 and 106.03. Provide production 

certifications with each shipment of UHPC material.

UHPC mix properties will be evaluated under Subsections 106.02 and 106.04. 

Construction of UHPC will be evaluated under Subsections 106.02 and 106.04. 

Temporary works will be evaluated under Section 562. 

Measurement

571.22 Measure the Section 571 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring UHPC by the cubic yard, measure in the structure. 

Do not measure test sections not incorporated in the work. 

Payment

571.23 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 571 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 571-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

UHPC

Measured &

tested for

conformance

(106.04) 

Chloride ion 

penetrability(1) – ASTM

C1856

1 per

material 

type

Source of

material No

14 days 

minimum 

before test 

section

– 

Production Start-up (Test Section)

UHPC

Measured &

tested for

conformance

(106.04) 

Compressive 

strength(2) – ASTM

C1856

1 set per test 

section

Discharge 

stream at 

point of 

placement

Yes

Upon 

completing 

tests

– 

Effective 

cracking 

strength

– AASHTO

T 397 " " No " – 

Peak tensile 

strength – AASHTOT 397 " " " " – 

Direct tension 

bond strength – ASTMC1583 " " " " – 

Modulus of 

elasticity(3) – ASTM

C1856 " " " " – 

Long-term

drying 

shrinkage

– " " " " " – 

Abrasion – " " " " " – 

Freeze thaw 

resistance – " " " " " – 
Table 571-2 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production Start-up (Test Section) (continued)

UHPC

Measured & 

tested for 

conformance

(106.04) 

Temperature – ASTM

C1064 1 per batch

Discharge 

stream at 

point of 

placement

No

Upon 

completing 

tests

– 

Flow – ASTM

C1856 " " – " – 

Production

UHPC Statistical

(106.05) 

Compressive 

strength(2) II ASTM

C1856

1 set per 

30 yd3 but

not less than

1 per day

Discharge 

stream at 

point of 

placement

Yes

Upon 

completing 

tests

– 

UHPC

Measured & 

tested for 

conformance

(106.04) 

Temperature – ASTM

C1064 1 per batch " No

Upon 

completing 

tests

– 

Flow(4) – ASTM

C1856 " " " " – 

Surface 

tolerance – 

Straightedge 

measurement, 

Subsection 

571.19

Continuous 

after concrete 

has hardened

Finished 

surface " 24 hours – 

(1) Cast at least three, 4- by 8-inch maximum chloride permeability cylinders per set and carefully transport the cylinders to the job site curing 

facility. A single maximum chloride permeability test result is the average result from three cylinders cast from the same load.

(2) Cast at least six, 3- by 6-inch compressive strength cylinders per set and carefully transport the cylinders to the job site curing facility. Test 

compressive strength at 4 and 28 days. A single compressive strength test result is the average result from three cylinders cast from the same 

load.

(3) Cast at least one, 3- by 6-inch modulus of elasticity cylinder per set and carefully transport the cylinder to the job site curing facility. 

(4) Perform flow test only for UHPC closure pour.
Section 572

634

Section 572. — CONCRETE REPAIR

Description

572.01 This work consists of repairing concrete in bridges, culverts, and other structures. This work also 

includes crack sealing by the gravity method. 

Material 

572.02 Conform to the following Section and Subsections: 

Coarse aggregate for concrete 703.02

Color coating 725.15

Concrete curing material and additives 711

Epoxy resin adhesives 725.12

Fine aggregate for concrete 703.01

Galvanic anodes 725.16

High molecular weight methacrylate 725.18

Hydraulic cement 701.01

Non-shrink grout 701.04(b)(1)

Packaged repair mortar 701.05(b)

Penetrating stain for concrete 719.05

Polyester resin binder 725.17

Pozzolans 701.03

Reinforcing steel 709.01

Sealants, fillers, and seals 712.01

Water for cementitious materials 725.01(a)

Construction Requirements

572.03 Composition. Provide repair materials for the different classes of repairs that conform to the 

following:

(a) Hydraulic cement concrete. Submit written concrete mix designs for approval at least 30 days 

before production. Include the items listed in Subsection 601.03 in each mix design submittal. Do not 

start production until the mix design is approved. Provide a concrete mixture that conforms to the 

requirements shown in Table 572-1 or 572-2. 
Section 572

635

Table 572-1 

Composition of Repair and High Early Strength (HES) Concrete

Class of 

Concrete(1)

Early Age

48-Hour 

Design 

Compressive 

Strength, 

AASHTO T22 

pounds per 

square inch

28-Day

Design 

Compressive 

Strength, 

AASHTO T22 

pounds per 

square inch

Plastic

Air Content, 

percent 

minimum(2)

Maximum

Water/

Cementitious

Material

Ratio(4)

Slump,

inches(3)

Nominal 

Maximum Size 

Aggregate, 

AASHTO M 40

Repair 2000 4500 5.0 0.45

±1 from 

provided 

target

#67 or #78

HES 3000 5000 5.0 0.40

±1 from 

provided 

target

#67 or #78

(1) Conform to ASTM C1157 for portland cement in concrete.

(2) Measure plastic air content according AASHTO T 152 Method B. Maximum plastic air content is 9 percent. 

(3) Conform to the supplier provided target slump. Maximum slump is 8 inches if approved mix design includes a 

high-range water reducer.

(4) If supplementary cementitious materials are used, conform to Table 552-2 limits.

Table 572-2 

Composition of Very High Early Strength (VHES) Concrete

Class of 

Concrete(1)

Early Age

4-Hour Design 

Compressive 

Strength,

AASHTO T22 

pounds per 

square inch

28-Day

Design 

Compressive 

Strength,

AASHTO T22

pounds per 

square inch

Freeze

Thaw 

Resistance

ASTM 

C666 

Method A 

(minimum)

Maximum

Water/

Cementitious

Material

Ratio

Slump,

inches(3)

Nominal 

Maximum Size 

Aggregate, 

AASHTO M 40

VHES 3000 5000 RDME(2) > 

96% 0.42

±1 from 

provided 

target

#67 or #78

(1) Conform to ASTM C1600 Class URH or Class VRH for hydraulic cement in concrete.

(2) Relative dynamic modulus of elasticity (RDME) measured according to ASTM C666. 

(3) Conform to the supplier provided target slump.

Submit concrete mix designs on Form FHWA 1606, Minor Portland Cement Concrete Mix Design

for hydraulic cement concrete mixtures supplied by a ready-mix truck or a volumetric mixer.

For hydraulic concrete mixtures using prepackaged bags, submit the manufacturer’s product data 

sheet, mixing requirements, and placement methods. When using prepackaged bag mixtures for HES 

classes of concrete, provide mixes able to generate a stable air void system with a minimum air content 

shown in Table 572-1. Demonstrate that the prepackaged bag mixture conforms to the requirements 

of the class of concrete submitted for the items of work. Complete a trial batch to demonstrate 

conformance with entrained air requirement with mixing methods and type of equipment that will be 

used for the work. 

(b) Polymer resin concrete. Provide an organic polymer resin concrete mixture consisting of organic 

polymer and aggregates, including an epoxy resin adhesive or polyester resin binder. Submit the 
Section 572

636

manufacturer’s product data sheet, mixing requirements, and placement methods. Conform to the 

requirements shown in Table 572-3.

Table 572-3 

Composition of Polymer Resin Concrete

Class of 

Concrete

6-Hour 

Compressive 

Strength,

AASHTO T22

pounds per 

square inch

24-Hour

Compressive 

Strength,

AASHTO T22

pounds per 

square inch

Thermal

Compatibility

ASTM C884

ASTM C1202

Rapid Chloride 

Permeability, 

Coulombs

Nominal Maximum 

Size Aggregate

AASHTO M 40

Polymer resin

concrete 1000 3500 Pass <100 #67, #78, or #8

(c) Hydraulic cement repair mortar. Provide a mortar that conforms to the requirements of ASTM 

C882 R1, R2, or R3 as modified in Table 572-4. 

Table 572-4 

Hydraulic Cement Repair Mortar

Class of Mortar(1)

24-Hour 

Compressive 

Strength, 

ASTM C109

pounds per 

square inch

7-Day

Compressive 

Strength,

ASTM C109

pounds per 

square inch

Freeze Thaw 

Resistance, 

ASTM C666 

Method A 

(minimum)

Maximum Drying Shrinkage, 

ASTM C157, 

(modified by ASTM C882)

28-Day

Horizontal 2000 4500 RDME(2) > 95% 0.06%

Vertical & 

overhead 3000 5000 RDME(2) > 95% 0.07%

(1) Conform to ASTM C1157 or ASTM C1600 hydraulic cement in repair mortar.

(2) Relative dynamic modulus of elasticity (RDME) as measured according to ASTM C666.

Submit the manufacturer’s product data sheet, mixing requirements, and placement methods. 

(d) Polymer resin mortar. Provide an organic polymer binder mortar mixture consisting of organic 

polymer and fine aggregates, including an epoxy resin adhesive or polyester resin binder. Submit the 

manufacturer’s product data sheet, mixing requirements, and placement methods for the polymer 

mortar. Conform to the requirements shown in Table 572-5. 

Table 572-5 

Composition of Polymer Resin Mortar

Class of Mortar

8-Hour 

Compressive 

Strength, 

ASTM C109, 

pounds per 

square inch

24-Hour

Compressive 

Strength, 

ASTM C109, 

pounds per 

square inch

Thermal

Compatibility, 

ASTM C884

Polymer resin 

mortar 3000 7000 Pass

(e) Crack sealing (gravity feed method). Provide low viscosity epoxy resin adhesive or low viscosity 

high molecular weight methacrylate (HMWM), for crack sealing by the gravity feed method. Conform 
Section 572

637

to AASHTO M 235, Type I, Class C performance requirements for epoxy resin adhesive. For low 

viscosity HMWM conform to requirements shown in Table 572-6. 

Table 572-6 

Performance Requirements of High Molecular Weight

Methacrylate for Gravity Feed Crack Sealing

Maximum 

Viscosity, 

ASTM D1084, 

centipoises

Minimum

7-Day

Tensile 

Strength,

ASTM D638, 

pounds per 

square inch

Minimum

7-Day

Compressive 

Strength,

ASTM D638, 

pounds per 

square inch

Minimum

Elongation at 

Break, 

ASTM D638, 

percent

25 7000 12,000 4.0

572.04 Concrete Repair Mapping and Repair Type Categorization. Verify each concrete repair shown 

in the plans. Sound concrete or use other approved methods to verify that concrete adjacent to the 

designated repair area is not defective. Determine the extent of the additional unsound concrete around 

designated repair area. Mark boundaries and document extent of repair area. Determine length of cracks 

that are designated in the plans for sealing. Determine if the cracks have extended in length. Mark length 

and document. 

Verify that shallow repairs shown in the plans have not deteriorated into a deep repair by sounding with a 

hammer or other approved methods. Categorize type of repair as follows: 

(a) Shallow repairs. Repairs that do not extend to the depth of the reinforcing steel. 

(b) Deep repairs. Repairs in which reinforcing steel is exposed and will require removal of concrete 

under the reinforcing steel.

Submit results of findings for concrete repair mapping and repair types to the CO. Do not start preparation 

for additional concrete repair areas or cracks lengths discovered during mapping until approved. Repair 

areas, repair types, and cracks with no changes from plans may be prepared for the selected concrete repair 

material according to Subsection 572.06. 

572.05 Quality Control Plan for Concrete Repair. Submit a QCP according to Section 153. Include the 

following:

(a) Concrete repair material for each repair area;

(b) Substrate preparation work required for the repair material;

(c) Concrete repair conditioning requirements of repair area. List hold points for CO to inspect repair 

area before placing repair material;

(d) Testing and sampling plan; 

(e) Repair material placement methods for each type of repair;

(f) Curing method for each type of repair; 
Section 572

638

(g) Method to protect concrete repairs during adverse weather conditions during repair material curing 

period; and 

(h) Method to protect the concrete adjacent to the repair.

572.06 Concrete Repair. Saw cut 3⁄4 inch deep along boundaries of repair areas. Use power-driven hand 

tools to remove existing concrete. Do not damage concrete designated to remain in place. Construct 

structurally adequate debris shields to contain debris within the construction limits. Do not allow debris 

to enter waterways, travel lanes open to public traffic, or areas designated not to be disturbed. 

Where the bond between existing concrete and reinforcing steel is destroyed, remove concrete adjacent to 

the steel to provide at least 3⁄4-inch clearance for the new concrete to bond to the reinforcing steel. Use 

care to prevent damage to remaining concrete when achieving the final surface.

Clean exposed concrete surfaces that will be in contact with repair material. Provide a residue free surface.

Before placing hydraulic cement-based repair materials, thoroughly flush repair area with clean water 

under pressure or with compressed air. If compressed air is used, provide a filter in the airline to ensure 

that the air is oil-free. For non-hydraulic cement-based repair materials, use compressed air to flush repair 

area.

Cover prepared substrate to prevent recontamination. Obtain approval of substrate preparation and 

cleanliness before placement of repair material. Place repair material within 24 hours of preparing the 

repair area.

(a) Deep repairs. Chip at least a 1-inch clearance under and behind the exposed reinforcing steel. 

Examine exposed reinforcing steel for evidence of corrosion. If reinforcing steel is exposed and 

exhibits corrosion, clean the reinforcing steel until corrosion is eliminated. Remove concrete cover 

2 inches beyond the endpoints of the original corroded portion of the reinforcing steel. Inspect for 

corrosion. Continue this process until reaching the boundary of the approved repair area. If corrosion 

is still evident at the boundary of the previously approved repair area, obtain approval to remove 

additional concrete cover. Do not strike the reinforcing steel with heavy blows. If the bond between 

existing concrete and reinforcing steel has been compromised, remove the concrete adjacent to the 

steel to a depth that will allow new concrete to bond to the entire periphery of the exposed steel. 

Provide at least 2 inches of clearance behind the steel if galvanic anodes are used with low resistivity 

mortar.

Remove and replace deteriorated reinforcing steel according to Section 554. Remove and replace 

reinforcing steel that has lost 25 percent or more of its original cross-section area with new bars of the 

same size, shape, and composition. If a sufficient length of the existing bar is exposed, lap the new 

bars with the existing bars for a length of 30 diameters on each side of the damaged portion. Otherwise, 

connect the new bar by mechanically connecting the new bar to the existing according to Section 554. 

Shot blast exposed structural steel, reinforcing steel, and concrete surfaces which will be in contact 

with repair material until free of rust and foreign material. Clean the sound concrete surface by flushing 

with clean water from a high-pressure water jet or compressed air.

In repair areas with exposed reinforcing steel, install galvanic anodes on the reinforcement according 

to ACI Repair Application Procedure Bulletin 8, Installation of Embedded Galvanic Anodes, the 

manufacturer’s recommendations, and the following: 
Section 572

639

(1) For repair areas less than 2 square feet, install one anode. 

(2) For repair areas between 2 and 4 square feet, install two anodes on the reinforcement. Install 

the anodes at opposite sides of the repair and within 4 inches of the edge of the repair. 

(3) For repair areas 4 square feet and larger, install anodes at the rate of 2 anodes for each 4-square 

foot of repair area. Install the anodes in a grid pattern. 

Maintain a minimum concrete cover of 1 inch around each anode. 

If a concrete repair material that has a chloride permeability of less than 2000 coulombs is used, encase 

the anode in a low resistivity mortar bed which extends to the sound substrate concrete and 2 inches 

beyond the anode on all sides. 

If the reinforcing steel is to receive a barrier coating, do not coat the reinforcing steel within 1 inch of 

the anode and do not apply coating to any surface of the anode or the steel tie wires.

Verify steel-to-steel continuity and anode-to-steel continuity within the repair area with a direct current 

(DC) multimeter. Tie discontinuous reinforcing to continuous reinforcing using tie wire and retest. 

The electrical connection is acceptable if the DC resistance measured with the multimeter is no more 

than 1.0 ohm or the DC potential is no more than 1 millivolt.

Pre-wet the concrete substrate and the anodes to achieve a saturated surface dry condition before 

placing the hydraulic cement repair material. Do not soak anodes for more than 20 minutes.

Apply a scrub coat of the hydraulic cement repair material immediately before placement of the repair 

material if recommended by repair material manufacturer. Place hydraulic cement-based repair 

material before scrub coat dries out.

(b) Shallow repairs. Remove concrete to the boundary of the approved repair area. If unsound 

concrete is still evident at the boundary of the approved repair area, obtain approval to remove 

additional concrete until sound concrete is encountered. Roughen saw cuts to provide bond by 

shotblasting or other approved methods. Shot blast the substrate concrete at the bottom of the repair 

to remove any microcracked concrete from any chipping operations. 

If recommended for use by the concrete repair material manufacturer, a bonding coat of an epoxy resin 

adhesive that conforms to AASHTO M 235, Type V may be applied to surfaces of the concrete repair. 

Follow the epoxy resin adhesive manufacturer’s recommendations for application time before 

placement of concrete repair material to promote optimal bonding.

(c) Crack sealing. Remove dirt, laitance, and other debris from the exterior and interior of the crack. 

Rout the surface of the crack to provide a reservoir for crack sealant. Clean the adjacent surface to the 

crack and apply a temporary dam on each side of the crack. Obtain approval of crack preparation and 

cleanliness before placing repair material. Protect cleaned crack from debris and dirt. Ensure that dam 

material is functional before placing crack sealant.

572.07 Handling and Storing Material. Handle and store material to prevent segregation, contamination, 

or other harmful effects. Do not use cement and fly ash containing evidence of moisture contamination. 

Store and handle aggregate to ensure uniform moisture content at the time of batching. Store prepackaged 

repair materials according to the manufacturer’s recommendations for protection from moisture and 
Section 572

640

within the allowable temperature range. Submit documentation of proper storage when requested. Do not 

use prepackaged materials in the work that has moisture damage or exposed to temperatures exceeding 

the manufacturer’s recommended range.

572.08 Batching. Conform to the following:

(a) Hydraulic cement-based repair products. When using prepackaged bags, provide a scale that 

has accuracy to the nearest 0.001 kilogram. Convert mixing water required according to the 

manufacturer’s recommendations from volumetric measurement to mass of water. Batch water to 

within ±100 grams of the target.

(b) Polymer concrete and polymer mortar. Weigh or measure ingredients according to the 

manufacturer’s recommendations. 

(c) Crack sealer. Weigh or measure ingredients according to the manufacturer’s recommendations.

572.09 Mixing. For hydraulic cement concrete mixed in a central plant, conform to Subsection 552.04(b). 

For truck mixed hydraulic cement concrete, conform to Subsection 552.04(c). Produce concrete of 

uniform consistency. 

Provide mixer type recommended by product manufacturer for mixing of prepackaged hydraulic cement 

concrete mixes, hydraulic cement repair mortar, polymer concrete, polymer mortars, and crack sealers. 

Size mixer to the repair such that all batches of prepackaged repair materials can be mixed, discharged, 

and placed within the manufacturer’s placement limits for each repair. Maintain batch size of repair 

materials for mixing at a minimum of 20 percent but no more than 80 percent of rated mixer capacity. 

Keep mixer maintained, clean, and free of partially dried or hardened material.

(a) Volumetric batching and continuous mixed concrete. Provide proportioning and mixing 

equipment with an integral mobile unit with continuous mixing capability that meets the requirements 

of ASTM C685 and the following: 

(1) Capable of producing at least 6 cubic yards of concrete without recharging; and

(2) Capable of discharging the mixture through a conventional chute directly into the work. 

Calibrate equipment with material for the approved mix design within 6 months of the placement date. 

Calibrate according to VMMB 1000-01, Volumetric Mixer Standards of the Volumetric Mixers 

Manufacturers and ACI 304.06, Guide for Use of Volumetric Measuring and Continuous-Mixing 

Concrete Equipment. Submit documentation on mixing uniformity according to ASTM C685, Annex 

A.1. 

(b) Small quantities (less than 0.5 cubic yards per repair). Provide mixer type recommended by 

product manufacturer for mixing of prepackaged hydraulic cement concrete mixes, hydraulic cement 

repair mortar, polymer concrete, and polymer mortars. Size mixer to the repair such that all batches of 

prepackaged repair materials can be mixed, discharged, and placed within the manufacturer’s 

placement limits for each repair. Maintain batch size of repair materials for mixing at a minimum of 

20 percent but no more than 80 percent of rated mixer capacity.

(c) Polymer concrete and polymer mortars. Provide a hand-held mixing device recommended by 

the manufacturer.
Section 572

641

(d) Crack sealers. If crack sealer is a multicomponent system, mix according to the manufacturer’s 

recommendations. Mix in the appropriate component sequence. Size mixing container so that the crack 

sealer being mixed is at least 20 percent of the volume of the container but no more than 80 percent of 

the container. Provide a hand-held mixing device recommended by the manufacturer. Ensure the 

mixing container, mixer blades, and mixer shaft are clean and free of any deleterious material.

572.10 Delivery. Produce and deliver concrete repair materials to allow a continuous placement for each 

repair area. Place concrete repair material according to the manufacturer’s recommendations for time, 

substrate temperature, repair material temperature, and ambient weather conditions. Deliver, handle, and 

place repair materials to minimize rehandling and to prevent damage to the structure. For hydraulic cement 

concrete and mortar, do not place material that has developed an initial set. Do not re-temper hydraulic 

cement concrete and mortar by adding water. 

(a) Hydraulic cement concrete mixed in a central mix plant or truck mixed hydraulic cement 

concrete. Conform to Subsection 552.05. 

(b) Hydraulic cement concrete mixed in a volumetric mixer. Mix on site adjacent to concrete 

repair. Discharge directly into repair area unless repair is inaccessible to the volumetric mixer. If 

inaccessible, discharge into wheelbarrows or buggies and deliver concrete to repair areas.

(c) Prepackaged hydraulic cement concrete and hydraulic cement repair mortars. Mix on site 

adjacent to concrete repair. Evaluate uniformity of mixed repair material after discharge into 

wheelbarrow or buggy. If segregation or phase separation occurs, do not use in repair area and dispose 

according to Subsection 203.07. 

(d) Polymer concrete, polymer mortars, and crack sealer. Mix on site adjacent to concrete repair.

572.11 Temperature and Weather Conditions. Conform to Subsection 552.07 for hydraulic 

cement-based repair materials. Conform to manufacturer’s temperature and weather condition limits for 

non-hydraulic cement-based repair materials.

572.12 Handling and Placing Concrete Repair Material. 

(a) Hydraulic and non-hydraulic cement concrete and mortars. Conform to Subsection 552.08 for 

hydraulic cement concrete and hydraulic cement mortars. Handle and place non-hydraulic 

cement-based repairs according to the manufacturer’s recommendations.

If formwork is required, conform to Section 562 including use of an approved formwork release agent.

Place repair material continuously without interruption unless there is a planned construction or 

expansion joint in the repair area. Do not create cold joints in a repair area. Control the delivery rate, 

placing sequence, and construction methods to ensure fresh repair material is always placed and 

consolidated against previously placed material before the setting or the maximum allowable working 

time of the material has been reached.

Remove and replace concrete repair material represented by the appropriate test sample and test 

method having a compressive strength less than 90 percent of the latest age compressive strength 

according to Subsection 572.03 for each of the concrete repair material type.
Section 572

642

(b) Crack sealant. Place crack sealant by gravity feed methods according to ACI Repair Application 

Procedure Bulletin 2, Crack Repair by Gravity Feed with Resin and the manufacturer’s 

recommendations. Keep crack sealant within dams. Grind the excess crack sealant on the concrete 

surface when crack sealant has hardened and gained sufficient strength. Remove dams before grinding.

572.13 Construction Joints. Provide construction joints at locations shown in the plans. Conform to 

Subsection 552.09. Obtain approval for additional construction joints. 

572.14 Expansion and Contraction Joints. Provide expansion and contraction joints at locations shown 

in the plans. Conform to Subsection 552.10. 

572.15 Finishing Concrete Repair Material. Strike off concrete repair material surfaces that are not 

placed against forms. Finish the concrete repair material surface. Use straightedge with sufficient length 

to span the concrete repair. Correct deviations more than 1⁄8 inch from the testing edge of the straightedge. 

For concrete bridge deck repairs that are to receive an overlay, correct deviations more than 1⁄4 inch. 

Remove excess material from concrete surfaces adjacent to the repair immediately. Dispose of excess 

material properly.

Protect the surface from precipitation damage.

When the repair has gained enough strength to not be damaged by texturing, texture the surface of the 

repair. Texture surface of concrete repair to match surrounding concrete unless directed to provide another 

texture. For a concrete repair that requires the use of formwork, finish surface according to 

Subsection 552.14 after formwork is stripped. For a surface subject to foot traffic or vehicular traffic, 

provide a skid resistant surface matching adjacent existing concrete according to Subsection 552.12(c)(1)

or 552.12(c)(2).

For surfaces underneath bearings, finish bearing surfaces to within 1⁄8 inch of the plan elevation. If 

applicable, set masonry plate according to Subsection 552.12(d). 

572.16 Curing Concrete Repairs. For hydraulic based cement concrete repair materials, start curing 

immediately after finishing and texturing is complete. If the surface of the concrete starts to dry before the 

selected curing method can be implemented, keep concrete surface moist using a fog spray without 

damaging the surface.

Cure hydraulic based cement concrete repair materials according to Subsection 552.13(b) or (c). 

Cure hydraulic based cement concrete repair materials at least 7 days. 

Cure non-hydraulic cement-based materials according to the manufacturer’s recommendations. Adjust 

curing period to account for variations in field temperature and humidity. Cure until a minimum 

compressive strength of 3000 pounds per square inch is attained. 

Sound concrete repairs at 28 days after repair installation. If a concrete repair when sounded indicates the 

presence of delamination, remove and replace. If concrete repairs exhibit excessive cracking 28 days after 

installation, remove or replace as directed. Excessive cracking is defined for a shallow concrete repair that 

exhibits cracking of 12 linear inches of cracking per square foot of concrete repair or for a deep concrete 

repair that exhibits more than 6 linear inches of cracking per square foot. A crack is defined as having a 

measured width greater than 0.006 inch in three locations.
Section 572

643

572.17 Loads on Concrete Repairs. Do not allow traffic over a concrete repair until the repair has 

attained a compressive strength of at least of 3000 pounds per square inch.

572.18 Acceptance. See Table 572-7 for sampling, testing, and acceptance requirements.

Material for concrete repairs will be evaluated under Subsections 106.02 and 106.03, except compressive 

strength will be evaluated under Subsections 106.02 and 106.04. Provide production certifications with 

each shipment of cementitious material.

Hydraulic cement concrete mixture’s slump, air content, density, and temperature will be evaluated under

Subsections 106.02 and 106.04. 

Construction of concrete repairs will be evaluated under Subsections 106.02 and 106.04. 

Reinforcing steel will be evaluated under Section 554. 

Temporary works will be evaluated under Section 562. 

Measurement

572.19 Measure the Section 572 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

572.20 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 572 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 572-7 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

(fine & 

coarse) 

(concrete 

repair 

materials 

containing 

aggregate)

Measured &

tested for

conformance

(106.04) 

Quality −

Subsections

703.01 & 

703.02

1 per

material

type

Source of

material If requested Beforebatching −

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11 " " " " – 

Mix Design - For Central Batched, Truck Mixed, Volumetric Mixer Mixed Hydraulic Cement-Based Concrete

Concrete

composition

(repair, HES, 

& VHES 

concrete class)

Measured &

tested for

conformance

(106.04) 

All − Subsection

552.03

1 per mix

design " If requested " −

Production - For Central Batched, Truck Mixed, Volumetric Mixer Mixed Hydraulic Cement-Based Concrete

Produced

aggregate

(fine & 

coarse)

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11 1 per day

Flowing

aggregate

stream

(bin, belt,

discharge

conveyor 

belt, or 

stockpile)

Yes Before

batching −

Fineness

modulus − AASHTOT 27 − " " " −

Moisture test − AASHTO

T 255 − " " " −
Table 572-7 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production - For Central Batched, Truck Mixed, Volumetric Mixer Mixed Hydraulic Cement-Based Concrete (continued)

Hydraulic 

cement 

concrete(1)

(572.03) 

Measured &

tested for

conformance

(106.04) 

Density − AASHTO

T 121

1 per load 

after

0.25 yd3 

minimum is 

discharged(4)

Point of

discharge No

Upon

completing

tests

−

Air content −

AASHTO

T 152 or

AASHTO

T 196

" " No " −

Slump − AASHTO

T 119 " " No " −

Temperature − ASTM

C1064 " " No " −

Compressive

strength(2),(3) 

(at specified 

ages according 

to hydraulic 

cement 

concrete class)

− AASHTO

R 100 & T 22 " 

Discharge

stream at

point of

placement

Yes

24 hours 

after 

completion 

of test

Deliver

verification

cylinders to

the CO or

designated

laboratory for 

scheduled 

testing
Table 572-7 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production - For Bagged Products 

Hydraulic 

cement 

concrete(1)

(572.03)

Measured &

tested for

conformance

(106.04) 

Density − AASHTO

T 121

1 per

0.33 yd3

 & 

one per day 

minimum(4)

Point of

discharge No

Upon

completing

tests

−

Air content −

AASHTO

T 152 or

AASHTO

T 196

" " No " −

Slump − AASHTO

T 119 " " No " −

Temperature − ASTM

C1064 " " No " −

Compressive

strength(2),(3)

(at specified 

ages according 

to hydraulic 

cement 

concrete class)

− AASHTO

R 100 & T 22 " 

Discharge

stream at

point of

placement

Yes

24 hours 

after 

completion 

of test

Deliver

verification

cylinders to

the CO or

designated

laboratory

for 

scheduled 

testing
Table 572-7 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production - For Polymer Concrete

Polymer 

concrete(1)

(572.03) 

Measured &

tested for

conformance

(106.04) 

Compressive

strength(2),(3) 

(at specified 

ages)

− AASHTO

R 100 & T 22

1 per

day minimum(4)

Point of

discharge If requested

Upon

completing

tests

Deliver

verification

cylinders to

the CO or

designated

laboratory

for 

scheduled 

testing

Production - For Hydraulic Cement Repair Mortar

Hydraulic 

cement repair 

mortar

(572.03) 

Measured &

tested for

conformance

(106.04) 

Compressive

strength(2),(3) 

(at specified 

ages according 

to hydraulic 

cement 

concrete class)

− ASTM

C109

1 per

day minimum(4)

Point of

discharge Yes

Upon

completing

tests

Deliver

verification

cylinders to

the CO or

designated

laboratory

for 

scheduled 

testing
Table 572-7 (continued)

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Production - For Polymer Repair Mortar

Polymer repair

mortar

(572.03) 

Measured &

tested for

conformance

(106.04) 

Compressive

strength(2),(3)

(at specified 

ages)

− ASTM

C109

1 per

day minimum(4)

Point of

discharge If requested

Upon

completing

tests

Deliver

verification

cylinders to

the CO or

designated

laboratory

for 

scheduled 

testing

Production - For Crack Sealing by Gravity Method

Crack sealing

(572.03) 

Measured &

tested for

conformance

(106.04) 

Tensile 

strength

(at specified 

ages)

− ASTM

D638 If requested Point ofdischarge No

Upon

completing

tests

−

(1) Sample according to AASHTO R 60, except composite samples are not required.

(2) Cast at least four compressive strength test cylinders for 6- by 12-inch specimens or six compressive strength cylinders for 4- by 8-inch specimens 

and transport the cylinders to the job site curing facility.

(3) A single compressive strength test result is the average result from two 6- by 12-inch or three 4- by 8-inch cylinders cast from the same load.

(4) If three successive samples are tested and compliance to the specifications is indicated, screening tests may be reduced to an approved frequency. 

Resume Table 572-7 testing frequency if a test shows a failing temperature, air content, or slump, or when directed.
Section 573

649

Section 573. — HELICAL PILES

Description

573.01 This work consists of designing, providing, and installing helical piles. 

Material 

573.02 Conform to the following Subsection: 

Helical piles 715.08

Construction Requirements

573.03 Submittals. At least 30 days before starting helical pile work, submit the following according to 

Subsection 104.06(b)(3): 

(a) Product data. Manufacturer’s product data including appurtenances and installation instructions. 

(b) Drawings and calculations. Drawings and calculations complying with the helical pile capacity 

shown in the plans. At a minimum, include the following: 

(1) Pile number, location, and pattern by assigned identification number; 

(2) Pile design load and design calculations. Include the relevant references used for design;

(3) Design notes. Include a description of symbols, terminology, and computer programs used in 

the design; 

(4) Type and size of central shaft;

(5) Helix configuration; 

(6) Minimum effective installation torque;

(7) Displacement plates or centralizers and their locations;

(8) Minimum and anticipated overall pile length and tip elevation; 

(9) Inclination of pile; 

(10) Minimum cased length, if applicable;

(11) Cut-off elevation; and 

(12) Working drawings for the temporary yoke or load frame to be used for testing. Include 

identification number and calibration test certification for each load cell, test jack pressure gauge, 

and master pressure gauge. Clearly indicate the serial number of each component of the testing 

assembly on calibration graphs. Include results from calibration tests conducted by an independent 

testing laboratory within the previous 60 days. 
Section 573

650

(c) Equipment. A listing of excavating and drilling equipment with the capacity to install helical piles 

at the maximum specified diameter to the depth and capacity specified in the plans and conforming to 

the following:

(1) Torque motor. A torque motor capable of continuous adjustment to number of revolutions per 

minute during installation and with a torque capacity 15 percent greater than the torsional strength 

rating of the central steel shaft to be installed. Do not use percussion drilling equipment. 

(2) Installation equipment. Installation equipment of rotary type, with hydraulic power-driven 

torque motor with clockwise and counterclockwise rotation capabilities, that can apply adequate 

downward pressure and torque simultaneously to suit project soil conditions and load 

requirements, and that can continuously adjust position to maintain proper pile alignment.

(d) Construction methods. A detailed construction sequence for helical pile work describing 

materials, methods, and equipment to be used. Include the following: 

(1) Drilling equipment including the manufacturer’s specifications for the drill rig.

(2) Installation methods to ensure required helical pile placement and inclination. 

(3) Methods of materials handling and disposal. 

573.04 Production Start-Up Procedures. Conduct a pre-helical pile preparatory phase meeting at least 

7 days before the start of helical pile operations according to Subsection 153.06(a). 

573.05 Installation of Helical Piles. Install the helical piles according to the approved drawings. 

Install piles within 1 inch of the position or the line, and within 1⁄2 inch of the elevation shown in the plans. 

Install piles so that the axial alignment is within 1⁄4 inch per foot along the longitudinal axis of the required 

alignment.

Piles will be rejected if any of the following occurs:

(a) Damaged by internal defects or by improper installation;

(b) Unable to provide the design capacity shown in the plans; or 

(c) Installed out of tolerance.

Correct rejected piles using an approved method according to Subsection 106.01. 

573.06 Construction Memorandum. Submit a helical pile foundation memorandum that includes the 

following for all piles:

(a) Installed tip elevation; 

(b) Installation torque with depth including maximum torque; and

(c) Load tests results.
Section 573

651

Provide confirmation of the adequacy of the helical pile axial and lateral capacity based on the installation 

and load test results. Provide a memorandum that bears the seal and signature of a professional engineer

according to Subsection 104.06(b)(2). 

573.07 Acceptance. Material for helical piles will be evaluated under Subsections 106.02 and 106.03. 

Construction of helical piles will be evaluated under Subsections 106.02 and 106.04. 

Measurement

573.08 Measure the Section 573 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

573.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 573 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 574

652

Section 574. — GEOSYNTHETIC REINFORCED SOIL-INTEGRATED BRIDGE 

SYSTEM

Description

574.01 This work consists of constructing geosynthetic reinforced soil-integrated bridge systems (GRSIBS).

Material 

574.02 Conform to the following Subsections: 

GRS reinforcement geosynthetic 714.06

GRS open-graded backfill 703.20

Segmental retaining wall units 720.01(a)

Select borrow 704.02

Construction Requirements

574.03 Qualifications. Submit one of the following for approval at least 30 days before starting GRS-IBS 

work: 

(a) On-site supervisor and installation personnel. A résumé for each individual describing at least

five constructed projects of similar size and complexity. Include project names, locations, contact

information for project owners, and at least two photographs of each of the completed projects; or

(b) Manufacturer’s representative. Submit a list of five previously constructed projects of similar

size and complexity assisted by the manufacturer’s representative. Provide at least two photographs

of each of the completed projects. Include project names, locations, and contact information for project

owners.

574.04 Submittals. At least 30 days before starting GRS-IBS work, submit the following according to 

Subsection 104.06: 

(a) Plan and elevation drawings for the structure containing the following:

(1) A plan view of the structure showing:

(a) Horizontal offset from the construction centerline to the face of the structure at defining

points along the base. Include start and end roadway stations, and start and end wall stations,

if different;

(b) Location, length, coverage ratio, and type of reinforcement;

(c) Centerline and size of drainage structure or drainage pipe behind, passing through, or

passing under the structure; and

(d) Location, length, and offset from the face of wall to guardrail, guardwall, and parapet

structures.
Section 574

653

(2) An elevation view of the structure showing: 

(a) Elevation and station at horizontal and vertical break points and at least every 20 feet along 

the top of the structure face;

(b) Elevation and station at the top of the reinforced soil foundation (RSF) and at least every 

20 feet along the structure base;

(c) Length and type of reinforcement; 

(d) Location and elevation of each layer of geosynthetic; 

(e) Distance and elevation along the structure face to all steps of the RSF;

(f) Distance along the structure face to where change in reinforcement lengths occur; 

(g) Construction joints; and 

(h) Original and final ground-lines.

(b) A typical cross-section view showing:

(1) Type and depth of facing elements and structural connections to reinforcing elements; 

(2) Structure batter and angle of slopes below and above wall, if any; 

(3) Length, spacing and type of reinforcement, and corresponding limits of excavation and 

reinforced fill placement zones;

(4) Location of guardrail, guardwall, and parapet structures. Include embedment depths, offset 

from structure facing, and connection details with structure reinforcement;

(5) Original and final ground-lines, including right-of-way limits; 

(6) Estimated or known location of subsurface soil and rock units; 

(7) Beam seat and beam seat retention details; and

(8) Top of abutment cap or coping details. 

(c) General construction notes.

(d) Horizontal and vertical curve data and superelevation affecting the structure. Include match lines 

or other details to relate structure stationing to centerline stationing.

(e) Material list and summary of quantities. 

(f) Details and dimensions for the RSF. Include steps and step encapsulation details.

(g) Details for the installation of structure drainage features. Include strip, sheet, edge, blanket, and 

underdrain systems, and associated piping if shown in the plans. 
Section 574

654

(h) Details for constructing the structures around drainage features, utilities, lighting foundations, 

traffic barriers, and other obstructions.

(i) Details for end of wall construction and transition to adjacent ground. 

(j) Details for architectural treatment.

(k) Details for corners and curves.

(l) Details and dimensions of SRWU.

(m) Proposed compaction equipment. Include light-weight equipment for use within 3 feet of the wall 

face and methods for stabilizing the face during compaction. 

Include a checklist showing each of the items specified have been addressed. If revisions are required, 

make corrections and resubmit.

574.05 General. Survey according to Section 152 and verify the limits of the GRS-IBS installation. 

Perform excavation and dewatering according to Section 209. 

Excavate wall foundations to within 4 inches horizontally and vertically from the staked location. 

574.06 Reinforced Soil Foundation Construction. RSF consists of GRS open-graded backfill 

encapsulated in geosynthetic reinforcement.

Provide a smooth, uniform foundation surface without protruding objects. Place geosynthetic 

reinforcement perpendicular to the abutment and wingwall faces. Overlap geosynthetic reinforcement so 

the upstream geosynthetic sheet overlies the downstream sheet (such as shingled). Overlap geosynthetic 

joints at least 3 feet in all directions. Pull the geosynthetic taut, remove wrinkles, and lay flat before 

placing the GRS open-graded backfill. 

Do not operate equipment directly on the geosynthetic reinforcement. Place at least a 6-inch lift of GRS 

open-graded backfill over the geosynthetic reinforcement before operating equipment over the 

reinforcement. Compact GRS open-graded backfill according to Subsection 574.09. Grade and level the 

top of the RSF before final encapsulation. Construct the top of the RSF to within 1 inch of plan elevation.

Final encapsulation includes the following: 

(a) Fold the geosynthetic from the back of the RSF at the top finish elevation, then fold over the 

geosynthetic from the front of the RSF so it overlies the geosynthetic at the back of the RSF and secure.

(b) Secure geosynthetic firmly against the backfill, wrapping and securing the geosynthetic tight 

around the corners of the RSF. 

(c) Do not leave exposed backfill or loose geosynthetic. 

574.07 Segmental Retaining Wall Units Requirements. Provide SRWUs that have smooth upper and 

lower bearing surfaces. Do not use SRWUs with finished faces containing chips larger than 1 inch in any 

direction, finished faces having cracks in any orientation wider than 0.02 inch and longer than 25 percent 

of the nominal height of the unit, or SRWUs that are broken. Remove without damaging the SRWUs 

protrusions and loose material from the SRWU surfaces that come in contact with one another or the 
Section 574

655

geosynthetic reinforcement to achieve full contact between the geosynthetic reinforcement and the SRWU 

surfaces.

574.08 Erection Procedures. Erect the GRS-IBS according to the approved drawings and manufacturer’s 

recommendations and to the tolerance requirements in Table 574-1. 

Table 574-1 

Construction Tolerance

Facing Type Vertical, 

inch(1) (±)

Horizontal, 

inch(2) (±)

Horizontal

Straightedge

Point Check,

inch(3) (±)

SRWUs 0.6 0.6 0.6

(1) Wall vertical tolerance at top of wall for every 10 feet of wall height. For example, 65 feet 

wall height multiply 6.5×value.

(2) Wall horizontal tolerance at top of wall for every 10 feet of wall height.

(3) Maximum horizontal deviation at a point in the wall from a 10-foot metal straightedge 

placed horizontally or vertically on the theoretical plane of the design face.

Place the first course of SRWUs so that they are level, even, and within 1 inch of planned horizontal and 

vertical locations. Fill SRWUs with unit fill as shown in the approved drawings. Construct the external 

face of the first row of SRWUs in the abutment face and wingwalls to within 1 inch of the horizontal 

location shown in the approved drawings. Place SRWUs side by side for the full length of the wall such 

that adjoining blocks are located according to the manufacturer’s recommendations. 

Sweep the top of the SRWU clean of debris and fill material before placement of geosynthetic 

reinforcement and SRWUs. Place each SRWU tightly against the adjacent SRWU so that vertical joints 

of each course have less than a 1⁄4-inch gap and the joint is midway between those of the underlying course. 

Remove SRWUs that have become cracked, chipped, or broken. Complete each course of SRWUs before 

starting the next course.

Pull layers of geosynthetic reinforcement taut, remove wrinkles, and lay flat. Use pins, stakes, fill piles, 

or the manufacturer’s recommended method to anchor the reinforcement before placing backfill to prevent 

wrinkles and ensure full contact between the reinforcement and top of the RSF backfill. Place the 

geosynthetic within 1 inch of elevations shown in the approved drawings. Where placing geosynthetic 

reinforcement between SRWUs place the reinforcement so that no less than 85 percent of the full depth 

(front to back) of the SRWU is covered by the reinforcement as measured to the front face of the wall. 

Cut excess geosynthetic reinforcement that extends past the front face of the SRWUs clean and flush with 

the wall face.

Construct subsequent courses following the same procedure. 

Check the GRS wall for plumbness at least every other lift. Correct deviations greater than 1 inch when 

measured vertically with a 10-foot metal straightedge. Correct high areas by grinding or shimming with 

manufacturer recommended shims. Do not use shims over 1⁄16 inch in stack thickness or within 1 inch of 

the face. Check every other row of SRWU alignment before placing backfill. Construct corners according 

to the approved drawings. 

In the bearing bed zone, place secondary geosynthetic reinforcement as shown in the plans. No connection 

between the SRWUs and secondary geosynthetic is required. When seams are necessary, butt adjacent 

rolls together without overlap. Stagger seams at least 24 inches apart on subsequent lifts and only in the 
Section 574

656

direction parallel to bridge centerline. Trim geosynthetic reinforcement overlaps in contact with the 

surfaces between the SRWUs to avoid varying the geotextile reinforcement thicknesses between the 

SRWUs.

574.09 Backfilling and Compaction. Do not operate equipment directly on the geosynthetic 

reinforcement. Place at least 6 inches of uncompacted GRS open-graded backfill over the geosynthetic 

reinforcement before operating equipment over the reinforcement except in the bearing bed zone where 

at least 4 inches of uncompacted GRS open-graded backfill is allowed. Place GRS open-graded backfill 

immediately following placement of each course of SRWUs and geosynthetic reinforcement. Backfill 

from the front of the wall to the back and remove wrinkles that form during the backfilling operation. 

Correct damaged or misaligned geosynthetic reinforcement.

Place and grade the GRS open-graded backfill level for areas behind the SRWUs before compacting. 

Except for the area within 3 feet from the SRWUs, use only light-weight mechanical tamper, plate, or 

roller or rubber-tire equipment for compaction. If rubber tire equipment is used, limit speeds to less than 

5 miles per hour with no sudden starting, braking, or sharp turning. Use only an approved hand-operated 

lightweight vibrating plate or roller within 3 feet of the back of the SRWUs. Correct SRWUs that are 

displaced by compaction operations before placing additional rows of SRWUs. 

Perform a method compaction test for approval on the first two lifts to establish the number of passes, lift 

thickness, and quantity of wetting needed to adequately consolidate the GRS open-graded backfill until 

there is no visible evidence of further consolidation. Follow the approved compaction procedure for the 

remainder of the abutment construction without the need for density tests. 

Fill and compact depressions caused during compaction so that the compacted lift is level with the top of 

the SRWUs before constructing the next lift. 

At the end of the day’s operation, slope the last lift of backfill away from the GRS-IBS structure to direct 

surface runoff away from the interior of the structure. Do not allow surface runoff from adjacent areas or 

stream flow to enter the GRS abutment construction area. 

574.10 Wingwall Fill Slope Side. Construct wingwalls above the RSF. Backfill in front of the wingwalls 

as the GRS wall advances upward. Construct the fill slope to original ground elevation that allows water 

to drain from wall face outward. Prevent surface water runoff on fill slopes.

574.11 Superstructure Placement. After folding the final wrap in the beam seat zone, adjust the final 

grade to provide an even contact between the top of the reinforced beam seat zone and the bottom of the 

concrete beam seat. Set bridge structure elements square and level without dragging across the beam seat 

surface.

574.12 Integrated Approach Construction. Following the placement of the superstructure, place 

geosynthetic reinforcement layers along the back of the superstructure and backfill according to 

Subsection 574.09. Place geosynthetic reinforcement with seams that are perpendicular to the abutment 

face.

574.13 Acceptance. See Table 574-2 for sampling, testing, and acceptance requirements.

Material for GRS-IBS will be evaluated under Subsections 106.02 and 106.03. 

Construction of GRS-IBS will be evaluated under Subsections 106.02 and 106.04. 
Section 574

657

Excavation and dewatering will be evaluated under Section 209. 

Survey work will be evaluated under Section 152. 

Measurement

574.14 Measure the Section 574 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring GRS-IBS by the square foot, measure the front face of wall, including cap units. 

Payment

574.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 574 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 574-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications Tolerance SamplingFrequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

GRS-IBS

backfill

Measured &

tested for

conformance

(106.04) 

Gradation – AASHTO

T 27 & T 11 – 1 per 1000 tons Each source Yes Before use in work

See 

Subsection 

703.20

GRS-IBS

backfill

Measured &

tested for

conformance

(106.04) 

Quality – AASHTO

T 104 – " Each source Yes " 

See 

Subsection 

703.20

Quality

Electrochemical 

requirements

– 

AASHTO

T 90 – " 

Each source Yes

Yes

" 

See 

Subsection 

703.20

AASHTO

D 5821 – " " 

ASTM T289 – " 24 hours

Compaction – (1) – 1 for each 

lift In place Yes, if requested " – 

(1) Do not apply density requirements as measured by AASHTO T 310 to material cannot be tested or compacted to maximum values determined by AASHTO 

T 99. Compact each lift, full width, until there is no visible evidence of further consolidation.
Section 575

659

Section 575. — TEMPORARY BRIDGES

Description

575.01 This work consists of designing, constructing, maintaining, and removing temporary bridges. 

Construction Requirements

575.02 Submittals. Submit drawings and calculations according to Subsection 104.06. Submit detailed 

drawings showing sizes, arrangement, and quality of materials to be used in the construction. Provide 

design calculations and supporting data in sufficient detail to allow a structural and safety review of the 

proposed design. Provide catalog or equivalent data indicating a manufactured device’s recommended 

safe load capacity. Include foundation design calculations and other relevant foundation design data. 

575.03 General. Construct concrete structures according to Section 552. 

Construct prestressed concrete structures according to Section 553. 

Construct steel structures according to Section 555. 

Construct timber structures according to Section 557. 

Construct falsework according to Section 562. 

Construct bearing devices according to Section 564. 

Construct temporary bridges that meet the minimum strength requirements for the HL-93 live load 

according to AASHTO, LRFD Bridge Design Specifications. Provide bridges that can carry applied 

loadings from construction vehicles that will cross the temporary bridge. Design the temporary bridge to 

meet 2-year flood requirements.

Remove temporary bridges when they are no longer needed as directed or approved. Repair damage to the 

existing structure or roadway approaches due to the Contractor’s activities as directed.

Limits of the available work area are shown in the plans.

575.04 Acceptance. Material for temporary bridges will be evaluated under Subsections 106.02, 106.03, 

and 106.04. 

Construction of temporary bridges will be evaluated under Subsections 106.02 and 106.04. 

Bearing devices will be evaluated under Section 564. 

Concrete will be evaluated under Section 552. 

Prestressing steel will be evaluated under Section 553. 

Steel structures will be evaluated under Section 555. 

Timber structures will be evaluated under Section 557. 
Section 575

660

Temporary works will be evaluated under Section 562. 

Measurement

575.05 Measure the Section 575 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

575.06 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 575 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for temporary bridges by the lump sum will be paid as follows: 

(a) 25 percent of the pay item amount will be paid after the drawings are approved.

(b) An additional 50 percent of the pay item amount will be paid after installation.

(c) The remaining portion of the pay item amount will be paid after the temporary bridge is removed

from the project.
Section 576 

661

Section 576. — RESERVED
Section 577

662

Section 577. — FIBER-REINFORCED POLYMER STRUCTURES

Description

577.01 This work consists of designing, fabricating, transporting, and erecting FRP bridges and structural 

components. 

Material 

577.02 Conform to the following Subsections: 

Bolts and nuts 717.01(d)

Fiber-reinforced polymer 725.19

Construction Requirements

577.03 Qualifications. At least 30 days before starting FRP work, submit the following for approval: 

(a) On-site supervisor. A résumé describing experience on at least five projects of similar 

construction and complexity, each of which have been in service for at least 2 years. Include bridge 

size, project names, locations, and contact information for project owners; and

(b) FRP components manufacturer. Documentation describing experience on at least five projects 

of similar size and scope within the past 5 years. Include project names, overlay system and quantities, 

construction dates, locations, and contact information for project owners. 

577.04 Submittals. At least 30 days before starting FRP structure fabrication, submit the following 

according to Subsection 104.06: 

(a) Drawings. Drawings and calculations for the design of FRP bridges and structural components; 

(b) Fabrication drawings. Detailed dimensions and sizes of component parts of the structure and 

details of miscellaneous parts, including FRP components, decking, hardware, railings, and 

accessories; and

(c) Erection drawings. Proposed method of erection. Show details of falsework, bracing, lifting 

devices, and bridge member attachments. Include the erection sequence, equipment locations, lifting 

point locations, and bridge member masses. Include details for anticipated phases and erection 

conditions, which account for the limitations of the construction site. 

577.05 General. Construct falsework according to Section 562. 

Construct bearing devices according to Section 564. 

577.06 Design. Design FRP structures according to AASHTO, Guide Specifications for Design of FRP 

Pedestrian Bridges and AASHTO, LRFD Guide Specifications for Design of Pedestrian Bridges. 

577.07 Fabrication and Installation. Protect corners and edges of structural members by using slings or 

other devices.
Section 577

663

Store components on site flat and off the ground, and support with blocks to prevent bending and damage 

from water and dirt.

Cut and form structural members so all joints have even bearing over the entire contact surface. Do not 

use shims in making joints. Construct all joints to be closed. Do not perform field cutting, drilling, or other 

field modifications unless shown in the plans or approved fabrication drawings.

Fabricate structural members from pultruded FRP composite profiles and structural shapes as required. 

Fabricate pultruded parts according to ASTM D4385 and ASTM D3917. 

Use carbide or diamond-tipped tooling to a tolerance of 1⁄16 inch when cutting or drilling FRP material. 

Clean and seal cut edges.

Camber FRP structures to eliminate initial dead load deflection.

Provide structural components with a minimum thickness of 1⁄4 inch. 

577.08 Acceptance. Material for FRP structures will be evaluated under Subsections 106.02 and 106.03. 

Construction of FRP structures will be evaluated under Subsections 106.02 and 106.04. 

Bearing devices will be evaluated under Section 564. 

Temporary works will be evaluated under Section 562. 

Measurement

577.09 Measure the Section 577 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

577.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 577 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for FRP bridges by the lump sum will be paid as follows:

(a) 25 percent of the pay item amount will be paid after the design submittal is approved.

(b) An additional 40 percent of the pay item amount will be paid after the bridge components are 

delivered to the project site.

(c) The remaining portion of the pay item amount will be paid after the bridge components are 

installed.
Section 578

664

Section 578. — PRECAST CONCRETE ELEMENTS

Description

578.01 This work consists of providing and installing precast concrete elements. 

Material

578.02 Conform to the following Subsections: 

Anchorage devices 722.01

Non-shrink grout 701.04(b)(1)

Construction Requirements

578.03 Qualifications. Provide a precast concrete manufacturing plant, precast concrete QCM, and grouting 

personnel with experience in precast concrete. At least 30 days before starting precast concrete work, submit the 

following for approval:

(a) Precast concrete QCM. Appropriate certifications; 

(b) Plant certification. NPCA certification or equivalent PCI certification. Use the same precast plant for the 

fabrication of all the precast elements; and 

(c) Grouting personnel. A résumé for each individual that will be responsible for grouting if grouting 

operations will be necessary for the fabrication or installation of the precast elements. Describe installation 

experience on at least two projects of similar complexity within the past 3 years.

578.04 Submittals. At least 30 days before starting precast concrete work, submit the following according to 

Subsection 104.06: 

(a) Precast bridge elements. Prepare fabrication and installation drawings and an installation plan.

(1) Fabrication. Show details necessary for fabrication. Include the following: 

(a) Details and location of lifting holes, inserts, hardware, devices, and any additional reinforcing 

required for lifting; 

(b) Size of precast elements with consideration for shipping restrictions, equipment availability, and 

site constraints;

(c) Method of curing, handling, storing, and transporting the elements; 

(d) Leveling inserts in the deck and leveling procedure; 

(e) Details of vertical elevation adjusting hardware;

(f) Minimum compressive strength to be attained before handling precast concrete deck and deck 

overhang elements; 
Section 578 

665

(g) Details of structural steel, shear connectors, bearing assemblies, and elastomeric bearing pads; and

(h) Concrete volume, reinforcing steel weight, and total section weight for each element.

(2) Installation. Describe details necessary for installation. Include the following:

(a) A work area plan depicting utilities overhead and below the work area, drainage inlet structures, 

protective measures, temporary staging areas, crane locations, and other features of the site necessary 

for successful installation;

(b) Lifting procedures and supporting calculations, including details of equipment and devices 

(including slings, hooks, and jacks) used for lifting and assembling the superstructure, substructure, 

and approach slabs. Include the make, model, lift capacity, and operating radii; 

(c) Computations showing the magnitude of stress in the prefabricated components during erection is 

within allowable limits, and that the erection equipment has adequate capacity for the work to be 

performed;

(d) Detailed sequence of construction activities, and a CPM schedule according to Section 155 for 

installation operations. Include setting and cure time for grout, concrete closure pours, splice couplers, 

and fill of pile pockets; 

(e) Methods of providing temporary support of the elements. Include methods of adjusting, bracing, 

and securing the element after placement;

(f) Procedures for controlling tolerance limits;

(g) Methods of forming closure pours and fill concrete, and sealing lifting holes; and 

(h) Methods for curing grout, closure pours, and lifting hole concrete.

(b) Other precast elements.

(1) Fabrication. Submit drawings including tolerances.

(2) Installation. Submit an installation plan. Describe details necessary for installation. Include the 

following:

(a) A work area plan depicting utilities overhead and below the work area, drainage inlet structures, 

protective measures, temporary staging areas, crane locations, temporary support elements, and other 

features of the site necessary for successful assembly; and

(b) Details of equipment and devices (including slings, hooks, and jacks) used for lifting and 

installation. Include the make, model, lift capacity, and operating radii. 

578.05 Tolerances. Fabricate precast bridge elements conforming to the tolerances shown in Tables 578-1, 578-2, 

and 578-3. Fabricate other precast elements conforming to the tolerances in the approved drawings. Provide 

measurements and documentation to support that the precast elements were fabricated in conformance with the 

requirements.
Section 578

666

Before shipping precast elements from the fabrication plant, verify that the precast elements will fit-up and align 

properly by assembling the elements or using other approved methods. Dry fit connections in the fabrication yard 

before installation of the elements at the project site.

Table 578-1

Precast Bent Cap Fabrication Tolerances

Property Tolerance, inch (±)

Length 3⁄4

Width (overall) 1⁄4

Depth (overall) 1⁄4

Variation from specified plan end squareness or 

skew

1⁄4 per 1 ft width

1⁄2 maximum

Variation from specified elevation end squareness 

or skew

1⁄4 per 1 ft width

1⁄2 maximum

Location of grouted splice coupler measured from 

a common reference point

1⁄2 maximum

Local smoothness of any surface 1⁄4 per 10 ft

Erection elevation tolerance 1⁄4

Table 578-2

Precast Abutment and Wall Elements Fabrication Tolerances

Property Tolerance, inch (±)

Length 1⁄4

Width (overall) 1⁄4

Depth (overall) 1⁄4

Variation from specified plan end squareness or 

skew

1⁄8 per 1 ft width

1⁄2 maximum

Variation from specified elevation end squareness 

or skew

1⁄4 per 1 ft width

1⁄2 maximum

Location of grouted splice coupler measured from 

a common reference point 1⁄4 

Local smoothness of any surface 1⁄4 per 10 ft

Location of blockouts for piles or voids 1
Section 578 

667

Table 578-3

Precast Approach Slab Fabrication Tolerances

Property Tolerance, inch (±)

Length 1⁄4

Width (overall) 1⁄4

Depth (overall) 1⁄4

Variation from specified plan end squareness or 

skew 1⁄2 

Location of leveling bolts 1

Sweep over member length 3⁄8

Location of projecting reinforcing measured 

from a common reference point 1⁄2 

Local smoothness of any surface 1⁄8 per 10 ft

Erection elevation tolerance (surface approach 

slab only) 1⁄8

Location of blockouts 1⁄2

578.06 Concrete and Reinforcing Steel. Construct concrete for precast bridge elements according to 

Section 552. Construct concrete for other precast elements according to Section 601. Construct reinforcing steel 

according to Section 554. 

Rough cast the top surface of members against which concrete will be cast. Rake the top surface of members 

receiving a concrete overlay to a depth of 3⁄8 inch.

Do not expose the concrete to temperatures below 40 °F for at least 7 days after casting. 

578.07 Quality Control. 

(a) Precast bridge elements.

(1) Permanently mark each element with date of fabrication, supplier identification, and module 

identification. Stamp markings in fresh concrete;

(2) Prevent cracking or damage of precast components during handling and storage; 

(3) Replace or repair defective or broken precast concrete deck and concrete deck overhang elements as 

approved. Requests to repair defective or broken elements are subject to the following: 

(a) Obtain approval before performing concrete repairs;

(b) Repair concrete to reestablish the precast elements structural integrity, durability, and aesthetics;

(c) Describe the cause of damage and the corrective action taken to eliminate future damage; and

(d) Update the CPM schedule showing the effects of repair work on project completion. 

(4) Reject elements if they do not conform to the contract and for the following:

(a) Elements fabricated before the date that drawings are approved;
Section 578

668

(b) Full-depth cracking of concrete, and concrete breakage that is not repairable; 

(c) Cracks that extend to the nearest reinforcement plane, or fine surface cracks that do not extend to 

the nearest reinforcement plane but are numerous or extensive; 

(d) Camber that does not meet the requirements of the plans or approved drawings; 

(e) Honeycombed texture; and

(f) Damage during fabrication, transportation, erection, or construction. 

(5) Document and submit the following: 

(a) Element identification;

(b) Date and time of fabrication concrete pour; 

(c) Concrete cylinder test results;

(d) Concrete mix design and the batch print out; 

(e) Form-stripping date; 

(f) Location and number of blockouts and lifting inserts; 

(g) Temperature, moisture, and duration of curing period; and 

(h) Approved repair procedures. 

(b) Other precast elements.

(1) Document and submit the following: 

(a) Date and time of fabrication concrete pour; 

(b) Concrete cylinder test results;

(c) Concrete mix design and the batch print out; and 

(d) Temperature, moisture, and duration of curing period. 

(2) Inspect elements for damage and cracking on site before installation. Reject elements if they do not 

conform to the contract and for the following: 

(a) Full-depth cracking of concrete; 

(b) Concrete breakage that is not repairable; and

(c) Cracks that extend to the nearest reinforcement plane, or fine surface cracks that do not extend to 

the nearest reinforcement plane but are numerous or extensive.
Section 578 

669

578.08 Transporting, Handling, and Storing. Before transporting precast elements, provide written certification 

from the precast concrete manufacturing plant QCM that the precast elements were fabricated and inspected to 

ensure compliance with the contract requirements. Move elements after the concrete attains a minimum 

compressive strength of 4500 pounds per square inch for precast bridge elements or a minimum of 80 percent of 

the required design compressive strength for other precast elements or as shown in the plans.

(a) Transporting. Transport precast elements horizontally with beams on the bottom side for support. 

Support the precast elements at approximately the same points they will be supported when installed. Use 

shock-absorbing material at bearing points during transportation. Locate the tie-down straps at the lines of 

blocking only. 

(b) Handling and storing. Store the precast elements in a horizontal and upright position, supported at their 

designated bearing points. Follow Chapter 5 of the PCI Design Handbook for handling and erection bracing 

requirements.

Lift the precast elements so that the angle between the top surface of the precast element and the lifting line 

is not less than 60 degrees when measured from the top surface of the precast elements to the lifting line. If 

two cranes are used, maintain vertical lifting lines. Lift the precast elements at the designated points. Account 

for stresses in precast elements during handling operations. Choose the locations of the lifting points so that 

the anticipated flexural tensile stress induced in the top of the structural concrete for the assumed support 

locations is not greater than the allowable stress.

Select smooth and well compacted storage areas to prevent damage due to differential settlement. Support 

precast elements during storage to prevent cracking or creep-induced deformation (sagging). Check precast 

elements at least once per month to ensure that creep-induced deformation does not occur. 

(c) Lifting devices. Do not cause damage, cracking, or torsional forces when using lifting devices. Place the 

lifting devices in locations that are not visible once the precast element is placed, or within recessed pockets 

that can be patched after installation.

(d) Safety. Ensure the safety and stability of precast elements during all stages of handling, transportation, 

and construction. 

(e) Damage and cracking. Prevent cracking or damage of precast elements during storing, transporting, and 

erecting. Replace or repair damaged precast elements as approved.

578.09 Acceptance. Anchor devices and material for grout will be evaluated under Subsections 106.02 and 

106.03. 

Construction of precast elements will be evaluated under Subsections 106.02 and 106.04. 

Concrete for precast bridge elements will be evaluated under Section 552. 

Concrete for other precast elements will be evaluated under Section 601. 

Reinforcing steel will be evaluated under Section 554. 
Section 578

670

Measurement

578.10 Measure the Section 578 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

578.11 The accepted quantities will be paid at the contract price per unit of measurement for the Section 578 pay 

items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See 

Subsection 109.05. 
671

DIVISION 600

INCIDENTAL CONSTRUCTION
Section 601

672

Section 601. — MINOR CONCRETE

Description

601.01 This work consists of constructing minor concrete. 

Material 

601.02 Conform to the following Section and Subsections:

Coarse aggregate for concrete 703.02

Color coating 725.15

Concrete curing material and additives 711

Fine aggregate for concrete 703.01

Hydraulic cement 701.01

Penetrating stain for concrete 719.05

Pozzolans 701.03

Reinforcing steel 709.01

Sealants, fillers, and seals 712.01

Water for cementitious materials 725.01(a)

Construction Requirements

601.03 Composition (Concrete Mix Design). Conform to Table 601-1. Before batching concrete, submit 

the proposed concrete proportions for approval on Form FHWA 1606, Minor Portland Cement Concrete 

Mix Design or other approved form. As a minimum, submit the following at least 30 days before 

production: 

(a) Concrete. Include the following in each mix design submittal: 

(1) Type and sources of material; 

(2) Material certification for material;

(3) Saturated surface dry mass of the fine and coarse aggregate per cubic yard of concrete;

(4) Gradation of fine and coarse aggregate;

(5) Mass of mixing water per cubic yard of concrete;

(6) Mass of cement per cubic yard of concrete. Fly ash, ground iron blast-furnace slag, or silica 

fume (micro-silica) may be substituted for cement according to Table 552-2; 

(7) Entrained air content of plastic concrete in percent by volume; and 

(8) Maximum slump of plastic concrete in inches.

(b) Integral colored admixture. If integral color admixture is used, prepare five 2- by 2-foot test 

panels. Construct the test panels using the proposed mix design. Determine coloring agent batch 

amounts by weight. Use variable quantities of coloring agent as approved. Provide additional mixing 
Section 601

673

time according to the manufacturer’s recommendations. Cure the test panels similar to the structure. 

Transport the panels to an approved location. Provide at least 2 weeks outside exposure. The CO will 

select the acceptable test panel. Use the same rate of integral color admixture for the item of work.

Table 601-1 

Composition of Minor Concrete

Property Specification

Water to cementitious material ratio 0.49 maximum

Air content 4% minimum

Size of coarse aggregate AASHTO M 43 with 100% passing the 11⁄2-in sieve

28-day compressive strength 4000 psi minimum

601.04 General. Excavate and backfill according to Section 209. 

Design and construct forms that are free of bulge and warp and allow for removal without injuring the 

concrete. Design the forms for a lateral pressure equal to that exerted by a fluid weighing 150 pounds per 

cubic foot. 

Use wood, metal, or other suitable material for forms. Keep forms clean and coat with a form release agent 

or form oil before placing concrete.

Place and fasten reinforcing steel according to Subsection 554.08. 

601.05 Placing Concrete. Conform to Subsection 552.07. Moisten the forms and foundation immediately 

before placing concrete. Discharge concrete within the time limit shown in Table 552-5. 

Place concrete to avoid segregation of material. Consolidate with vibrators according to 

Subsection 552.08(c). Do not use aluminum pipe for transporting or placing concrete. Do not exceed 

30 minutes between deliveries of batches for a single pour on a structure.

Do not apply water to plastic concrete surfaces during finishing operations. 

601.06 Curing and Finishing of Concrete. Cure concrete at least 7 days. Cure according to 

Subsection 552.13. Finish exposed concrete surfaces according to Subsection 552.14 as applicable.

Do not place backfill against concrete until 80 percent of the design strength is attained. Construction 

loads less than 4000 pounds may be placed on the concrete when 80 percent of the design strength is 

attained. 

Remove and replace cracking, spalling, or scaling concrete to the nearest joint. 

601.07 Acceptance. See Table 601-2 for sampling, testing, and acceptance requirements.

Material for minor concrete including concrete, reinforcing steel, and structural steel for minor structures 

will be evaluated under Subsections 106.02 and 106.03. 

The concrete mixture’s density, air content, slump, temperature, and compressive strength will be 

evaluated under Subsections 106.02 and 106.04. 
Section 601

674

Construction of minor concrete will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Measurement

601.08 Measure the Section 601 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When concrete is measured by the cubic yard, measure in the structure.

Payment

601.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 601 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 601-2 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Aggregate

(fine & 

coarse)

Measured &

tested for

conformance

(106.04 & 105) 

Quality −

Subsections

703.01 & 

703.02

1 per

material

type

Source of

material Yes Beforeproducing −

Mix Design

Concrete

composition 

(601.03) 

Measured &

tested for

conformance

(106.04 & 105) 

All − Subsection

601.03

1 per

mix

design

Source of

material

If

requested

Before

producing −

Production

Concrete(1) 

Measured &

tested for

conformance

(106.04) 

Density − AASHTO

T 121

1 per

load after

0.25 yd3 

minimum is 

discharged(4)

Point of 

discharge No

Upon

completing

tests

−

Air content − AASHTO T 152 or

AASHTO T 196 " " " " −

Slump − AASHTO T 119 " " " " −

Temperature − ASTM C1064 " " " " −

Compressive

Strength(2),(3)

(28-day)

− AASHTO

R 100 & T 22

1 set per

30 yd3

but not less 

than 1 per

day

" Yes 28

days

Deliver

verification

cylinders to

the CO or

designated

laboratory

for scheduled 

testing
Table 601-2 (continued)

Sampling, Testing, and Acceptance Requirements

(1) Sample according to AASHTO R 60, except composite samples are not required.

(2) Cast at least four compressive strength test cylinders for 6- by 12-inch specimens or six compressive strength cylinders for 4- by 8-inch and carefully transport 

the cylinders to the job site curing facility.

(3) A single compressive strength test result is the average result from two 6- by 12-inch or three 4- by 8-inch cylinders cast from the same load.

(4) If three successive samples are tested and compliance to the specifications is indicated, screening tests may be reduced to an approved frequency. Resume 

Table 601-2 testing frequency if a test shows a failing temperature, air content, slump, or when directed.
Section 602

677

Section 602. — CULVERTS AND DRAINS

Description

602.01 This work consists of providing and installing culverts, drains, and precast concrete box culverts. 

Material 

602.02 Conform to the following Sections and Subsections:

Asphalt mastic 702.04

Concrete pipe 706

General mortar 701.05(a)

Metal pipe 707

Plastic pipe 708

Precast concrete units and accessories 725.09

Sealants, fillers, and seals 712.01

Construction Requirements

602.03 General. Provide culvert pipe with a wall thickness at least that shown in the plans or determined 

from the fill-height tables shown in the plans. Use the same material and coating on contiguous pipe 

sections and special sections (such as elbows and branch connections). For culvert extensions, provide the 

same material as the existing culvert.

Plans show the size, length, and approximate location of culverts. Determine final location, skew, length, 

elevations, and grade according to Section 152. Do not order culvert material until the CO has accepted 

the final structure size, length, and alignment. 

Construct cast-in-place concrete box culverts according to Section 552. For precast concrete box culverts, 

submit design drawings and details with supporting calculations according to Subsection 104.06. Design 

and construct precast concrete box culverts according to Section 578. 

Excavate and backfill according to Section 209. 

Place elongated pipes with the minor axis within 5 degrees of vertical.

Construct a piping plug unless the culvert inlet is protected with a full-height headwall, slope paving, or 

an embankment consisting of AASHTO M 145 classification A-6 or A-7 material. Construct the piping 

plug with AASHTO M 145 classification A-6, A-7, or other approved material with a permeability no 

more than 0.004 inch per second. 

602.04 Laying Concrete Pipe and Precast Concrete Box Culverts. Start at the lower end and lay the 

bell or groove end upgrade. Fully join sections with leak-resistant seals using one of the following 

methods: 

(a) Mortared joints. Clean the lower portion of the receiving end of the pipe. Plaster the inside with 

sufficient joint mortar to bring the inner surfaces of the abutting pipe sections flush and even. Fit the 
Section 602

678

sections as close as the construction of the culvert allows. Fill and seal joints with mortar inside and 

out. Use the mortar within 30 minutes after mixing. Clean excess mortar from the inside of the joint.

Cure mortar outside of joints by covering with polyethylene sheeting or spraying with a curing 

compound. Backfill while mortar is plastic or, if mortar sets before backfilling, wait at least 24 hours 

before backfilling. 

(b) Gasket joints. Conform to ASTM C990 or ASTM C443 and the following: 

(1) Protect the joint ends from mud, silt, gravel, or other foreign material. Lay the pipe sections 

with gaskets attached. Remove, clean, relubricate, and reseat gaskets disturbed or contaminated.

(2) Align the pipe sections. Force the joints home using the pipe manufacturer’s recommended 

procedure. Do not drive or ram by hand or machinery. Block the last section of each day’s run to 

prevent creep.

Install supplemental concrete pipe ties on the last downstream pipe-to-pipe joint and at the downstream 

pipe-to-end section joint, if present. 

602.05 Laying Metal Pipe. Position the pipe with a longitudinal joint so the joint is opposite the invert. 

Fully join pipe sections with leak-resistant seals according to AASHTO M 36 or AASHTO M 196. Use 

one of the following: 

(a) Gasket, bell, and spigot joints. Use on slopes of 10 percent or less and lay the pipe with the bell 

end up slope. 

(b) Coupling bands with gaskets. Limit the use of coupling bands with projections (dimples) to 

attaching prefabricated flared end sections.

If aluminum alloys come in contact with other metals, coat the contacting surfaces with asphalt mastic or 

a preapproved impregnated caulking compound. 

602.06 Laying Plastic Pipe. Lay plastic pipe according to the pipe manufacturer’s recommendations. 

Fully join pipe sections with leak-resistant seals using gasket, bell, and spigot joints according to 

ASTM D3212. 

602.07 Laying Slotted Drain Pipe. Fully join pipe sections with leak-resistant seals using coupling bands 

and gaskets. Cover the slots with roofing paper or other approved covering during backfilling and paving 

to keep material out of the pipe. Backfill with a flowable backfill.

602.08 Acceptance. Material for culverts and drains will be evaluated under Subsections 106.02 and 

106.03. 

Installation of culverts and drains will be evaluated under Subsections 106.02 and 106.04. 

Cast-in-place concrete box culverts will be evaluated under Section 552. 

Excavation and backfill will be evaluated under Section 209. 

Precast concrete box culverts will be evaluated under Section 578. 
Section 602

679

Survey work will be evaluated under Section 152. 

Measurement

602.09 Measure the Section 602 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring pipe and box culverts by the linear foot, measure along the invert. 

Measure end sections, elbows, and branch connections by the each. If there is no pay item for elbows or 

branch connections, measure them as additional pipe length along the invert. 

Payment

602.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 602 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 603

680

Section 603. — STRUCTURAL PLATE STRUCTURES

Description

603.01 This work consists of designing and constructing structural plate pipes, arches, pipe arches, boxes, 

and underpasses. 

Material 

603.02 Conform to the following Subsections: 

Aluminum-alloy structural plate structures 707.06

Asphalt-coated structural plate structures 707.07

Steel structural plate structures 707.05

Construction Requirements

603.03 General. Excavate and backfill according to Section 209. 

603.04 Erecting. Provide steel, aluminum alloy, asphalt coated steel, or asphalt-coated aluminum alloy 

structural plate structures.

Submit a copy of the manufacturer’s assembly instructions before assembly. Show the position of each 

plate and assembly order.

Assemble the structural plates according to the manufacturer’s recommendations. Prevent damage to the 

structural plate and its coating. Clear sand, gravel, and other foreign material from the corrugations within 

lapped sections of the plates. Ensure plates have a proper fit-up. 

Where aluminum alloys come in contact with other types of metal, coat the contacting surfaces according 

to Subsection 602.05. 

Torque bolts according to the manufacturer’s recommendations. 

For structures having a span greater than or equal to 20 feet:

(a) Tighten the longitudinal seams when the plates are assembled unless the plates are held in shape 

by cables, struts, or backfill. Properly align plates circumferentially to avoid permanent distortion from 

the design shape. Before backfilling, do not exceed 2 percent variation from the design shape;

(b) Do not distort the shape of the structure by operating equipment over or near it; 

(c) Provide survey control on the structure to check structure movement;

(d) Check and control the deflection movements of the structure during the backfilling operation. Do 

not exceed the manufacturer’s recommended limits; and

(e) Provide a manufacturer’s representative to monitor the erecting and backfilling of the structure.
Section 603

681

603.05 Acceptance. Material for structural plate structures will be evaluated under Subsections 106.02

and 106.03. 

Installation of structural plate structures will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Measurement

603.06 Measure the Section 603 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

603.07 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 603 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 604

682

Section 604. — MANHOLES, INLETS, AND CATCH BASINS

Description

604.01 This work consists of constructing, adjusting, shifting, or modifying manholes, inlets, and catch 

basins.

Material 

604.02 Conform to the following Subsections: 

Concrete building brick 725.06

Concrete masonry units 725.07

Corrugated metal units 707.09

Frames, grates, covers, and ladder rungs 725.10

Gaskets for concrete pipe 706.08

Gaskets for metal pipe 707.17

General mortar 701.05(a)

Neat hydraulic cement grout 701.04(a)(2)

Precast concrete units and accessories 725.09

Reinforcing steel 709.01

Sealants, fillers, and seals 712.01

Construction Requirements

604.03 General. Excavate and backfill according to Section 209. 

Separate catch basins and inlets from adjacent concrete structures with at least 1⁄2-inch thick preformed 

expansion joint.

Construct minor concrete according to Section 601. 

604.04 Concrete Construction. Concrete units may be cast-in-place or precast.

Finish surfaces according to Subsection 552.14 as applicable.

Finish the flow line in manholes, inlets, and catch basins to match the pipe flow line. 

Assemble precast concrete manhole sections with flexible gaskets or fillers in the tongue and groove joints. 

Handle the precast units carefully after the gasket has been attached to avoid damaging the gasket or 

contaminating the joint. Ensure the proper alignment before the joints are forced home. Seat gaskets 

uniformly. If mastic is used, apply mastic joint filler according to the manufacturer’s recommendations.

Set metal frames in a full mortar bed.

Space ladder rungs uniformly on 12-inch centers and align vertically. Grout ladder rungs into precast 

concrete walls.
Section 604

683

604.05 Concrete Masonry Unit Construction. Construct masonry block plumb. Stagger vertical joints 

and set block with the cells vertical. Moisten blocks before using in work. Butter bearing members and 

vertical joints full of mortar. Bond block using mortar on sides. Construct joints straight, level, plumb, 

flush, and 1⁄4 to 1⁄2 inch thick. Backfill the structure after the masonry block joints have moist cured for 

7 days. 

604.06 Metal Construction. Fabricate metal drop inlets from the same material and thickness as adjoining 

metal pipes. Connect metal inlets to adjoining metal pipes according to Subsection 602.05. 

604.07 Grade Adjustment of Structures. Adjust metal frames and grates to grade before placing the 

surface course.

Remove and clean the frames, covers, and grates. Trim the walls down to solid material. Reconstruct the 

walls with the same material as existing and reset the cleaned frames at the required elevation. 

If the existing casting and supporting walls are in good condition, an approved device may be used to 

adjust the manhole casting cover to the correct grade.

Clean each structure of foreign material.

604.08 Shifting and Modifying Structures. Shift structures using methods to ensure structural integrity. 

Reshape the channel flow line in manholes, inlets, and catch basins as necessary to match the pipe flow 

line.

Set and reassemble structures according to the applicable requirements of Subsections 604.04 through 

604.07. Provide and install gaskets, seals, and other accessories according to the applicable requirements 

of Subsections 604.04 through 604.06. Grout or use a preformed joint seal to make joints and openings 

leak resistant. Finish mortar joints with a bead on the outside and a smooth finish on the inside.

When modifying a concrete structure, do not loosen the reinforcement in the wall. Cut the reinforcing 

steel flush with the opening wall face. Grout joints and openings cut in the wall. 

Seal openings no longer required in the structure. 

Abandon structures according to Subsection 203.06. 

604.09 Acceptance. Material for metal, concrete brick, concrete masonry, precast concrete units, and 

cast-in-place concrete (except concrete) units will be evaluated under Subsections 106.02 and 106.03. 

Construction of metal, concrete brick, and concrete masonry units will be evaluated under 

Subsections 106.02 and 106.04. 

Installation of precast concrete units will be evaluated under Subsections 106.02 and 106.04. 

Shifting, modifying, and adjusting units will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Minor concrete will be evaluated under Section 601. 
Section 604

684

Measurement

604.10 Measure the Section 604 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring manholes by the linear foot, measure from finished grade to the flow line surface of the 

manhole. 

Do not measure metal frames and grates when included as part of the original inlet, manhole, or catch 

basin construction. 

Payment

604.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 604 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 605

685

Section 605. — UNDERDRAINS, SHEET DRAINS, AND

PAVEMENT EDGE DRAINS

Description

605.01 This work consists of providing and installing underdrains, sheet drains, and pavement edge drains.

Material 

605.02 Conform to the following Section and Subsections: 

Aluminum-alloy corrugated pipe 707.03

Asphalt-coated pipe 707.04

Geocomposite drain 714.02

Geotextile 714.01

Metallic-coated corrugated steel pipe 707.02

Perforated concrete pipe 706.03

Plastic pipe 708

Sand 703.14

Soil and soil-aggregate materials 704.01

Underdrain backfill 703.03

Construction Requirements

605.03 General. Elevate and protect sheets, panels, or rolls of geotextile filter and geocomposite with a 

waterproof and ultraviolet resistant cover if stored outdoors. Limit geotextile filter and geocomposite 

exposure to less than 10 days if using for a permanent installation.

Use the same material and coating on contiguous drain sections, extensions, elbows, branch connections, 

and other special sections.

Drain material, size, and approximate location are shown in the plans. Determine the final location and 

length in the field.

Do not install drain material until the CO has accepted the final location and length. 

Excavate and backfill according to Section 209. 

If geotextile filter or geocomposite is used, smooth the trench surfaces by removing projections that may 

damage the geotextile filter or geocomposite. Replace geotextile filter or geocomposite damaged during 

installation.

Do not allow soil or other foreign material to enter the drain systems. Plug the highest end of installations.

Provide nonperforated pipe for outlet pipe. Install outlet pipe according to Section 602. Immediately place 

and secure a screen made of 0.055-inch diameter galvanized wire having approximately 1⁄2- by 1⁄2-inch 

mesh openings over the outlet ends of exposed pipes and weep holes.
Section 605

686

605.04 Placing Underdrain. Join pipe sections securely with coupling fittings or bands. Join PVC and 

acrylonitrile-butadiene-styrene (ABS) pipe using either a flexible elastomeric seal or solvent cement. Join 

polyethylene pipe with snap-on, screw-on, or wrap around coupling bands according to the manufacturer’s 

recommendations.

Backfill and compact trenches within the limits of the roadbed according to Section 209, except use 

underdrain backfill. Trenches for geocomposite underdrains within the limits of the roadbed may also be 

backfilled with sand and compacted.

If underdrain is placed in ditch lines, prevent infiltration of surface water by placing material conforming 

to AASHTO M 145, classification A-4, A-5, A-6, or A-7 in the top 12 inches of the trench. 

(a) Standard underdrain. Place the long dimension of the geotextile filter parallel to the centerline 

of the trench. Position the geotextile filter, without stretching, in contact with the trench surface. 

Overlap the joints at least 24 inches with the upstream geotextile filter placed over the downstream 

geotextile filter.

Place collector pipe with the perforations facing downward. 

Place underdrain backfill to a height of 12 inches above the top of the collector pipe and compact. Do 

not displace the collector pipe. Place and compact the remainder of the underdrain backfill according 

to Section 209. 

Fold the geotextile filter over the top of the underdrain backfill with a minimum overlap of 12 inches.

(b) Geocomposite underdrain. Extend the geotextile filter from the bottom of the drainage core 

around the collector pipe. 

Construct splices and install outlet fittings according to the manufacturer’s recommendations. Prevent 

infiltration of soil into the geocomposite core.

Place the assembled geocomposite in the trench with the face of the geocomposite against the inflow 

side of the trench. If the trench wall is irregular, smooth the trench wall or place a lift of underdrain

backfill between the geocomposite and the trench wall. Temporarily support the drain against the 

trench wall while backfilling.

If the trench is less than 18 inches wide, backfill the trench using sand. Backfilling and compacting in 

lifts are not required. Compact the sand by vibrating or tamping with a mechanical tamper. 

If the trench is at least 18 inches wide, place underdrain backfill or sand to a height of 12 inches above 

the top of the collector pipe and compact. Place and compact the remainder of the underdrain backfill 

or sand according to Section 209. 

605.05 Placing Geocomposite Sheet Drain System. Do not place sheet drains against a mortar course 

less than 4 days old. 

If a geocomposite is used in conjunction with a waterproof membrane, install drainage panels compatible 

with the membrane according to the membrane manufacturer’s recommendations. Assemble and place the 

geocomposite drain against the surface to be backfilled according to the manufacturer’s recommendations. 
Section 605

687

Splice geocomposite drains so the flow across the edges is continuous. Overlap the geotextile filter at least 

3 inches in the direction of water flow. For vertical splices, overlap the geotextile filter in the direction 

backfill proceeds.

Connect the drainage core to the collector pipe or weep holes so the flow is continuous through the system. 

Extend the geotextile filter from the bottom of the drainage core around the collector pipe.

Backfill with structural backfill and compact according to Subsections 209.09 and 209.10. 

605.06 Placing Geocomposite Pavement Edge Drain. Assemble the geocomposite pavement edge drain 

and outlet material according to the manufacturer’s recommendations and place it in the trench. If the 

trench wall is irregular, smooth the trench wall or place a lift of sand between the geocomposite and the 

trench wall. Temporarily support the drain against the trench wall while backfilling.

If the trench is less than 18 inches wide, backfill the trench using sand. Backfilling and compacting in lifts 

are not required. Compact the sand by vibrating or tamping with a mechanical tamper. 

If the trench is at least 18 inches wide, place and compact underdrain backfill or sand according to 

Section 209. 

605.07 Acceptance. See Table 605-1 for sampling, testing, and acceptance requirements.

Material (except underdrain backfill) for underdrains, sheet drains, and edge drains will be evaluated under 

Subsections 106.02 and 106.03. 

Underdrain backfill will be evaluated under Subsections 106.02 and 106.04. 

Geocomposites will be evaluated under Subsections 106.02 and 106.03. Submit a production certification 

with each shipment of geocomposite that includes the name of the manufacturer, product name, style 

number, chemical composition of the core and encapsulating geotextile filaments or yarns, and other 

appropriate information to fully describe the geocomposite drain. 

Installation of underdrains, sheet drains, and edge drains will be evaluated under Subsections 106.02 and 

106.04. 

Excavation and backfill will be evaluated under Section 209. 

Geotextile filter will be evaluated under Section 207. 

Outlet pipe will be evaluated under Section 602. 

Measurement

605.08 Measure the Section 605 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring for a system, do not measure geotextile filters, geocomposites, collector pipes, backfill, 

and outlet pipes that are part of the system.

When measuring underdrain backfill and sand by the cubic yard, measure in place. 
Section 605

688

Payment

605.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 605 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Table 605-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point

of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Underdrain

backfill

(703.03) 

Measured &

tested for

conformance

(106.04 & 

105) 

Quality − Subsection

703.03

1 per

aggregate 

type & 

source of

material

Source of

material Yes

Before

using

in work

Not required

if using

Government

-furnished

source

Production

Underdrain

backfill

(703.03) 

Measured &

tested for

conformance

(106.04)

Gradation − AASHTO

T 27 & T 11

1 per

600 yd3

Production

output

or

stockpile

Yes 4 hours −
Section 606

690

Section 606. — CORRUGATED METAL SPILLWAYS

Description

606.01 This work consists of providing and installing corrugated metal spillways. 

Material 

606.02 Conform to the following Section: 

Metal pipe 707

Construction Requirements

606.03 Placing Corrugated Metal Spillways. Spillway, inlet, outlet, and connector dimensions and 

proportions may vary to allow the use of the manufacturer’s standard jigs and templates.

Install spillway inlet assemblies as shown in the plans and consolidate the earth backfill by tamping. 

Excavate and backfill according to Section 209. 

Lay spillway outlet pipe according to Section 602. Anchor the spillway as shown in the plans. 

606.04 Acceptance. Pipes, anchor assemblies, hardware, and other material provided to fabricate metal 

spillways will be evaluated under Subsections 106.02 and 106.03. 

Construction of corrugated metal spillways will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Spillway inlet pipe will be evaluated under Section 602.

Measurement

606.05 Measure the Section 606 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

606.06 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 606 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 607

691

Section 607. — CLEANING, RELAYING, AND

REPAIRING EXISTING DRAINAGE STRUCTURES

Description

607.01 This work consists of cleaning, relaying, and repairing existing drainage and appurtenant 

structures.

Construction Requirements

607.02 Cleaning Drainage Structures in Place. Remove foreign material within the structure and 

accessories by approved methods.

Remove debris, vegetation, and earthen material that impedes inlet and outlet channel flow to the structure. 

Obtain approval from the CO before removing trees.

Dispose of removed material according to Subsection 203.07. 

Regrade inlet and outlet channels at structures to provide positive drainage. Reshape inlet to direct flow 

into the structure entrance.

607.03 Relaying or Stockpiling Salvaged Pipe. Relay removed and cleaned pipe according to 

Section 602. 

Salvage and stockpile pipe according to Subsection 203.04. 

Replace damaged pipe and install according to Section 602. Dispose of damaged pipe according to 

Subsection 203.07. 

607.04 Repairing Drainage Structures. Remove debris from structures designated to be repaired. Repair 

leaks and structural damage and replace missing or broken metalwork according to Sections 602 and 603. 

607.05 Acceptance. Cleaning and repairing existing drainage structures will be evaluated under 

Subsection 106.02. 

Relaying pipe will be evaluated under Section 602. 

Repairing drainage structures will be evaluated under Sections 602 and 603. 

Measurement

607.06 Measure the Section 607 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

607.07 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 607 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 608

692

Section 608. — PAVED WATERWAYS

Description

608.01 This work consists of constructing paved waterways not contiguous to the traveled way. 

Paved waterways are designated as follows:

Type 1 – Grouted rubble 

Type 2 – Mortared rubble 

Type 3 – Concrete and rubble 

Type 4 – Concrete 

Type 5 – Asphalt 

Material 

608.02 Conform to the following Subsections: 

Soil and soil-aggregate materials 704.01

General mortar 701.05(a)

Neat hydraulic cement grout 701.04(a)(2)

Reinforcing steel 709.01

Rock for masonry structures (rubble) 705.03

Sand 703.14

Construction Requirements

608.03 General. Excavate and backfill according to Section 209. Place and compact the bedding material 

with at least three passes of a lightweight mechanical tamper, roller, or vibratory system. 

Construct minor concrete according to Section 601. 

Construct rubble masonry according to Section 620. 

608.04 Grouted Rubble Paved Waterway (Type 1). Clean and wet the rubble to near saturation. Set 

rubble in a broken pattern with no continuous joint across the waterway or parallel to the flow line. Place 

rubble into the mortar bed with the flat faces up and the longest dimension at right angles to the flow line. 

Make the joints 1 to 2 inches wide.

Ram each piece of rubble until it is firm and true to the surface in grade, alignment, and cross-section. 

Remove and relay rubble having an irregular or uneven surface. 

Fill the joints with sand to within 4 inches of the surface. Pour and broom grout into the joints until the 

grout is 1⁄2 inch below the surface of the rubble. Clean excess grout from the rubble surface. 

608.05 Mortared Rubble Paved Waterway (Type 2). Clean and wet the rubble to near saturation. Set 

rubble in a broken pattern with no continuous joint across the waterway or parallel to the flow line. Place 

rubble into the mortar bed with the flat face up and the longest dimension parallel to the flow line. Make 

joints 1 to 2 inches wide.
Section 608

693

Ram each piece of rubble until it is firm and true to the surface in grade, alignment, and cross-section. 

Remove and relay rubble having an irregular or uneven surface. 

Fill joints to within 1⁄2 inch below the surface of the rubble. Clean excess mortar from the rubble surface.

608.06 Concrete and Rubble Paved Waterway (Type 3). Perform concrete work according to 

Section 601. Secure the reinforcing steel within the middle third of the depth of the concrete foundation 

if shown in the plans. 

Clean and wet the rubble to near saturation. Embed rubble into the concrete foundation in a broken pattern 

with no continuous joint across the waterway or parallel to the flow line.

Make the joints 1 to 2 inches wide. Fill the joints with mortar to 1 inch below the surface of the rubble. 

Clean excess mortar from the rubble surface.

608.07 Concrete Paved Waterway (Type 4). Perform the work according to Section 601. 

608.08 Asphalt Paved Waterway (Type 5). Perform the work according to Section 403, Type II. Clean 

and seal the cracks according to Section 414 before overlaying existing asphalt paved waterway.

608.09 Acceptance. See Table 608-1 for sampling, testing, and acceptance requirements.

Bedding material and sand will be evaluated under Subsections 106.02 and 106.04. 

Material for grout and mortar will be evaluated under Subsections 106.02 and 106.03. 

Mortar placement will be evaluated under Subsections 106.02 and 106.04. 

Construction of paved waterways will be evaluated under Subsections 106.02 and 106.04. 

Asphalt concrete will be evaluated under Section 403. 

Cleaning and sealing cracks will be evaluated under Section 414. 

Excavation and backfill will be evaluated under Section 209. 

Minor concrete will be evaluated under Section 601. 

Rubble masonry will be evaluated under Section 620. 

Measurement

608.10 Measure the Section 608 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring paved waterways by the square yard, measure the width horizontally to include the total 

width. Measure the length parallel to the flow line.

When measuring paved waterways by the linear foot, measure along the flow line of the paved waterway.
Section 608

694

Payment

608.11 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 608 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 608-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Bedding

material

(704.01) 

Measured &

tested for

conformance

(106.04 & 

105) 

Gradation − Subsection

704.01

1 per

soil type

& 

source of

material

Source of

material Yes

Before

using in

work

Not 

required

if using

Governmen

t-furnished 

source

Liquid limit −

AASHTO

R 58 & T 89,

Method A

" " " " " 

Sand

(703.14) " 

Gradation &

deleterious

material

− AASHTO

M 6 " " " " " 

Production

Bedding

material

(704.01) 

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11

1 per

600 yd3

Production

output or

stockpile

Yes 4 hours " 

Liquid limit −

AASHTO

R 58 & T 89,

Method A

" " " " " 

Sand

(703.14) " Gradation − AASHTO

T 27 & T 11 " " " " " 
Section 609

696

Section 609. — CURB AND GUTTER

Description

609.01 This work consists of constructing or resetting curb, gutter, combination curb and gutter, and 

wheelstops.

Material 

609.02 Conform to the following Subsections: 

General mortar 701.05(a)

Reinforcing steel 709.01

Rock for masonry structures (stone curbing) 705.03

Sealants, fillers, and seals 712.01

Soil and soil-aggregate materials 704.01

Construction Requirements

609.03 General. Excavate and backfill according to Section 209. Place and compact the bedding material. 

Compact the bedding material with at least three passes of a lightweight mechanical tamper, roller, or 

vibratory system. Construct minor concrete according to Section 601. 

609.04 Stone Curb. Do not use stone with visible drill marks on the exposed faces. 

Conform to the dimensions of stone curb specified and the following: 

(a) Type 1. Saw or point the top surface of vertical stone curb to an approximate true plane with no 

depression or projection on that surface of over 1⁄4 inch. Pitch the front and back arris lines straight and 

true. Limit projections or depressions on the back surface to not exceed a batter of 1 inch horizontal 

to 3 inches vertical.

Saw, point, or smooth quarry split the front exposed face of the vertical stone curb and form to an 

approximately true plane. Limit projections or depressions on the remaining face distance to 1 inch or 

less from the plane of the exposed face.

Square the ends of vertical stone curb so when the sections are placed end to end, no space more than 

1⁄2 inch shows for the full width of the top surface and for the entire exposed front face. The remainder 

of the end may break back no more than 4 inches from the plane of the joint. Cut the joints of circular 

or curved stone curb on radial lines. 

Make stone curb segments at least 48 inches long, but the length may vary where a depressed or 

modified section of curb is required for driveways, crossings, or closures.

(b) Type 2 (sloped stone curb). Conform to the requirements of Type 1 stone curb, except as follows:

The maximum allowable projection or depression on a horizontal top surface is limited to 1⁄2 inch. On 

other exposed faces, the maximum allowable projection or depression is limited to 1 inch.
Section 609

697

For unexposed surfaces, the maximum allowable projection or depression from a true plane on a 

24-inch length is 3 inches.

The maximum allowable space showing on exposed faces between adjacent segments of slope stone 

curb is 3⁄4 inch. Make slope stone curb segments at least 24 inches long. 

Clean the curb material thoroughly and wet it immediately before setting. Set the curb in bedding material 

so the face and top lines are to line and grade. Make the joints 1⁄2 to 1 inch wide and fill the joints with 

mortar.

Complete the first 25 feet of curb to demonstrate the ability to build a curb conforming to these 

requirements. Do not continue construction until the 25-foot test section is approved. 

Where a concrete pavement is constructed contiguous to the curb, construct the joints in the curb directly 

in line with the pavement expansion joints. 

Make the curb joint 3⁄4 inch wide and fill it with expansion joint filler of the same nominal thickness as the 

pavement joint. Fill voids between the joint filler and the curb with mortar.

609.05 Concrete Curb or Curb and Gutter. The curb or curb and gutter may be cast-in-place or slipformed.

(a) Cast-in-place. Use forms that extend for the full depth of the concrete. Use curved forms for curb 

with a radius of 300 feet or less.

(1) Contraction joints. Construct at intervals no more than 10 feet. Use metal divider plates or 

form joints with a jointing tool or saw joints to a depth of 1⁄4 to 1⁄3 the thickness of the concrete and 

about 1⁄8 inch wide. If the curb is constructed adjacent to or on concrete pavement, match the 

contraction joints in the pavement. 

(2) Expansion joints. Form expansion joints at intervals of 60 feet using a 3⁄4-inch thick preformed 

expansion joint filler. Where the curb is constructed adjacent to or on rigid pavement, match the 

expansion joints in the pavement.

Finish the concrete smooth and even with a wood float. Broom finish parallel to the curb line according 

to Subsection 552.12(c)(2). If an exposed aggregate finish is required, finish according to 

Subsection 552.12(c)(4). Leave forms in place for 24 hours or until the concrete has set sufficiently so 

the forms can be removed without harming the curb. 

(b) Slip-formed. Use a self-propelled automatic curb machine or a paver with curb attachments. Use 

a machine that is heavy enough to obtain consolidation without the machine riding above the 

foundation. 

Adjust the concrete aggregate gradation, if necessary, to produce a curb or curb and gutter that has 

well defined web marks of water on the surface. Remove and replace sections with craters larger than 

3

⁄16 -inch or other sections determined to be damaged or defective. Repairing surface craters and other 

defective sections by plastering is not allowed. 
Section 609

698

After the concrete has hardened sufficiently to allow sawing without damage, saw contraction joints 

according to Subsection 609.05(a)(1). Construct expansion joints according to 

Subsection 609.05(a)(2). 

609.06 Asphalt Concrete Curb or Gutter. Where curb is constructed on a pavement, apply an asphalt

tack coat according to Section 412 on the area under the curb. 

Construct asphalt concrete curb according to Section 403, Type II. Use a self-propelled automatic curb 

machine or a paver with curb attachments that is heavy enough to compact a curb without riding above 

the foundation. Make the curb uniform in texture, shape, and density. Curb may be constructed by other 

means only in short sections or sections with short radii. 

Construct gutters according to Section 403, Type II. 

609.07 Bonding Concrete Curb to Surface. If bonding curb to asphalt pavement, thoroughly clean the 

pavement surface before placing the curb. Remove dust and loose material on the asphalt pavement. 

Bond the extruded curb to the asphalt pavement using an approved adhesive or a two-component epoxy 

designed to bond curb to the pavement. 

609.08 Resetting Stone Curb. Salvage the stone curb according to Subsection 203.04. Cut or fit the curb 

as necessary for installation. Replace lost, damaged, or destroyed curb. Reset the curb according to 

Subsection 609.04. 

609.09 Wheelstops. Pin the wheelstops in place with two 36-inch sections of No. 6 reinforcing steel or 

3⁄4-inch steel rods. Reset wheelstops in the same manner.

609.10 Acceptance. See Table 609-1 for sampling, testing, and acceptance requirements.

Bedding material will be evaluated under Subsections 106.02 and 106.04. 

Material for mortar will be evaluated under Subsections 106.02 and 106.03. 

Mortar will be evaluated under Subsections 106.02 and 106.04. 

Precast units (wheelstops) will be evaluated under Subsections 106.02 and 106.03. 

Stone for stone curbing will be evaluated under Subsections 106.02 and 106.04. 

Construction of curb, curb and gutter, gutter, and wheelstops will be evaluated under Subsections 106.02

and 106.04. 

Asphalt concrete will be evaluated under Section 403. 

Asphalt tack coat will be evaluated under Section 412. 

Excavation and backfill will be evaluated under Section 209. 

Minor concrete will be evaluated under Section 601. 
Section 609

699

Measurement

609.11 Measure the Section 609 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring curb or curb and gutter by the linear foot, do not deduct the length for drainage structures 

installed in the curb section or for driveway and accessibility ramp openings where the gutter is continuous 

across the opening.

Payment

609.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 609 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 609-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Bedding

material

(704.01) 

Measured &

tested for

conformance

(106.04 & 105) 

Gradation − Subsection

704.01

1 per

soil type

& source

of material

Source of

material Yes

Before

using in

work

Not required

if using

Governmentfurnished 

source

Liquid limit −

AASHTO

R 58 & T 89,

Method A

" " " " " 

Production

Bedding

material

(704.01) 

Measured &

tested for

conformance

(106.04) 

Gradation − AASHTO

T 27 & T 11

1 per

600 yd3

Production

output or

stockpile

Yes 4 hours −

Liquid limit −

AASHTO

R 58 & T 89,

Method A

" " " " −
Section 610

701

Section 610. — SIDEWALKS, PADS, AND MEDIANS

Description

610.01 This work consists of constructing sidewalks, pads, and medians. 

Material 

610.02 Conform to the following Subsections: 

Concrete grid paving units 725.09(c)

Elastomeric joint sealant 712.01(a)(4)

Paving brick 725.08

Preformed expansion joint filler for concrete 712.01(b)(1)

Soil and soil-aggregate materials 704.01

Solid concrete interlocking paving units 725.09(f)

Construction Requirements

610.03 General. Excavate and backfill according to Section 209. Place bedding material in lifts no more 

than 4 inches in compacted thickness. Compact each lift with at least three passes of a lightweight 

mechanical tamper, roller, or vibratory system.

610.04 Concrete Sidewalks, Pads, and Medians. Construct minor concrete according to Section 601. 

Use forms extending the full depth of concrete.

(a) Joints. Construct joints perpendicular to the outside slab edges and other joints. Match the joints 

in adjacent curb or pavement. Tool and remove free mortar and concrete from joints.

(1) Expansion joints. Construct at intervals no more than 20 feet. Use 3⁄4-inch thick preformed 

expansion joint filler for the full depth of the joints. If joints are sealed, use elastomeric joint 

sealant.

(2) Contraction joints. Construct at intervals no more than 10 feet. Form joints with a jointing 

tool or saw joints to a depth of 1⁄4 to 1⁄3 the thickness of the concrete and about 1⁄8 inch wide.

(3) Construction joints. Form construction joints around appurtenances (such as manholes, utility 

poles, buildings, and bridges). Use 1⁄2-inch thick preformed expansion joint filler for the full depth 

of the joints. If joints are sealed, use elastomeric joint sealant.

(b) Finishes. Provide a sidewalk finish unless otherwise specified.

(1) Sidewalk finish. Conform to Subsection 552.12(c)(2). 

(2) Exposed aggregate finish. Conform to Subsection 552.12(c)(4). 

Use a 1⁄4-inch radius edging tool on slab edges and joints. Cure the concrete according to 

Subsection 552.13. Protect the work for 72 hours. 
Section 610

702

610.05 Asphalt Concrete Sidewalks, Pads, and Medians. Perform the work according to Section 403, 

Type II. 

610.06 Concrete Paving Unit and Paving Brick Sidewalks, Pads, and Medians. Lay units or bricks in 

successive courses on a prepared surface. Lay each course to grade. Relay courses that deviate from a 

straight line by more than 2 inches in 30 feet.

Sweep and inspect the surface before the bed sets. Remove and replace imperfect units or bricks.

Chock the joints flush with a dry mixture of 4 parts sand and 1 part cement by mass and carefully water 

the surface to saturate the joint filler.

610.07 Acceptance. See Table 610-1 for sampling, testing, and acceptance requirements.

Paving brick, concrete paving units, and joint filler and sealant will be evaluated under Subsections 106.02

and 106.03. 

Construction of sidewalks, pads, and medians will be evaluated under Subsections 106.02 and 106.04. 

Asphalt concrete will be evaluated under Section 403. 

Excavation and backfill will be evaluated under Section 209. 

Minor concrete will be evaluated under Section 601. 

Measurement

610.08 Measure the Section 610 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

610.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 610 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Table 610-1 

Sampling, Testing, and Acceptance Requirements

Material or

Product

(Subsection)

Type of

Acceptance

(Subsection)

Characteristic Category Test Methods

Specifications

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time Remarks

Source

Bedding

material

(704.01) 

Measured &

tested for

conformance

(106.04 & 

105) 

Gradation − Subsection

704.01

1 per

soil type

& 

source of

material

Source of

material Yes

Before

using in

work

Not required

if using

Government

-furnished

source

Liquid limit −

AASHTO

R 58 & T 89,

Method A

" " " " " 

Production

Bedding

material

(704.01) 

Measured &

tested for

conformance

(106.04) 

Gradation – AASHTO

T 27 & T 11

1 per

600 yd3

Production

output or

stockpile

Yes 4 hours – 

Liquid limit – 

AASHTO

R 58 & T 89,

Method A

" " " " – 
Section 611

704

Section 611. — WATER SYSTEMS

Description

611.01 This work consists of constructing or reconstructing water systems. 

Material 

611.02 Conform to the following Subsections:

Seamless copper water tube and fittings 707.16

Smooth wall polyethylene pipe 708.01(b)

Smooth wall polyvinyl chloride (PVC) pipe 708.06(c)

Soil and soil-aggregate materials 704.01

Steel pipe 717.06

Construction Requirements

611.03 General. Conform to the standards of APWA, AWWA, International Building Code and local 

agency plumbing and safety codes.

Obtain permits, arrange for inspections, and pay fees necessary to obtain water service.

Excavate according to Section 209. Place bedding for pipes according to Subsection 209.08. 

Coordinate service interruptions with the user or owner of the waterline. Provide temporary waterlines to 

ensure a water supply is maintained. Connection work may be required during times other than normal 

working hours. Do not stop work on a connection until it is completed.

Dispose of disinfectant for water lines according to Subsection 107.01. Do not allow disinfectant to enter 

a body of water. 

611.04 Backfilling. Backfill according to Subsection 209.09. Place backfill to a depth of 12 inches above 

the top of the pipe using a method that does not damage the pipe. 

611.05 Acceptance. Material for water systems will be evaluated under Subsections 106.02 and 106.03. 

Installation of water systems will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Measurement

611.06 Measure the Section 611 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring waterlines and encasement pipes by the linear foot, measure along the flow line including 

the length through tees, bends, valves, or other fixtures. 
Section 611

705

Payment

611.07 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 611 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for lump sum pay items will be prorated based on the price breakdown and total work 

completed under this Section. 
Section 612

706

Section 612. — SANITARY SEWER SYSTEMS

Description

612.01 This work consists of constructing or reconstructing sanitary sewer systems.

Material 

612.02 Conform to the following Subsections: 

Acrylonitrile-butadiene-styrene (ABS) pipe 708.08

Cast iron soil pipe and fittings 707.15

Detectable warning tape 725.11

Gaskets for plastic pipe 708.09

Precast concrete water and wastewater structures 725.09(e)

Smooth wall polyvinyl chloride (PVC) pipe 708.06(b)

Soil and soil-aggregate materials 704.01

Construction Requirements

612.03 General. Conform to the standards of APWA, AWWA, International Building Code and local 

agency plumbing and safety codes. 

Obtain permits, arrange for inspections, and pay fees necessary to obtain sewerage service.

Excavate according to Section 209. Place bedding for pipes according to Subsection 209.08. 

Coordinate service interruptions with the user or owner of the sewer line. Provide temporary sewer lines 

to ensure a sewer supply is maintained. Connection work may be required during times other than normal 

working hours. Do not stop work on a connection until it is completed. 

Dispose of disinfectant for sewer lines according to Subsection 107.01. Do not allow disinfectant to enter 

a body of water. 

612.04 Laying Sewer Lines. Inspect each joint and clean the pipe and bell before placing in the trench. 

Lay the sewer line from the lower end with the spigot ends pointing in the direction of flow. Fully support 

each length between joints and check for line and grade before placing the next length. 

Check the gasket for proper positioning and shove sewer pipe into proper position where premolded 

watertight gaskets are used. 

Position the pipe and fill the joint completely with joint sealer if poured joints are used. Allow the sealer 

to cool completely before removing the runner. 

612.05 Backfilling. Backfill according to Subsection 209.09. Place backfill to a depth of 12 inches above 

the top of the pipe using a method that does not damage the pipe. Install continuous underground 

detectable warning tape during backfilling of trench for underground sewer-distribution piping. Locate 

below finished grade, directly over piping. Flush the lines with water to ensure they are unobstructed after 

backfilling. 
Section 612

707

Provide acid- and alkali-resistant, polyethylene film warning tape manufactured for marking and 

identifying underground utilities, at least 6 inches wide and 4 mils thick, continuously inscribed with a 

description of the utility, with metallic core encased in a protective jacket for corrosion protection, 

detectable by metal detector if tape is buried up to 30 inches deep; colored to comply with local practice 

or requirements of authorities having jurisdiction.

612.06 Acceptance. Material for sanitary sewer systems will be evaluated under Subsections 106.02 and 

106.03. 

Installation of sanitary sewer systems will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Measurement

612.07 Measure the Section 612 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring sewer lines by the linear foot, measure along the flow line including the length through 

valves, ells, tees, valve boxes, reducers, manholes, or other fixtures. Where two different sizes enter or 

exit a manhole, measure each size to the center of the manhole.

Payment

612.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 612 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for lump sum pay items will be prorated based on the price breakdown and total work 

completed under this Section. 
Section 613

708

Section 613. — SIMULATED STONE MASONRY SURFACE

Description

613.01 This work consists of constructing simulated stone masonry surfaces using concrete, staining, and 

grouting to simulate the texture and color of native stone masonry in a stone pattern. 

Material 

613.02 Conform to the following Subsections: 

Neat hydraulic cement grout 701.04(a)(2)

Penetrating stain for concrete 719.05

Preformed expansion joint fillers 712.01(b)

Construction Requirements

613.03 Form Liner Fabrication. Take an impression of the stone shape, texture, and mortar joints from 

a designated location. Design form liners from the impressions according to the stone pattern shown in 

the plans. Submit detailed drawings of the form liner according to Subsection 104.06. 

613.04 Test Wall. Before production work on the simulated stone masonry, construct a 36-inch-high by 

24-inch-wide by 10-foot-long test wall according to Section 552 and this Section. 

Cast the test wall on site using the same forming methods, procedures, form liner, texture configuration, 

expansion joint, concrete mixture, and stain application proposed for the production work. Demonstrate 

the quality and consistency of joint treatment, end treatment, top embossing methods, back treatment, and 

stain application on the test wall. If a test wall is rejected, construct a new test wall.

Start production structural concrete work after the test wall is approved. Start production stain application 

after the stain application on the test wall is approved. Dispose of the test wall after use.

613.05 Form Liner Installation. Provide a form liner that attaches easily to the forming system. Install 

the form liner so it does not compress more than 1⁄4 inch during the concrete pour. 

Attach the form liners to the form. Attach adjacent form liners to each other with less than a 1⁄8-inch seam. 

Do not repeat the form liner pattern between expansion joints or within 20-foot intervals, whichever is 

greater.

Form expansion joints at the intervals shown in the plans. Blend the butt joints into the pattern and the 

final concrete surface.

Coordinate the forms with wall ties. Place form tie holes in the high point of rustication or in the mortar 

joint.

Clean off build-up before reusing form liners. Visually inspect each liner for blemishes and tears. Repair 

the liner before installation. 
Section 613

709

613.06 Top Surface. Emboss the plastic concrete in the exposed top surface by stamping, tooling, 

troweling, hand shaping, or a combination thereof, to simulate the stone masonry texture and mortared 

joints. Match the side pattern of the formed mortared joints. After the free surface water evaporates and 

the finish embossing is complete, cure the concrete for 7 days according to Subsection 552.13(b). Do not 

use liquid membrane curing compounds. 

613.07 Form Liner Removal. Within 24 hours after placing concrete, remove or break free the form 

liners without causing concrete surface deterioration or weakness in the substratum. Remove form tie 

material to a depth of at least 1 inch below the concrete face without spalling and damaging the concrete. 

613.08 Preparation of Concrete Surface. Finish exposed formed concrete surfaces according to 

Subsection 552.14(b). Finish so that vertical seams, horizontal seams, and butt joint marks are not visible. 

Minimize grinding and chipping to avoid exposing aggregate. 

Provide a completed surface free of blemishes, discolorations, surface voids, and conspicuous form marks. 

Make the finished texture and patterns continuous without visual disruption. 

613.09 Stain Application. Age concrete, including patches, at least 30 days. Clean the surface of latency, 

dirt, dust, grease, and foreign material by approved methods. 

Remove efflorescence with a pressure water wash. Do not sand blast surfaces that receive stain.

Correct surface irregularities created by the surface cleaning.

Maintain the concrete temperature between 40 and 85 °F when applying stain and for 48 hours after 

applying stain. 

Stain exposed concrete surfaces. Use a stain application suitable to obtain the appearance of the native 

stone masonry. Use at least 3 colors of stains.

Provide protection and avoid over-spray and color overlap at boundaries between two color tones or 

between surfaces receiving color at different times.

Apply grout of a natural cement color to each form joint. Use sufficient grout so the over-spray of the 

stain is not visible. Give the form pattern grout joint the appearance of mortared joints in completed 

masonry. 

Recoat areas inconsistent with the approved test wall.

Treat expansion joints with caulk, grout, or both to blend with the appearance of the adjacent stone or 

mortar joint.

613.10 Acceptance. Material for simulated stone masonry surface treatment will be evaluated under 

Subsections 106.02 and 106.03. 

Installation of form liners will be evaluated under Subsections 106.02 and 106.04. 

Application of stain to exposed concrete surfaces will be evaluated under Subsection 106.02. 

Construction of the simulated stone masonry test wall will be evaluated under Subsection 106.02. 
Section 613

710

Construction of simulated stone masonry surfaces will be evaluated under Subsections 106.02 and 106.04. 

Measurement

613.11 Measure the Section 613 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

613.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 613 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 614

711

Section 614. — FLOWABLE BACKFILL

Description

614.01 This work consists of constructing flowable backfill of controlled low strength material.

Material 

614.02 Conform to the following Subsections: 

Chemical admixtures 711.03

Flowable backfill aggregate 703.15

Hydraulic cement 701.01

Pozzolans 701.03

Water for cementitious materials 725.01(a)

Construction Requirements

614.03 Composition of Mix. Design a well-graded, flowable, self-leveling mix. Design a mix with a 

7-day compressive strength between 75 and 250 pounds per square inch according to ASTM D4832. 

Verify the mix design with trial batches prepared from the same sources proposed for the mix. Submit the 

following for approval at least 21 days before production: 

(a) Type and source of aggregates; 

(b) Type and source of cement; 

(c) Type and source of pozzolans, if used in the mix; 

(d) Type and supplier of admixtures, if used in the mix;

(e) Mix proportions; 

(f) Commercial certifications for each material contained in the mix;

(g) Target values for water to cementitious material ratio and slump; and

(h) Compressive strength at 7 days. 

614.04 General. Excavate and backfill according to Section 209. 

Do not place flowable backfill in contact with aluminum or aluminum-coated structures.

Do not use flowable backfill above the top of subgrade. 

614.05 Mixing and Placing Flowable Backfill. Mix flowable backfill by pugmill, rotary drum, or other 

approved mixer to obtain a uniform mix. 

Place flowable backfill in a uniform manner that prevents voids or segregation in the backfill. 
Section 614

712

Maintain the temperature of flowable backfill to at least 50 °F at the time of placement. Protect the material 

from freezing for 24 hours after placement.

If backfilling around culverts and other structures, place flowable backfill so that the structure does not 

float or shift. Bring the backfill up evenly on all sides of the structure. Maintain correct alignment of 

structures by use of straps, soil anchors, or other approved methods of restraint.

If placing flowable backfill at or below an ambient temperature of 35 °F, perform the work according to 

Subsection 552.07(a). 

Wait at least 4 hours before backfilling over flowable backfill. 

614.06 Acceptance. Material for flowable backfill will be evaluated under Subsections 106.02

and 106.03, and 106.04 if tested for compressive strength according to ASTM D4832. 

Construction of flowable backfill will be evaluated under Subsection 106.02. 

Excavation and backfill will be evaluated under Section 209. 

Measurement

614.07 Measure the Section 614 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring flowable backfill by the cubic yard, measure in the hauling vehicle. 

Payment

614.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 614 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 615

713

Section 615. — RESERVED
Section 616

714

Section 616. — SLOPE PAVING

Description

616.01 This work consists of constructing slope paving. 

Material 

616.02 Conform to the following Section and Subsections: 

Concrete masonry units 725.07

General mortar 701.05(a)

Geosynthetic material 714

Non-shrink grout 701.04(b)(1)

Paving brick 725.08

Sand 703.14

Solid concrete interlocking paving units 725.09(f)

Rock for Masonry Structures 705.03 

Topsoil 713.01

Welded deformed steel wire reinforcement 709.01(j)

Construction Requirements

616.03 General. Excavate and backfill according to Section 209. Place and compact a sand lift with at 

least three passes of a lightweight mechanical tamper, roller, or vibratory system.

If shown in the plans, place geosynthetic material according to Subsection 207.04. Bury the ends of the 

geosynthetic material for anchorage. Pin the strips at 5-foot intervals to hold the geosynthetic material lap 

in place until slope paving is placed. 

616.04 Concrete Slope Paving. Construct toe walls. Place welded deformed steel wire reinforcement at 

the center of the slab. Run the wire fabric continuously through the joints. Lap adjacent runs of wire fabric 

by at least 6 inches.

Construct minor concrete according to Section 601. Place slabs starting at the bottom of the slope. 

Construct horizontal joints parallel to the bottom of the slope and the vertical joints perpendicular to the 

horizontal joints. Construct cold joints without filler.

Finish the surface according to Subsection 552.12(c)(2). Use a 1⁄4-inch radius edging tool on slab edges 

and joints. 

616.05 Stone Masonry Paving. Perform stone masonry paving work according to Section 620. Start 

placing masonry block or rubble at the bottom of the slope. Place paving material on the sand lift with the 

flat face up and the longest dimension parallel to the bottom of the slope. Ram the masonry block or rubble 

into place. 

Apply sufficient mortar on the exposed side to produce masonry block joints up to 1⁄2 inch wide and rubble 

joints up to 1 inch wide. Ram the masonry block or rubble into place so the mortar is within 1⁄2 inch of the 

surface. Do not allow mortar to protrude above the surface. Clean mortar stain from the surface.
Section 616

715

616.06 Slope Paving with Concrete Masonry Units, Paving Brick, and Solid Concrete Interlocking 

Paving Units. Start placing units and bricks in a trench or against a suitable anchorage at the bottom of 

the slope. Lay each unit or brick on the slope and bed it firmly against adjoining blocks. Use non-shrink 

grout to fill misaligned joints or breaks at slope changes. Do not grout individual blocks to each other. 

If using units or bricks with open cells, place topsoil loosely inside the cells, filling the cell openings. Do 

not place topsoil when the ground or topsoil is frozen, excessively wet, or in a condition detrimental to 

the work. Remove and dispose of clods and stones larger than 2 inches, stumps, roots, and other litter 

according to Subsections 203.05 and 203.07. If shown in the plans, establish turf according to Section 625. 

616.07 Acceptance. Concrete masonry units, geosynthetic materials, non-shrink grout, mortar, paving 

brick, sand, solid concrete interlocking paving units, topsoil, and welded steel wire fabric will be evaluated 

under Subsections 106.02 and 106.03. 

Slope paving construction will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Minor concrete will be evaluated under Section 601. 

Stone masonry will be evaluated under Section 620. 

Turf establishment will be evaluated under Section 625. 

Measurement

616.08 Measure the Section 616 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

616.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 616 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 617

716

Section 617. — GUARDRAIL

Description

617.01 This work consists of constructing or modifying guardrail systems. This work also consists of 

removing, resetting, and raising guardrail systems. 

Types and classes of metal beam guardrail are designated according to AASHTO M 180. 

Material 

617.02 Conform to the following Section: 

Guardrail 724

Construction Requirements

617.03 Qualifications. At least 14 days before starting guardrail work, submit one of the following for 

the guardrail supervisor: 

(a) Résumé describing at least 3 years’ experience in guardrail installation;

(b) A certificate showing successful completion of the ATSSA Guardrail Installation Training; or

(c) A certificate showing successful completion of a state department of transportation guardrail 

installation training course.

617.04 General. Provide guardrail systems and terminals that are crashworthy.

If proprietary systems, terminals, or crash cushions are required, install according to the manufacturer’s 

recommendations. Submit the installation manual, completed inspection checklists, and drawings from 

the manufacturer according to Subsection 104.06. 

Construct minor concrete according to Section 601. 

617.05 Post Installation. Complete adjacent earthwork, aggregate placement and other roadway surfaces 

to line and grade as applicable before installation of guardrail posts.

Do not damage adjacent pavement, subsurface utilities, or drainage features during post installation. 

Posts may be installed by either drilling or driving. Ensure posts installed by drilling have sufficiently 

sized holes to allow thorough compaction of backfill around each post. Backfill post holes in 6-inch lifts 

with approved material. Tamp and compact each lift. Replace posts damaged during driving operations. 

Install the posts plumb and at the location, spacing, and elevation as shown in the plans. If a post cannot 

be placed at its normal location due to a non-removable obstruction, an additional blockout may be added 

as approved. If the post cannot be offset with the addition of a blockout, the following options are allowed 

as approved: the post-in-rock detail, the long span detail, or the omission of a post as shown in the plans. 
Section 617

717

Use post lengths shown in the plans. Do not change the post lengths or spacings in terminals or structure 

transitions.

Treat field cuts for wood posts with two coats of preservative. Do not place field cuts in contact with the 

ground. 

617.06 Rail Element Installation. Do not modify specified hole diameters or slot dimensions. 

(a) Steel rail. Shop bend curved guardrail with a radius of 150 feet or less.

Install rail elements in a smooth continuous line with the laps in the direction of traffic flow. Use bolts 

that extend at least 1⁄4 inch, but no more than 1 inch beyond the nuts. 

Coat scrapes on galvanized surfaces that expose the base metal with two coats of zinc-oxide coating 

material.

(b) Steel-backed timber and log rail. Treat field cuts with two coats of preservative.

617.07 Terminal Systems, Anchorage Systems, and Structure Transitions. Do not connect the 

guardrail to cast-in-place anchors until the concrete has cured 7 days. Install end anchor cables without 

slack.

617.08 Guardrail Construction Exposed to Traffic. If a roadway is open to traffic during construction, 

complete guardrail installations within 5 days from the day the structure, pavement, shoulder, or 

whichever is the controlling item of work is sufficiently completed to allow guardrail installation. In areas 

where guardrail construction is not restricted by other construction, complete removal of existing guardrail 

and construct new guardrail within 48 hours of starting work. 

Delineate unfinished sections of guardrail installation or follow an approved method of protecting traffic 

from the unfinished guardrail elements.

Schedule guardrail installation so work is finished before work suspension or other extended periods of 

time.

617.09 Removing and Resetting Guardrail. Salvage the existing rail elements, posts, and appurtenances

according to Subsection 203.04. Do not salvage posts that are set in concrete. Remove and dispose of 

material not used in resetting guardrail according to Subsections 203.05 and 203.07. 

Backfill holes resulting from the removal of guardrail posts and anchors with approved material. Reset 

guardrail to the height shown in the plans. Replace guardrail, posts, and hardware damaged during 

removal, storage, or resetting. 

617.10 Raising Guardrail. Salvage the existing rail elements and appurtenances according to 

Subsection 203.04. Dispose of damaged material according to Subsection 203.07. 

Replace or reset posts as needed. Backfill holes resulting from the removal or raising of guardrail posts 

and anchors with approved material. Raise guardrail to the height shown in the plans. Replace rail 

elements, posts, and hardware damaged during the removal and raising. 
Section 617

718

617.11 Acceptance. Material for guardrail will be evaluated under Subsections 106.02 and 106.03. 

Construction of guardrail will be evaluated under Subsections 106.02 and 106.04. 

Minor concrete will be evaluated under Section 601. 

Measurement

617.12 Measure the Section 617 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Measure removing and resetting guardrail and raising guardrail including reset terminal sections.

Measure replacement posts (except replacement posts for posts damaged by construction operations) used 

in raising guardrail or removing and resetting guardrail. 

Payment

617.13 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 617 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 618

719

Section 618. — CONCRETE BARRIERS

Description

618.01 This work consists of constructing concrete barrier systems. This work also consists of removing 

and resetting concrete barrier systems.

Material 

618.02 Conform to the following Subsections: 

Backer rod 712.01(f)

Guardrail hardware 724.04

Joint sealants and crack fillers 712.01(a)

Precast concrete units and accessories 725.09

Preformed expansion joint fillers 712.01(b)

Reinforcing steel 709.01

Construction Requirements

618.03 General. Excavate and backfill according to Section 209. 

Construct barriers that are crashworthy. 

Construct temporary terminal sections and crash cushions according to Section 635. 

618.04 Concrete Barriers. Concrete barriers may be cast-in-place, slip-formed, or precast according to 

Section 552 or Section 578. Finish the sides and top according to Subsection 552.14(a). 

(a) Cast-in-place. Tool or saw cut contraction joints 1⁄4 inch wide and 2 inches deep at 20-foot 

intervals. Saw cut after the concrete has set sufficiently, but before shrinkage cracking occurs. 

Decrease the depth of the saw cut at the edge adjacent to the pavement to prevent pavement damage.

Place 3⁄4-inch preformed expansion joint filler in construction joints. Cut the joint filler to fit the 

cross-sectional area at structures and barrier construction joints. Tool construction joint edges. Seal 

joints according to Subsection 501.11. 

(b) Slip-formed. Do not contact extruded concrete surface as it leaves the slip-form machine, except 

to remove offsets and fins by light troweling.

Adjust the operation to correct conditions causing surface blemishes larger than 1⁄2 inch. Do not use 

water on the completed barrier to correct imperfections.

(c) Precast. Precast barriers in section lengths. Prepare the barrier foundation so it does not vary over 

1⁄4 inch when a 10-foot metal straightedge is laid along the centerline of the barrier. Align the joints 

and connect adjacent sections.
Section 618

720

Use cast-in-place barrier where transitions, split barriers, or gaps shorter than 10 feet require it. At 

each joint between precast and cast-in-place barrier, provide hardware in the cast-in-place section to 

tie its end to the abutting precast section.

618.05 Removing and Resetting. Salvage the existing concrete barrier, terminal sections, and 

appurtenances according to Subsection 203.04. Reset concrete barrier and terminal sections according to 

Subsections 618.03 and 618.04. Replace concrete barrier, terminal sections, and hardware damaged during 

removal, storage, or resetting.

618.06 Acceptance. Material for concrete barrier (except concrete and reinforcing steel) will be evaluated 

under Subsections 106.02 and 106.03. 

Construction of concrete barriers will be evaluated under Subsections 106.02 and 106.04. 

Concrete will be evaluated under Section 552. 

Excavation and backfill will be evaluated under Section 209. 

Reinforcing steel will be evaluated under Section 554. 

Temporary terminal sections and crash cushions will be evaluated under Section 635. 

Measurement

618.07 Measure the Section 618 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Measure concrete barrier excluding terminal sections.

Measure reset concrete barrier in the relocated position including terminal sections.

Payment

618.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 618 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 619

721

Section 619. — FENCES, GATES, CATTLE GUARDS, AND BOLLARDS

Description

619.01 This work consists of constructing, and removing and resetting fences, gates, cattle guards, and 

bollards. 

Material 

619.02 Conform to the following Section and Subsection:

Fencing and mesh fabrics 710

Neat hydraulic cement grout 701.04(a)(2)

Construction Requirements

619.03 General. Clear along the fence line. Remove and dispose of trees, brush, logs, upturned stumps, 

roots of downed trees, rubbish, and debris according to Subsections 203.05 and 203.07. 

Grubbing is not required, except where short and abrupt changes in the ground contour require removal 

of stumps to properly grade the fence line. Remove or cut stumps according to Subsection 201.04(b). 

Perform clearing and leveling with minimum disturbance to the terrain outside the fence line.

Schedule the fence installation, provide temporary fence, or other adequate means to prevent traffic (such 

as pedestrian, livestock, and vehicular) from entering the project right-of-way, easements, or adjoining 

properties. 

At bridges, cattle underpasses, and culverts, connect new fence to structure to allow free passage of 

livestock under or through the structure. 

Construct cast-in-place concrete according to Section 601, where required. 

Construct precast concrete according to Section 578, where required. 

619.04 Fences and Gates. 

(a) Chain link fence and gates.

(1) Posts. Space posts at no more than 10-foot intervals. Measure the post spacing interval 

horizontally. Set posts vertically.

Where solid rock is encountered without overburden, drill line post holes at least 14 inches deep. 

Drill end, corner, gate, and pull posts at least 20 inches deep in the solid rock. Make the hole width 

or diameter at least 1 inch greater than the post width or diameter. Cut the post to the required 

length before installation or drill the hole deep enough to set the post at the required height. Set 

and plumb the post and fill the hole with grout. Thoroughly work the neat hydraulic cement grout 

into the hole to eliminate voids. Crown the grout to drain water away from the post.
Section 619

722

Where solid rock is covered with soil or loose rock overburden, set posts to the plan depth or to 

the minimum depth into the solid rock as specified above, whichever is less. If solid rock is 

encountered before the plan depth, grout the portion of the post in solid rock and backfill the post 

hole from the solid rock to the top of the ground with concrete.

Provide end, gate, corner, and pull posts with adjacent brace posts as shown in the plans. A change 

in the fence alignment of 20 degrees or more is considered a corner.

(2) Top rail. Install top rails through the loop caps of the line posts, forming a continuous brace 

from end-to-end of each stretch of fence. Join lengths of top rail with sleeve-type couplings. 

Securely fasten top rails to terminal posts by pressed steel fittings or other approved means.

(3) Tension wire. Attach tension wire to end, gate, corner, or pull posts by bands and clamps. 

Thread the top tension wire through the line post loop caps or hold in open slots to limit vertical 

movement. Tie or attach the bottom tension wire to the bottom of the line posts by ties or clamps 

to prevent vertical movement. Apply sufficient tension to avoid excess sag between posts. On the 

top tension wire, provide one turnbuckle or ratchet take-up in each run of fence. 

(4) Fence fabric. For fences placed on the right-of-way, place fence fabric on the post face away 

from the highway. On curved alignment, place the fence fabric on the post face on the outside of 

the curve. For residential fences and fences off the right-of-way, place fence fabric on the post face 

designated by the CO. 

Place the fabric approximately 1 inch above the ground and on a straight line between posts. 

Excavate high points of the ground to maintain grade. Do not fill in depressions without prior 

approval. 

Stretch the fabric taut and securely fasten the fabric to the posts. Do not stretch using a motor 

vehicle. Use stretcher bars and fabric bands to fasten to end, gate, corner, and pull posts or weave 

the fabric into the fastening loops of roll-formed posts. 

Fasten fabric to line posts using wire ties, metal bands, or other approved method. Fasten the top 

and bottom edge of the fabric with tie wires or hog rings to the top rail or tension wires as 

applicable. 

Join rolls of fabric by weaving a single strand into the ends of the rolls to form a continuous mesh.

(b) Gates. Fasten fabric to the end bars of the gate frame by stretcher bars and fabric bands. Fasten 

fabric to the top and bottom bars of the gate frame by tie wires similar to the method specified for 

fence fabric or by other approved standard methods. 

Thoroughly clean welded connections on gate frames where the smelter coating has been burned with 

a wire brush. Remove traces of the welding flux and loose or cracked smelter. Coat the cleaned areas 

with two coats of zinc-oxide coating material according to Section 563. 

Provide a concrete footing for the drop-bar locking device on double metal gates. Make a hole to 

receive the locking bar to the depth specified by the manufacturer of the locking device. 

Hinge each single gate to prevent removal of the gate without tools. Set the gate in an approximately 

horizontal plane. Set the gate so it swings freely inward and outward and fastens securely in its latch 
Section 619

723

holder, or in the case of double gates, in its latch holder and gate stops. Set double gates on their 

respective hinge pintles to provide a common horizontal plane in which each single gate swings. Set 

gates to swing open at least 90 degrees in each direction.

(c) Wire fences and gates.

(1) Posts. Excavate holes for posts, footings, and anchors as shown in the plans. Space posts at 

intervals shown for the type of fence being installed. Measure post spacing interval parallel to the 

existing ground slope. Set posts in a vertical position. Backfill post holes in 6-inch lifts. Tamp and 

compact each lift.

Wood posts may be driven in place if the method of driving does not damage the post. Metal posts 

may be driven. Set metal corner, gate, end, and pull posts in concrete. 

Where solid rock is encountered without overburden, drill line post holes at least 14 inches deep 

and end, corner, gate, and pull posts at least 20 inches deep in the solid rock. Make the hole width 

or diameter at least 1 inch greater than the post width or diameter. Cut the post to the required 

length before installation or drill the hole deep enough to set the post at the required height. Set 

and plumb the post and fill the hole with grout. Thoroughly work the grout into the hole to 

eliminate voids. Crown the grout to drain water away from the post. Metal posts set in this manner 

do not require anchor plates and concrete footings.

Where solid rock is covered with soil or loose rock overburden, set posts to the plan depth or to 

the minimum depth into the solid rock as specified above, whichever is less. If the depth of 

overburden is greater than 12 inches, use an anchor plate on steel line posts and backfill steel end, 

corner, gate, and pull posts with concrete from the solid rock to top of the ground. If the depth of 

overburden is 12 inches or less, anchor plates and concrete backfill are not required. Grout the 

portion of the post in solid rock. 

Install corner posts at changes in alignment of 30 degrees or more. Where new fence joins an 

existing fence, set end or corner posts and attach as approved. 

(2) Braces. Limit fence runs to no more than 650 feet between adjacent corner braces, gate braces, 

end braces, or line braces. Install line braces at uniform intervals so the distance between any two 

braces is 650 feet or less. Construct braces before placing the fence fabric and wires on posts.

(a) Metal braces. Provide corner posts and pull posts with two braces, one each direction from 

the post in the main fence line. Provide end posts and gate posts with one brace in the line of 

the fence. Attach metal braces to the metal end, corner, pull, and gate posts as shown in the 

plans. 

(b) Wood braces. Tap the posts to receive the braces. Anchor the brace to the post with three 

16d nails or a 3⁄8- by 4-inch dowel. Install brace wires as shown and twist together until the 

entire assembly is taut and firm. Lightly notch the posts to position the brace wire. Drive three 

staples at each notch to secure wire.

(3) Barbed wire, smooth wire, and woven wire. Place barbed wire, smooth wire, and woven 

wire on the side of the post facing away from the highway. On curved alignment, place the barbed 

wire, smooth wire, and the woven wire on the post face on the outside of the curve. Tightly stretch 

and fasten barbed wire, smooth wire, and woven wire to the posts. 
Section 619

724

Apply tension according to the manufacturer’s recommendations using a mechanical stretcher or 

other device designed for such use. Evenly distribute the pull over the longitudinal wires in the 

woven wire so no more than 50 percent of the original depth of the tension curves is removed. Do 

not use a motor vehicle to stretch the wire.

Splicing of barbed wire, smooth wire, and woven wire between posts is allowed provided no more 

than two splices, spaced at least 50 feet apart, occur in a run of fence. Use wrap or telephone type 

splices for the longitudinal woven wire and barbed and smooth wire with each end wrapped around 

the other wire for at least six complete turns.

(4) Fastening barbed wire, smooth wire, and woven wire. End the woven wire, smooth wire, 

and barbed wire at each end, corner, gate, and pull post. Wrap each line of barbed wire, smooth 

wire, and each longitudinal wire of the woven wire around the post and then itself with at least 

four turns. Where wood posts are used, staple the wires tightly to the posts.

At line posts, fasten the woven wire to the post at top and bottom and at intermediate points no 

more than 12 inches apart. Fasten each strand of barbed wire and smooth wire to each line post. 

Use wire ties or clamps to fasten the wires to metal posts. Securely splice tie wires to the fence on 

both sides of the post so there are two loops behind the post and one loop in front. On wood line 

posts, drive U-shaped staples diagonally across the wood grain so that both points do not enter 

between the same grain. In depressions where wire uplift occurs, drive staples with points slightly 

upward. On level ground and over knolls, slope the points slightly downward. Drive the staples 

just short of actual contact with the wires to allow free longitudinal movement of those lines and 

to prevent damage to the protective coating. 

At grade depressions, alignment angles, and other locations where stresses tending to pull posts 

from the ground or out of alignment are created, snub or guy the wire fence. Attach the guy wire 

to each strand of barbed wire and smooth wire, and to the top and bottom wires of woven wire to 

maintain the entire fence in its normal shape. Attach the guy wire to a deadman anchor buried no 

more than 24 inches in the ground or to an approved anchor at a point that best serves to resist the 

pull of the wire fence. If necessary to guy the fence in solid rock, grout the guy wire in a hole 

2 inches in diameter and 10 inches deep. Deadman may also be fastened to posts. Place the 

deadman anchors at locations as directed.

Where required, install vertical cinch stays as shown in the plans. Twist the wire to allow weaving 

into the horizontal fence wires to provide rigid spacing. Weave barbed wires and smooth wires 

and the top, middle, and bottom wire of the woven wire as applicable, into the cinch stay. 

Where existing fence intersects the new fence, cut the existing fence material or, splice in kind 

new material as necessary, and fasten each longitudinal wire of the woven wire and each strand of 

the barbed wire and smooth wire to a new end post in line with or immediately adjacent to the new 

fence line.

(5) Gates. 

(a) Wire gates. Construct wire gates of the same material as the fence and as shown. Provide 

a taut and well-aligned closure of the opening, that can be readily opened and closed by hand. 

(b) Metal gates. Install metal gates and fittings to gate posts previously set. Firmly attach the 

fittings to the posts and gates. Hinge each single gate to prevent removal of the gate without 
Section 619

725

tools. Set the gate in a horizontal plane. Set the gate so it swings freely inward and outward 

and fastens securely in its latch holder, or in the case of double gates, in its latch holder and 

gate stops. Set double gates and their respective pintles to provide a common horizontal plane 

in which each single gate swings. Set gates to swing open at least 90 degrees in each direction. 

For double gates, provide a drop-bar locking device with a concrete footing 12 inches in 

diameter and 12 inches deep. Crown the top of the footing and make a hole to receive the 

locking bar. Make the diameter and depth of the hole in the footing as specified by the 

manufacturer of the locking device. 

(c) Wood gates. Install wood gates similar to metal gates and as shown in the plans.

619.05 Grounding Fences. Where an electric line crosses the fence line, ground the fence. Drive an 8-foot 

long, 1⁄2-inch minimum diameter galvanized steel rod into the ground under the fence directly below the 

point of crossing. Drive the rod vertically until the top is 6 inches below the ground surface. Connect the 

grounding rod to each fence element with a 1⁄4-inch diameter solid copper conductor or equivalent. Either 

braze the connections or fasten with noncorrosive clamps.

Where an electric line runs parallel or nearly parallel to and above the fence, ground the fence at each end 

or gate post or at intervals no more than 1600 feet.

Where vertical penetration of the grounding rod cannot be accomplished, use an equivalent horizontal 

grounding system. 

619.06 Remove and Reset Fence and Gate. Salvage the existing fence and gate according to 

Subsection 203.04. If posts are set in concrete, remove concrete from old post and reset in new concrete. 

Replace fence and gate material damaged beyond reuse. 

Reset to approximately the same condition as the original. Firmly reset posts on new alignment. Space 

posts and attach the horizontal members or wires to posts the same as the original fence and gate. Provide 

and use new material to fasten members or wires to posts.

619.07 Temporary Fence. If necessary, construct temporary fence to keep traffic (such as pedestrian, 

livestock, and vehicular) off the project. Maintain the temporary fence during construction of the project 

or until the fence is directed to be removed. Dispose of temporary fence according to Subsection 203.07. 

619.08 Cattle Guards. 

(a) Excavating and backfilling. Excavate and backfill according to Section 209. Excavate foundation 

to depth with sufficient space for proper installation of formwork. 

If the cattle guard is to be installed on new embankment, construct the embankment according to 

Section 204 before excavating for the footing. 

(b) Concrete foundation. Concrete cattle guard foundations may be cast-in-place or precast. If 

placing cattle guard in cast-in-place concrete, set cattle guard units in the foundation concrete before 

it hardens. 

Finish stringer bearings to allow full bearing under each stringer. Firmly seat cattle guard on the 

concrete to prevent rocking.
Section 619

726

(c) Cattle guard. Provide cattle guards with HS-20 loading rating according to AASHTO, LRFD

Bridge Design Specifications. Provide suitable cleanouts. Submit drawings according to 

Subsection 104.06. 

Fabricate cattle guards according to Section 555. Assemble and place cattle guards as shown in the 

plans. Securely fasten the cattle guard to the foundation. Fasten the metal wings as shown in the plans. 

Connect fences and gates as shown in the plans. Weld according to AASHTO/AWS, Bridge Welding 

Code D1.5 (D1.5M). 

(d) Coating. Coat according to Section 563. Apply one shop coat to metal parts. Apply two additional 

coats in either the shop or in the field. 

619.09 Bollards. Drill holes for bollards. Set posts plumb, backfill with approved material, and compact.

619.10 Acceptance. Material for fences, gates, cattle guards, and bollards will be evaluated under 

Subsections 106.02 and 106.03. 

Construction of fences, gates, cattle guards, and bollards will be evaluated under Subsections 106.02 and 

106.04. 

Coatings will be evaluated under Section 563. 

Embankment for cattle guard will be evaluated under Section 204.

Excavation and backfill will be evaluated under Section 209. 

Minor concrete will be evaluated under Section 601. 

Precast elements will be evaluated under Section 578.

Steel structures will be evaluated under Section 555. 

Measurement

619.11 Measure the Section 619 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

619.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 619 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 620

727

Section 620. — STONE MASONRY

Description

620.01 This work consists of constructing or rehabilitating stone masonry structures and the stone masonry 

portions of composite structures. 

620.02 Definitions. 

(a) Dimensioned masonry. Stones are cut in two or more dimensions and laid in a broken-course 

pattern in mortar.

(b) Class A masonry. Stones are shaped, dressed to within 1⁄4 inch of true line, and laid in mortar. 

(c) Class B masonry. Stones are shaped, dressed to within 3⁄4 inch of true line, and laid in mortar. 

(d) Rubble masonry. Stones vary in size and shape, are roughly dressed, and laid in random courses 

in mortar.

Material 

620.03 Conform to the following Subsections:

General mortar 701.05(a)

Neat hydraulic cement grout 701.04(a)(2)

Preformed expansion joint fillers 712.01(b)

Reinforcing steel 709.01

Rock for masonry structures 705.03

Construction Requirements

620.04 General. Submit stone samples for approval representing the range of colors and sizes to be used 

14 days before starting work. When no dimensions are shown in the plans, provide the rocks in the sizes 

and face areas necessary to produce the general characteristics and appearance shown in the plans.

Keep an adequate inventory of stone on the site to provide a variety of stones. Mix new stone with existing 

stone to produce a uniform pattern and color. 

Do not use rock with depressions or projections that might weaken it or prevent it from being properly 

bedded. 

Excavate and backfill according to Section 209. 

Construct minor concrete according to Section 601. 

620.05 Dressing Rock. Remove thin or weak portions of rock. Dress face rock bed and joint lines to a 

maximum variation from true line as shown in Table 620-1. 
Section 620

728

Table 620-1 

Maximum Variation from True Line

Class Distance

Dimensioned Reasonably true

Class A 1⁄4 in

Class B 3⁄4 in

Rubble 11⁄2 in

(a) Bed surfaces. Dress face rock bed surfaces normal to the face to a depth of 3 inches. Beyond that 

point, do not exceed 1 inch departure from normal per 12 inches for dimensioned masonry or 2 inches 

departure from normal per 12 inches for other classes.

(b) Joint surfaces. For dimensioned masonry, dress face rock joint surfaces normal to the bed surface. 

For other classes of masonry, dress face rock joint surfaces to form an angle with the bed surface of at 

least 45 degrees.

Dress face rock joint surfaces normal to the face to a depth of 2 inches. Beyond that point, do not 

exceed 1 inch departure from normal per 12 inches.

Do not round corners at the meeting of the bed and joint lines more than the radii shown in Table 620-2. 

Table 620-2 

Masonry Rock Rounding

Class Radius

Dimensioned No rounding

Class A No rounding

Class B 1 in maximum

Rubble 11⁄2 in maximum

(c) Arch ring rock joint surfaces. Dress ring rock joint surfaces radial to the arch or normal to the 

front face to a depth of 3 inches. Beyond that point, do not exceed 3⁄4 inch departure from the radial or 

normal per 12 inches.

Dress the back surface adjacent to the arch barrel concrete parallel to the front face and normal to the 

intrados to a depth of 6 inches. If concrete is placed after the masonry is constructed, vary adjacent 

ring stones at least 6 inches in depth.

(d) Finish for exposed faces. Remove drill or quarry marks from exposed faces. Pitch face stones to 

the line along beds and joints. Finish the exposed faces as shown in the plans.

(1) Fine pointed. Make point depressions approximately 3⁄8 inch apart. Limit surface variations to 

no more than 1⁄8 inch from the pitch line.

(2) Medium pointed. Make point depressions approximately 5⁄8 inch apart. Limit surface 

variations to no more than 1⁄4 inch from the pitch line.

(3) Coarse pointed. Make point depressions approximately 11⁄8 inches apart. Limit surface 

variations to no more than 3⁄8 inch from the pitch line. 

(4) Split or seam face. Provide a smooth appearance, without tool marks, depressions below the 

pitch line, or projections exceeding 3⁄4 inch beyond the pitch line. 
Section 620

729

(5) Rock faced. Provide an irregular projecting surface without tool marks, concave surfaces 

below the pitch line, and projections beyond the specified pitch line. For example, the specification 

"1.50 R.F." means no projections 11⁄2 inches beyond the pitch line. Where a variable rock face is 

specified, uniformly distribute stones of the same height of projection. 

620.06 Placing Stone. Do not place stone masonry when the ambient temperature is below 32 °F.

Clean stones and moisten before placing. Use hand tools to clean the exposed faces of the stones of mortar 

if removing and resetting stone masonry. Clean and moisten the bed. Clean the bearing surface and 

moisten before spreading the mortar bed on footings. 

Level the cross beds for vertical walls. Lay beds for battered walls from level to normal to the batter line 

of the face of the wall.

Place stone to provide a consistent pattern and color. Lay stones with the longest face horizontal and the 

exposed face parallel to the masonry face.

Construct masonry joints to the thicknesses shown in Table 620-3 for face stones. Construct arch ring 

stone joints on the faces and soffits between 1⁄4 inch and 11⁄2 inches thick, but make the bed of each course 

of a uniform thickness throughout. Construct head joints vertically in dimensioned masonry. Construct 

head joints in other masonry classes at angles with the vertical from 0 to 45 degrees.

Maintain completed masonry at a temperature above 40 °F for 24 hours after construction.

Remove stones loosened after the mortar has taken initial set, clean off the mortar, and relay the stone 

with fresh mortar.

Table 620-3 

Masonry Joint Thicknesses

Class Bed Joint, inch Head Joints, inch

Dimensioned 3⁄8 to 1 3⁄4 to 1

Class A 1⁄2 to 2 1⁄2 to 11⁄2

Class B 1⁄2 to 2 1⁄2 to 2

Rubble 1⁄2 to 21⁄2 1⁄2 to 21⁄2

620.07 Pointing. 

(a) Pointing new joints. Crown the joint mortar slightly on top surfaces to provide drainage. 

If raked joints are required, squarely rake mortar in exposed face joints and beds to the required depth. 

Slightly rake the mortar where weather joints are required. Do not leave the mortar flush with the stone 

faces.

Clean stone faces of mortar stains while the mortar is fresh. After the mortar sets, clean stone faces 

again using wire brushes and acid. Protect masonry during hot or dry weather by keeping it moist for 

at least 3 days after the work is completed.

(b) Repointing joints. Remove loose mortar from joints using a small mason’s chisel, small 

pneumatically-power chisel, or other approved raking tool. Do not use power saws or grinders. If 

power equipment is used, demonstrate proficiency to the CO before removing mortar from the 

structure. Remove mortar to a depth of two and one-half times the width of the joint. Remove dirt or 
Section 620

730

vegetation with a wire brush or other approved tools. Clean joint of loose fragments and dust with 

pressurized air or water.

Construct a 36-inch test section of joint along the structure for approval before continuing with work. 

Approved test section may be incorporated in the work. Moisten adjacent stone before filling the joint. 

Do not place mortar to a depth greater than two and one-half times the joint width. Place mortar in 

layers of approximately 1⁄4 inch for joints deeper than 1⁄8 inch. Add successive layers once mortar has 

attained thumb-print hardness. Tool the final layer to match the approved joint appearance. 

Clean excess mortar and stain from stone masonry using a bristle brush after the mortar has dried, but 

before the initial set. Do not use chemicals for cleaning. Protect masonry during hot or dry weather by 

keeping it moist for at least 3 days after the work is completed.

620.08 Constructing Walls. Construct an L-shaped test section of wall at least 5 feet high and 8 feet long; 

showing examples of face wall, top wall, method of turning corners, and method of forming joints. Do not 

construct masonry other than the foundation masonry before the test section is approved. 

Set face stones to produce the effect demonstrated in the approved test section. Do not extend bed joints 

in an unbroken line through more than five stones and head joints through more than two stones. Bond 

each face stone with contiguous face stones at least 6 inches longitudinally and 2 inches vertically. Do not 

allow the corners of four stones to be adjacent to each other.

Do not bunch small stones or stones of the same size, color, or texture. Construct walls using stones 

decreasing in size from the bottom to the top. Use large stones in corners. 

(a) Headers. Distribute headers uniformly throughout the walls of structures to form at least 

20 percent of the faces.

(b) Backing. Construct the backing out of large stones. Bond the individual stones composing the 

backing and heart with the stones in the face wall and with each other. Fill openings and interstices in 

the backing with mortar or with spalls surrounded by mortar. 

(c) Coping. Finish with coping if shown in the plans. If copings are not required, finish the top of the 

wall with stones wide enough to cover the top of the wall from 1.5 to 5 feet in length, and of random 

heights, with a minimum height of 6 inches. Lay stones so that the cap course is an integral part of the 

wall. Pitch the top of the capstones to align in both vertical and horizontal planes. 

(d) Parapet walls. Use stones squared and pitched to line and with heads dressed in the ends of parapet 

walls and in exposed angles and corners. Interlock spreaders with as many headers as possible. Extend 

headers through the entire wall thickness. Interlock both the headers and stretchers in the two faces of 

the wall. Use headers and stretchers to comprise a majority of the wall volume. Fill openings and 

interstices with mortar or with spalls surrounded by mortar.

(e) Weep holes. Place weep holes at the lowest points where free outlets can be obtained. Space holes 

no more than 10 feet apart.

620.09 Facing for Concrete. 

(a) Stone placed before concrete. Make the back of the masonry uneven. Pack voids in the back of 

the masonry with grout. 
Section 620

731

Use No. 4 reinforcing steel bent into an elongated letter "S" to anchor the stone. Embed each anchor 

in a mortar bed to within 2 inches from the face of the stones. Project the other end about 10 inches 

into the concrete backing. Space the anchors 18 inches apart both horizontally and vertically. 

Clean the back masonry surface of dirt, loose material, and mortar drippings after the mortar has 

attained sufficient strength. Wash surfaces with pressurized water before placing concrete.

(b) Concrete placed before stone. Set galvanized metal anchor slots flush with the projected face of 

concrete. Set the slots vertically at maximum horizontal spacings of 24 inches. Use foam filled slots 

to prevent filling with concrete.

Fit the metal anchors in the slots at a maximum vertical spacing of 24 inches. Extend the anchors to 

within 2 inches of the face of the stones.

If the shape of the concrete face is unsuitable for the use of metal slots, use 9-gauge galvanized iron 

wire ties at a rate of 6 ties per square yard of exposed surface.

Keep the concrete face continuously wet for 2 hours preceding the placing of the stone and fill 

interstices with mortar or with spalls surrounded by mortar.

620.10 Constructing Arches. Submit drawings for falsework according to Section 562. Stratify arch ring 

stones parallel to the radial joint and stratify other stones parallel to the beds.

Lay out a full-size template of the arch ring showing face dimensions of each ring stone and thickness of 

joints. Do not shape or dress ring stones until falsework drawings have been approved. Do not place ring 

stones until all ring stones have been shaped and dressed.

Construct arch centering according to the drawings. Provide suitable wedges for adjusting the elevation 

of the forms.

Set arch ring stones and hold in place with wedges until the joints are packed with mortar. If required, 

support centering with jacks to prevent settlement during masonry placement. Lower the centering 

gradually and symmetrically to avoid overstresses in the arch. Ensure the arch is self-supporting before 

installing coping or other features.

Strike the centers of filled spandrel arches before constructing the spandrel walls to avoid jamming of the 

expansion joints. Place the backfill so the ring is uniformly and symmetrically loaded. 

620.11 Guardwall. Use rubble masonry. Construct cast-in-place concrete corewalls according to 

Section 601 and precast concrete corewalls according to Section 578. 

Construct a 25-foot test section of guardwall. Do not construct additional guardwall until the test section 

is approved. 

Construct the guardwall true and uniform along its length with no stone projecting more than 11⁄2 inches 

beyond the face of the guardwall. Construct masonry beds and joints for face stones to the thicknesses 

shown in Table 620-1. Rake the joints and beds to a depth of 2 inches on the front and top sides and to a 

depth of 11⁄2 inches on the back. 
Section 620

732

Use a one-piece capstone for the full width of the guardwall for at least 25 percent of the total length. Use 

a two-piece capstone with the joint within 4 inches of the guardwall center for the remaining length. 

Place stones (including the capstones) randomly to avoid a pattern. Lay stones to reflect the width of the 

expansion joints. Do not leave a gap or a mortar edge at the expansion joint. Use various size stones to 

coin or key the corners of the guardwall. 

620.12 Acceptance. Rock for masonry structures will be evaluated under Subsections 106.02 and 106.04. 

Material for mortar will be evaluated under Subsections 106.02 and 106.03. 

Mortar placement will be evaluated under Subsection 106.02. 

Construction or rehabilitation of stone masonry will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Minor concrete will be evaluated under Section 601. 

Precast elements will be evaluated under Section 578. 

Measurement

620.13 Measure the Section 620 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring stone masonry by the cubic yard, measure in the structure. 

When measuring stone masonry guardwall by the linear foot, measure along the gutter line including 

terminal sections.

When measuring remove and reset stone masonry by the cubic yard, measure in the structure after 

resetting.

When measuring repointing of stone masonry by the linear foot, measure along the centerline of joint. 

Do not measure test wall sections not incorporated in the work. 

Payment

620.14 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 620 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for lump sum pay items will be prorated based on total work completed under this 

Section. 
Section 621

733

Section 621. — MONUMENTS AND MARKERS

Description

621.01 This work consists of constructing and reestablishing monuments and markers. 

Construction Requirements

621.02 Monuments and Markers. Reestablish or locate permanent points according to 

Subsection 107.01 and Section 152. Excavate and backfill according to Section 209. Monuments may be 

cast-in-place according to Section 601 or precast according to Section 578. Set each monument and marker 

vertically at the required location and elevation such that the monument remains stable horizontally and 

vertically.

Unless otherwise specified, install markers or monuments that are commercially available and typical for 

the area and application. Mark the monuments with durable markings that identify the monument uniquely 

and unambiguously. 

621.03 Acceptance. Material (except concrete) for monuments and markers will be evaluated under 

Subsections 106.02 and 106.03. 

Construction of monuments and markers will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Location of permanent points will be evaluated under Sections 107 and 152. 

Minor concrete will be evaluated under Section 601. 

Precast elements will be evaluated under Section 578. 

Survey work will be evaluated under Section 152. 

Measurement

621.04 Measure the Section 621 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

621.05 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 621 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 622

734

Section 622. — RENTAL EQUIPMENT

Description 

622.01 This work consists of providing and operating equipment for construction work ordered and not 

otherwise provided for under the contract. 

Construction Requirements

622.02 Rental Equipment. The CO will order in writing rental equipment for use on the project. Submit 

the model number and serial number for each piece of equipment before use. Make equipment available 

for inspection and approval before use.

Provide an operator who is skilled in running the rental equipment. Provide equipment with auxiliary 

attachments necessary to complete the ordered work. Maintain the equipment in good working order. 

Obtain approval of the length of workday and workweek before starting work. Keep daily records of the 

number of operating hours for each piece of equipment. Submit records with pay notes within 24 hours of 

the work being performed. 

622.03 Acceptance. Rental equipment work will be evaluated under Subsections 106.02 and 106.04. 

Measurement

622.04 Measure the Section 622 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

Do not measure inoperable equipment or equipment dependent upon another piece of inoperable 

equipment. 

Payment

622.05 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 622 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 623

735

Section 623. — GENERAL LABOR

Description

623.01 This work consists of providing laborers for construction work, as well as specialized laborers for 

technical and professional services ordered and not otherwise provided. This work also includes providing 

associated equipment and hand tools needed to complete the work. 

Construction Requirements

623.02 General. The CO will order in writing labor and specialized labor to complete work and services 

on the project. Provide competent workers to perform the work. 

Obtain approval of the length of workday and workweek before starting work. Keep daily records of the 

number of hours worked. Submit records with pay notes within 24 hours of the work being performed. 

623.03 Specialized Labor. Perform special labor services as follows:

(a) Survey services. Provide personnel, equipment, and materials, and perform work according to 

Section 152. 

Survey services include performing both field survey and associated office work. The ordered work 

may consist of mapping and construction survey and staking. Work may include, but is not limited to, 

boundary surveys, setting permanent monuments and markers, preparing legal descriptions and 

exhibits, topographic mapping, taking cross-sections, setting construction stakes and finish grade 

stakes, or other miscellaneous survey and staking activities.

(b) Technical services. Provide qualified engineering personnel experienced in highway construction 

and design, that can perform in a timely and accurate manner.

Provide personnel with at least 2 years’ recent job experience in the type of highway design and 

construction provided for under the contract. Provide the names and relevant experience of personnel. 

Provide supporting tools and equipment. 

Technical services include both field work and associated office work. The ordered work may consist 

of, but is not limited to, conducting field investigations, engineering work, drafting, performing 

calculations, or other miscellaneous engineering activities.

Submit calculations, notes, and supporting documentation generated to complete the work. 

623.04 Acceptance. General labor work will be evaluated under Subsection 106.02. 

Technical services will be evaluated under Subsections 106.02 and 106.04. 

Survey services will be evaluated under Section 152. 

Measurement

623.05 Measure the Section 623 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:
Section 623

736

When measuring survey services by the hour, measure survey services by the crew hour regardless of 

crew size. Measure time spent in performing calculations, plotting cross-sections, or processing computer 

or other data.

When measuring technical services by the hour, measure time spent in performing calculations, drafting, 

plotting cross-sections, or processing computer or other data.

Do not measure time for transportation of laborers and special laborers to and from the project site.

Payment

623.06 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 623 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 
Section 624

737

Section 624. — TOPSOIL

Description

624.01 This work consists of providing and placing topsoil and placing conserved topsoil. 

Material 

624.02 Conform to the following Subsection: 

Topsoil 713.01

Construction Requirements

624.03 General. Provide at least 7 days’ notice before the start of topsoil placement. Do not place topsoil 

when the ground or topsoil is frozen, excessively wet, or otherwise in a condition detrimental to the work. 

Use topsoil conserved according to Subsection 204.05 before providing topsoil. Keep the roadway 

surfaces clean during hauling and spreading operations. 

624.04 Preparing Areas. Shape slopes and disturbed areas to be covered with topsoil. Disk or scarify 

slopes 1V:3H or flatter to a depth of 4 inches perpendicular to the natural flow of water. 

624.05 Placing Topsoil. Spread topsoil to a depth that after settlement, provides the required depth. Break 

clods and lumps with harrows, disks, or other equipment to provide a uniform textured soil. Remove and 

dispose of clods and stones larger than 2 inches, stumps, roots, and other litter according to 

Subsections 203.05 and 203.07. 

Construct longitudinal depressions at least 2 inches deep perpendicular to the natural flow of water without 

overly compacting the topsoil surface.

624.06 Acceptance. Material for provided topsoil will be evaluated under Subsections 106.02 and 106.03. 

Material for conserved topsoil will be evaluated under Subsection 106.02. 

Placing topsoil will be evaluated under Subsections 106.02 and 106.04. 

Measurement

624.07 Measure the Section 624 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring providing and placing topsoil by the cubic yard, measure in the hauling vehicle. 

When measuring providing and placing topsoil by the acre, measure on the ground surface. 

When measuring placing conserved topsoil by the cubic yard, measure in the hauling vehicle.

When measuring placing conserved topsoil by the acre, measure on the ground surface. 
Section 624

738

Payment

624.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 624 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 625

739

Section 625. — TURF ESTABLISHMENT

Description

625.01 This work consists of soil preparation, watering, fertilizing, seeding, and mulching. 

Material 

625.02 Conform to the following Subsections: 

Agricultural limestone 713.02

Fertilizer 713.03

Mulch 713.05

Seed 713.04

Tackifiers 713.11

Water for vegetation 725.01(b)

Construction Requirements

625.03 General. Within 14 days after completion and approval of finished slopes and ditches, apply turf 

establishment to those portions of the site. Do not seed during windy weather or when the ground is 

excessively wet, frozen, snow covered, extremely dry, cloddy, hard pan, or not friable. 

625.04 Preparing Seedbed. Remove weeds, sticks, stones 2 inches in diameter and larger, and other 

debris detrimental to application, growth, or maintenance of the turf.

Cultivate the seeding area to a minimum depth of 4 inches and prepare a firm, but friable seedbed before 

seeding. Do not cultivate aggregate-topsoil courses that were previously dry seeded according to 

Section 313. 

Minimize soil compaction of seedbed. 

625.05 Watering. Moisten seeding areas before seeding and maintain the moisture until turf is established 

or until final acceptance.

625.06 Fertilizing. Apply fertilizer by the following methods:

(a) Dry method. Incorporate the fertilizer into the upper portion of the seedbed before seeding. 

(b) Hydraulic method. Add fertilizer to the slurry and mix before adding seed. Apply the seed and 

fertilizer in one application.

625.07 Seeding. Apply seed by the following methods: 

(a) Dry method. Apply the seed with approved power-driven seeders, drills, or other mechanical 

equipment. Hand-operated seeding methods are satisfactory on areas inaccessible to mechanical 

equipment. 

(b) Hydraulic method. Use hydraulic-type equipment that can provide a uniform application using 

water as the carrying agent. Add a tracer material consisting of either wood or grass cellulose fiber 
Section 625

740

mulch to the water. Apply the tracer material at a rate of 400 pounds per acre to provide visible 

evidence of uniform application. Add the seed to the water slurry no more than 30 minutes before 

application. Seed by hand areas inaccessible to seeding equipment. 

625.08 Mulching. If wood chips are used, do not import without approval. Apply mulch within 48 hours 

after seeding by the following methods: 

(a) Dry method. Spread mulch material, except wood and grass cellulose fibers, by a mulch spreader 

utilizing forced air to blow the mulch material onto the seeded area. Apply straw mulch at a rate of 

4000 pounds per acre. Anchor the mulch material with an approved tackifier or approved mechanical 

method. Do not mark or deface structures, pavements, utilities, or plant growth with tackifier. 

(b) Hydraulic method. Apply mulch in a separate application from the seed using hydraulic-type 

equipment according to Subsection 625.07(b). 

Apply wood fiber or grass straw cellulose fiber mulch at a rate of 2000 pounds per acre. 

Apply bonded fiber matrix hydraulic mulch at a minimum rate of 3000 pounds per acre or as specified 

by the manufacturer. Apply so no hole in the matrix is greater than 0.04 inch. Apply so that no gaps 

exist between the matrix and the soil.

Mulch by hand areas inaccessible to mulching equipment.

625.09 Protecting and Caring for Seeded Areas. Protect and care for seeded areas including watering 

when needed. Repair or apply supplemental applications of seed, mulch, fertilizer, and water as many 

times as needed until vegetation is established. Vegetation is considered established when one of the 

following is attained: 

(a) A uniform perennial vegetative cover with a density of 70 percent of the native background 

vegetative cover (percent vegetative cover before ground disturbance); or 

(b) A uniform perennial vegetative cover with the density required by permits.

625.10 Acceptance. Material for turf establishment will be evaluated under Subsections 106.02 and 

106.03. 

Placing of turf establishment will be evaluated under Subsections 106.02 and 106.04. 

Measurement

625.11 Measure the Section 625 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring turf establishment and supplemental applications by the acre, measure on the ground 

surface.

When measuring water by volume or mass, measure in the hauling vehicle or by metering.
Section 625

741

Payment

625.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 625 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments will be paid as follows:

(a) 75 percent of the pay item amount will be paid after initial seeding and mulching. 

(b) The remaining 25 percent of the pay item amount price will be paid after the final acceptance.
Section 626

742

Section 626. — PLANTS, TREES, SHRUBS, VINES, AND GROUND COVERS

Description

626.01 This work consists of providing and planting trees, shrubs, vines, groundcovers, and other plants. 

Material 

626.02 Conform to the following Subsections: 

Fertilizer 713.03

Miscellaneous planting material 713.08

Mulch 713.05

Plant material 713.06

Topsoil 713.01

Water for vegetation 725.01(b)

Construction Requirements

626.03 General. Do not plant in frozen ground, when snow covers the ground, or when the soil is 

saturated, extremely dry, cloddy, hard pan, not friable, or is otherwise unsatisfactory for planting. 

Provide stock with a live and fibrous root system. Do not provide container-grown stock that is pot-bound, 

has a top system out of proportion (larger) than the size of the container, has rooting media that does not 

hold together when plant is removed from the container, or has roots growing out of the container. 

Dig out transplants by gently removing the root ball. Ball and burlap the root ball before moving the 

transplant. Ensure the attached soil root ball diameter is at least two-thirds the size of the branch spread.

Transplant shrubs and small trees after plants have gone dormant. Harvest stakes from dormant plants.

Do not salvage trees or shrubs within 15 feet of a stream bank.

Tag each plant or groups of plants with a weatherproof tag showing species name and date of delivery. 

Install plants received on site within 7 days. 

626.04 Delivery. Notify the CO at least 30 days before delivery of material to allow the CO the 

opportunity to select material at the source. Submit commercial certifications and complete written 

information concerning the source of supply for plant material at least 14 days before delivery of plants 

to the project.

626.05 Protection and Temporary Storage. Package plants to provide protection against weather and 

breakage during transit. Tie and cover plants to prevent wind damage and dehydration when transporting 

by open vehicle. Pack and ventilate plants to prevent sweating when transporting by closed vehicle. Keep 

bare root plants below 35 °F during transport. 

Keep growing media moist. Protect bark, branches, and root systems from damage. Replace damaged 

plants including plants with cracked or crushed root balls. 
Section 626

743

Protect plants not scheduled for immediate planting as follows: 

(a) Keep bare root plants below 35 °F;

(b) Protect plants from over-exposure to sunlight and keep moist; 

(c) Protect plants from animals and insects; and

(d) Hold salvaged woody species no more than 7 days.

626.06 Excavation for Plant Pits and Beds. At least 14 days before planting, submit planting locations 

and methods of planting for approval. Mark planting locations with stakes or flagging. Remove sod, 

weeds, roots, and other unsuitable material from the planting site. Excavate plant pits as follows:

(a) Width of excavation. 

(1) For root spread or ball diameters up to 48 inches, excavate the pits circular in outline to the 

root spread plus 24 inches.

(2) For root spread or ball diameters over 48 inches, excavate one and one-half times the root 

spread.

(b) Depth of excavation. Excavate the pits to a depth that allows at least 6 inches of backfill under 

the roots or balls or excavate the pits to the following depths, whichever is deeper: 

(1) Deciduous trees.

(a) Under 11⁄2-inch caliper 24 inches deep

(b) Over 11⁄2-inch caliper 36 inches deep

(2) Deciduous and evergreen shrubs.

(a) Under 2 feet height 12 inches deep

(b) Over 2 feet height 24 inches deep

(3) Evergreen trees.

(a) Under 5 feet height 8 inches plus ball height

(b) Over 5 feet height 12 inches plus ball height

(4) Vines and groundcovers. Double the size of the pot. 

Loosen soil at the sidewalls and bottom of the plant pit to a depth of 6 inches before setting the plant. 

Do not leave planting holes open overnight. 

626.07 Setting Plants. Do not plant material until inspected and approved. Prepare a backfill mixture of 

4 parts topsoil, loam, or selected soil to one part peat moss. Place backfill mixture in the bottom of the 
Section 626

744

plant pit. Set plants approximately plumb and at the same level or slightly lower than the depth at which 

they were grown in the nursery or collected in the field. Set plants as follows:

(a) Bare root stock. Place bare rooted plants in the center of the plant pit with the roots properly 

spread in a natural position. Work backfill mixture around and over the roots, tamp as hole is being 

filled, and water thoroughly. 

(b) Balled and burlapped stock. Handle and move plants by the ball. Place balled and burlapped 

plants in the prepared pits on tamped backfill mixture. Score the root ball to a depth of 1 inch along 

the entire side equally on 4 sides. Backfill around the plant ball to one-half of the depth of the ball. 

Tamp and thoroughly water. Cut the burlap and remove it from the upper half of the ball or loosen the 

burlap and fold it back. If wire baskets are used cut the wire from the upper half of the basket. Backfill 

the remainder of the plant with backfill mixture.

(c) Container-grown stock. Remove the container immediately before planting. Place plants in the 

prepared pits on tamped backfill mixture. Backfill the remainder of the plant with backfill mixture and 

tamp.

(d) Live stakes. Use a planting bar or other tool to plant live stakes in fine to medium textured soils. 

Make planting hole at least 24 inches deep and place one live stake in each hole. Place live stakes with 

the basal end pointed downward and in contact with the water table and with buds pointing upwards 

and the tip extending at least 5 to 7 inches above the soil surface. Backfill planting hole with topsoil 

and tamp soil around stake to ensure good soil to stem contact. 

(e) Plugs. Plant plugs slightly beneath the level of the soil grade. Place soil around the plug, tamp, and 

water thoroughly. 

626.08 Fertilizing. Fertilize using one of the following methods: 

(a) Mix the fertilizer with the backfill mixture when it is prepared.

(b) Spread the fertilizer uniformly around the pit area of individual plants or over shrub beds. Cultivate 

the fertilizer into the top 2 inches of the backfill mixture.

626.09 Watering. Construct 4-inch-deep water basins around trees and 3-inch-deep water basins around 

shrubs. Make the diameter of the basin equal to that of the plant pit. 

Water plants during and immediately after planting until final acceptance, and throughout the plant 

establishment period. Saturate the soil around each plant at each watering.

626.10 Guying and Staking. If guying and staking is specified, guy deciduous trees just below the first 

lateral branch and guy evergreen trees halfway up the height of the tree.

626.11 Pruning. Prune before or immediately after planting to preserve the natural character of each plant. 

Use experienced personnel to perform the pruning. Use accepted horticultural practices. Paint cuts over 

3⁄4 inch in diameter with tree wound dressing. 

626.12 Mulching. Remove weeds and other live vegetation from pit and water basin areas around 

individual plants and from entire shrub beds. If wood chips are used, do not import without approval. 
Section 626

745

Place mulch within 24 hours after planting. 

626.13 Plant Establishment Period. The plant establishment period starts after all plantings have been 

completed. The plant establishment period ends at 1-year after all plantings have been completed or final 

inspection, whichever occurs later. Employ necessary means to preserve the plants in a healthy growing 

condition during the plant establishment period. Water, weed, prune, adjust guys and stakes, and protect 

from animals, insects, and disease during the plant establishment period. At the end of the plant 

establishment period, remove guys and stakes. 

An inspection of the plant material will be made 14 days before the end of the plant establishment period 

to identify dead, dying, or diseased plants for removal and replacement. During the following planting 

season, remove and replace identified plants. A final inspection of all plant material within 15 days after 

completion of all replacement planting will be the basis for final acceptance.

626.14 Acceptance. Material for plants, trees, shrubs, vines, and groundcovers (including fertilizer, 

mulch, and topsoil) will be evaluated under Subsections 106.02 and 106.03. 

Planting of plants, trees, shrubs, vines, and groundcovers will be evaluated under Subsections 106.02 and 

106.04. 

Measurement

626.15 Measure the Section 626 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

626.16 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 626 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments will be paid as follows:

(a) 75 percent of the pay item amount will be paid after initial planting.

(b) The remaining 25 percent of the pay item amount price will be paid after the final acceptance.
Section 627

746

Section 627. — SOD

Description

627.01 This work consists of providing and placing living sod of perennial turf-forming grasses.

Material 

627.02 Conform to the following Subsections: 

Agricultural limestone 713.02

Fertilizer 713.03

Pegs for sod 713.10

Sod 713.09

Water for vegetation 725.01(b)

Construction Requirements

627.03 General. Move and place sod during dry weather and on dry, unfrozen ground. 

Avoid erosion when watering. 

627.04 Delivery. Provide at least 3 days’ notice before cutting sod. Obtain approval of the sod in its 

original position before cutting. Do not deliver sod until the soil is prepared. 

627.05 Preparing the Soil. Clear and grade the surface. Cultivate, disk, harrow, or otherwise loosen the 

grade to a depth of at least 4 inches. Finish the surface to a smoothness comparable to hand raking. 

Remove surface stones not passing a 1-inch sieve. Remove sticks, stumps, and other surface debris that 

interfere with sod placement or subsequent growth. 

Place topsoil according to Section 624 as shown in the plans. 

Apply fertilizer and agricultural limestone uniformly over the sodding area. Mechanical spreaders or 

blower equipment may be used. Disk or till the fertilizer and limestone into the soil to a depth of 4 inches.

Moisten the prepared soil.

627.06 Placing Sod. Place sod within 24 hours after cutting or within 5 days after cutting if the sod is 

stored in moist stacks, grass-to-grass and roots-to-roots. Protect sod against drying and from freezing. 

(a) Solid sod. Place sod perpendicular to drainage flows. Place sections of solid sod edge to edge with 

staggered joints. Plug openings with sod or fill openings with acceptable loamy seeded topsoil. Roll 

or tamp sod to eliminate air pockets and provide an even surface. On slopes 1V:2H or steeper and in 

channels, peg sod on 24-inch centers after rolling or tamping. Drive pegs flush with the sod bed 

surface.

(b) Spot sod. Place sod blocks. Roll or tamp the blocks into the soil until the sod surfaces are slightly 

below the surrounding ground surface. 
Section 627

747

Blend final grades with existing adjacent areas. Leave the entire area drainable and without abrupt changes 

in slope. 

627.07 Maintaining Sodded Areas. Water sod to a depth of 4 inches after placing and keep moist. 

Protect newly sodded areas using approved methods. Do not allow vehicles or equipment on newly sodded 

areas.

Mow sodded areas and repair or replace sodded areas that are damaged or fail to show a uniform growth 

of grass. Maintain sodded areas and replace nonliving sod until final acceptance of the project. 

627.08 Acceptance. Material for sod (including lime and fertilizer) will be evaluated under 

Subsections 106.02 and 106.03. 

Placing sod will be evaluated under Subsections 106.02 and 106.04. 

Topsoil will be evaluated under Section 624. 

Measurement

627.09 Measure the Section 627 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

627.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 627 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments will be paid as follows:

(a) 75 percent of the pay item amount will be paid after initial placement of sod.

(b) The remaining 25 percent of the pay item amount price will be paid after the final acceptance.
Section 628

748

Section 628. — TEMPORARY STREAM DIVERSIONS

Description

628.01 This work consists of constructing, maintaining, and removing temporary stream diversions. 

Material 

628.02 Conform to the following Subsections: 

Floating turbidity curtains 713.21

Gravel bags 713.13

Plastic lining 713.22

Rock for riprap 705.02

Sandbags 713.14

Sediment filter bags 713.19

Temporary culvert pipe 713.15

Construction Requirements

628.03 Submittals. At least 14 days before starting stream diversion work, submit the following according 

to Subsection 104.06: 

(a) Drawings and written narrative showing the type, size, location, elevation, and method of 

installation and removal for the stream diversion, and means of access to waterways;

(b) A Fish and Aquatic Life Removal and Passage Plan. Include applicable Federal, state, and local 

permits and approvals;

(c) Sequence and schedule for the following: 

(1) Installing and removing the diversion;

(2) Removal of water from the work area;

(3) Accessing the waterways; and

(4) Fish and aquatic life removal from the work area.

(d) Best management practices used to ensure minimization of erosion and turbidity; 

(e) Description of all construction stages; 

(f) A list of on-site backup materials and equipment for emergency use; and

(g) Capacity calculations and hydraulic profile in an approved hydraulic modeling software. 

628.04 General. Provide a stream diversion system for expected flow during in-water work activities that 

accommodates at least a 2-year peak flood event. Additional flow capacity may be required when in-water 
Section 628

749

work activities occur during higher flow periods. Divert sufficient flow to sustain fish and aquatic life 

downstream. Do not constrict flow such that fluctuations in water depth, flow volume, and velocity cause 

erosion upstream or downstream of the project. 

628.05 Diverting Stream Flow. Use materials that are non-erosive for the expected flows.

Maintain and control water flow downstream of the isolated work area for the duration of the diversion. 

Inspect and clean diversions of debris or sediment accumulation daily or according to an approved 

schedule.

If required, install floating turbidity curtains within a body of water to minimize the migration of sediment 

laden water out of the construction area.

Divert the stream using one of the following methods and according to Section 107: 

(a) In-stream diversion. Place diversion berm, working from upstream end to downstream end. 

Maintain at least half-width channel flow. Minimize disturbance of channel bed. Minor quantities of 

in-stream material can be moved to help seal and secure diversion structures.

(b) Diversion channel. Excavate, stabilize, maintain, and operate the stream diversion channel to 

carry the diverted stream flow. Stockpile excavated materials in areas outside of the floodplain. 

Excavate the diversion channel with barriers installed at both ends of the diversion channel so stream 

flow does not prematurely enter the diversion channel.

Line the entire length and width of the diversion channel with plastic liner or riprap according to 

Section 251. If plastic liner does not span the channel from bank to bank, place seams perpendicular 

to the flow and place upstream sections overlapping at least 18 inches of the downstream section. Lay 

plastic liner flat on the channel in direct contact with the soil without any void spaces. Remove sharp 

objects to avoid puncturing the plastic liner. Ensure that the liner is secured at the upstream end of the 

channel and along the channel before removing barriers and diverting stream flow. 

(c) Temporary culvert pipe diversion. Size and locate culvert pipe to minimize potential erosion. 

Stabilize the upstream and downstream ends of the culvert pipe to minimize erosion. Install the culvert 

pipe according to Section 602, and build the upstream flow barrier, followed by the downstream flow 

barrier.

(d) Bypass pumping diversion. Install the upstream barrier first, followed by the downstream barrier. 

Suspend the intake above the channel bottom to prevent sediment from entering the intake. Place a 

mesh screen over the intake with a minimum mesh size of 3

/32 inch. Enclose the intake with a secondary 

screen box 3 feet on each side if velocities at the intake are greater than 0.4 feet per second. Stabilize 

the discharge point at the downstream end to avoid erosion. Have spare pumps on site in the event of 

pump failures or higher than expected flow rates. Place the pump on firm ground with secondary 

containment measures.

Remove water from the isolated work area as necessary to perform the work. Dispose of water according 

to Federal, state, and local rules and regulations. Do not discharge sediment laden water directly or 

indirectly to wetlands or waters. Pump water from the isolated work area to a temporary storage and 

treatment site or into upland areas and allow water to infiltrate. Control erosion at the discharge point.
Section 628

750

628.06 Removal of Stream Diversions. Upon completion of in-water work activities, restore isolated 

work area to match original or planned contours. Slowly restore stream flow to prevent loss of surface 

water downstream. Ensure isolated work area is stabilized and streambed material is washed down to 

remove dirt and fine sediment before stream flow is restored to prevent sudden releases of suspended 

sediment. Maintain sufficient stream flow downstream of the project to prevent stranding of aquatic life.

Remove temporary flow barriers and diversion structures. Restore existing stream bank and floodplain 

topography, including restoring areas used for stream diversion to match original or planned contours. 

628.07 Acceptance. Material for stream diversions will be evaluated under Subsections 106.02 and 

106.03. 

Construction, maintenance, and removal of stream diversions will be evaluated under Subsections 106.02

and 106.04. 

Culvert pipe will be evaluated under Section 602.

Riprap will be evaluated under Section 251. 

Measurement

628.08 Measure the Section 628 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

628.09 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 628 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for temporary stream diversions by the lump sum will be paid as follows: 

(a) 50 percent of the pay item amount will be paid after installation.

(b) The remaining portion of the pay item amount will be paid after the temporary stream diversions 

are removed from the project.
Section 629

751

Section 629. — ROLLED EROSION CONTROL PRODUCTS

AND CELLULAR CONFINEMENT SYSTEMS

Description

629.01 This work consists of constructing and installing RECP and cellular confinement systems.

629.02 Definitions. 

(a) Mulch control netting. A planar woven natural fiber or extruded geosynthetic mesh used as a 

temporary degradable RECP to anchor loose fiber mulches. 

(b) Open weave textile. A temporary degradable RECP composed of processed natural or polymer 

yarns woven into a matrix, used to provide erosion control and facilitate vegetation establishment. 

(c) Erosion control blanket. A temporary degradable RECP composed of processed natural or 

polymer fibers mechanically, structurally, or chemically bound together to form a continuous matrix, 

used to provide erosion control and facilitate vegetation establishment. 

(d) Turf reinforcement mat. A permanent non-degradable RECP designed for critical hydraulic 

applications where design discharges exert velocities and shear stresses that exceed the limits of 

mature, natural vegetation.

Material 

629.03 Conform to the following Subsections:

Cellular confinement systems 713.07

Rolled erosion control products 713.17

Topsoil 713.01

Turf reinforcement mats 713.18

Construction Requirements

629.04 General. Make the soil surface stable, firm, and free of rocks and other obstructions. Install RECP 

and cellular confinement systems according to the manufacturer’s recommendations and to the following

minimum guidelines. Apply turf establishment according to Section 625. 

In areas to be mowed soon after installation, use temporary RECP consisting of rapidly degrading netting

with a functional longevity of 3 months or less.

629.05 Netting or Open Weave Textile (RECP, Types 1.A, 2.A, and 3.A). Apply mulch according to

Subsection 625.08(a). Immediately after mulching, install netting or open weave textile according to

Subsection 629.06. 

629.06 Erosion Control Blanket, Open Weave Textile, and Turf Reinforcement Mat (RECP, Types 

1.B, 1.C, 1.D, 2.B, 2.C, 2.D, 3.B, 4.A, 4.B, 5.A, 5.B, 5.C, 5.D, 5.E, and 5.F). Unless soil in-filling is

required, complete turf establishment work before installing RECP.
Section 629

752

If soil in-filling is required, first install RECP. Then apply seed and lightly brush or rake 1⁄4 to 3⁄4 inch of

topsoil into the voids in the RECP leaving only the top netting exposed. 

Unroll the RECP parallel to the primary direction of flow and place it in direct contact with soil surface. 

Do not stretch or allow RECP to bridge over surface inconsistencies. Overlap edges of adjacent RECP by

3 to 4 inches or according to the plans. Use fasteners according to the plans and use enough fasteners to 

prevent seam separation. Overlap roll ends of joining RECP 6 inches or according to the plans in the 

direction of flow.

(a) Slope installations. At the top of slope, anchor the RECP by one of the following methods: 

(1) Fasteners. Install the RECP 36 inches over the shoulder of the slope onto flat final grade.

Secure with a single row of fasteners on 12-inch centers or according to the plans. 

(2) Anchor trench. Construct a 6- by 6-inch trench. Extend the upslope terminal end of the RECP

36 inches past the trench. Use fasteners on 12-inch centers to fasten the RECP into the trench or 

according to the plans. Backfill the trench and compact the soil. Secure the terminal end with a 

single row of fasteners on 12-inch centers and cover the end with soil. Apply turf establishment. 

(3) Check slot. Install two rows of staples 4 inches apart on 4-inch centers across the top edge of

the RECP. Drive fasteners flush with soil surface. 

Securely fasten RECP to the soil by installing fasteners at a minimum rate of 1.5 per square yard. 

(b) Channel installations. At the start of the channel, construct a full width anchor trench according 

to Subsection 629.06(a)(2). Construct additional anchor trenches or check slots at intervals along the

channel reach and at the channel end according to Subsection 629.06(a)(2) or (a)(3) and the 

manufacturer’s installation guidelines.

Securely fasten RECP to the soil by installing staples at a minimum rate of 2 per square yard. 

Significantly higher anchor rates may be necessary in sandy, loose, or wet soils and in severe

applications.

Repair damaged areas immediately by restoring soil to finished grade, reapplying turf establishment, and 

replacing the RECP.

629.07 Cellular Confinement Systems. Excavate to the depth of the cellular confinement system and

smooth and compact the slope. Install the top of the system flush or lower than the adjacent slope. Expand

the geocell down the slope. Connect adjacent geocell sections with hog rings or staples in every other cell.

Anchor the system with wooden stakes across the top at every other cell. Repeat the anchoring pattern in

every tenth row and in the bottom row. Drive stakes to a minimum embedment of 12 inches below the 

base of the cellular confinement layer.

Backfill the cells with material as shown in the plans. Compact the material within each cell. Apply turf 

establishment according to Section 625, where shown in the plans.

629.08 Acceptance. Material for RECP and cellular confinement system will be evaluated under

Subsections 106.02 and 106.03. 
Section 629

753

Installation of RECP and cellular confinement systems will be evaluated under Subsections 106.02 and 

106.04. 

Material for topsoil will be evaluated under Subsection 106.02. 

Placing topsoil will be evaluated under Subsections 106.02 and 106.04. 

Turf establishment will be evaluated under Section 625. 

Measurement

629.09 Measure the Section 629 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

629.10 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 629 pay items listed in the bid schedule. Payment will be full compensation for the work

prescribed in this Section. See Subsection 109.05.
Section 630

754

Section 630. — RESERVED
Section 631

755

Section 631. — RESERVED
Section 632

756

Section 632. — LOCATING UTILITIES

Description

632.01 This work consists of locating, marking, and providing a record of existing underground utilities. 

Construction Requirements

632.02 General. Follow the requirements of FAR Clause 52.236-3 Site Investigation and Conditions 

Affecting the Work. The locations of existing utilities shown in the plans are approximate.

Locate, protect, and repair utilities according to Section 107. 

632.03 Locating Utility. Use appropriate means to locate utilities including, but not limited to, 

geophysical prospective techniques, and electromagnetic, sonic, or other energy field devices to establish 

alignment of utilities where applicable. Thread a traceable duct rod through non-metallic utility pipes to 

locate them.

Locate the utility by perpendicular trench or test pits, if approved. Excavate to the assumed depth using 

hand tools as needed to avoid disturbing utilities. If excavating within roadway pavements where traffic 

is being maintained, excavate by air-vacuum methods or equivalent, keeping the area of disturbance to a 

minimum. Uncover the utility sufficiently to make accurate measurements. Restore test pit or trenched 

areas to their original condition. Excavate and backfill according to Section 209. 

If a conflict exists, cooperate with the utility owner according to Section 107. 

632.04 Reporting. Submit a report of the utility locate within 48 hours. In the report, describe each utility 

found, the locating methods utilized, plan and profile mapping of the utility, photographs, and 

recommendations for mitigation or relocation.

632.05 Marking. Mark the utility location by flags or paint. Maintain the markings for the duration of the 

project.

632.06 Acceptance. Locating utilities will be evaluated under Subsection 106.02. 

Excavation and backfill will be evaluated under Section 209. 

Measurement

632.07 Measure the Section 632 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

632.08 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 632 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for lump sum pay items will be prorated based on total work completed under this 

Section. 
Section 633

757

Section 633. — PERMANENT TRAFFIC CONTROL

Description

633.01 This work consists of installing and removing and resetting permanent traffic control devices.

Material 

633.02 Conform to the MUTCD and the following Section: 

Traffic signing and marking material 718

Construction Requirements

633.03 General. Provide and install permanent traffic control devices according to the MUTCD and as 

shown in the plans. Provide traffic control devices that are crashworthy. Current state-approved permanent 

traffic control devices may be used if approved. Install permanent traffic control devices according to the 

manufacturer’s recommendations. 

Sign locations may be changed to fit field conditions as approved. Determine sign support lengths at time 

of staking. 

633.04 Sign Posts. Install sign posts plumb and according to the manufacturer’s recommendations. 

Drive sign posts with a suitable driving head or set posts in drilled or punched holes. Backfill and compact 

sign post holes with suitable material in 6-inch lifts until no visible evidence of further consolidation. 

Excavate, construct, and backfill concrete footings according to Section 601. 

633.05 Sign Panels. Mount sign panels with the legend horizontal. 

Use oversized bolt heads and neoprene or nylon washers for fastening plastic sign panels. 

Use antitheft fasteners. Cover exposed fasteners on the sign panel face with material matching the 

background of the panel. 

Turn sign panels 3 degrees away from the road in the direction of travel to reduce specular glare (mirror 

reflection).

Cover the sign face with an opaque material if a sign message is not applicable. Maintain the covering in 

good condition until the message becomes applicable. Do not use adhesive tape on the sign face. 

633.06 Delineators and Object Markers. Attach delineators and object markers to posts according to 

the manufacturer’s recommendations or as specified.

633.07 Rumble and Mumble Strips. Construct rumble and mumble strips within 2 inches of the specified 

alignment. Ensure that indentations conform to the specified dimensions within 1⁄4 inch in length and 1⁄4 

inch in width and that the depth of the indentation is within the range of 1⁄2 inch to 5⁄8 inch.

Dispose of excess material according to Subsection 203.07. 
Section 633

758

633.08 Metal Frame Road Closure Gates. Construct concrete foundations according to Section 601. 

Fabricate gates according to Section 555. Assemble and install gates as shown in the plans. Submit 

drawings according to Subsection 104.06. 

Coat according to Section 563. Provide and install signs, retroreflective sheeting, and object markers as 

shown in the plans. 

633.09 Removing and Resetting Permanent Traffic Control Devices. Salvage existing traffic control 

devices according to Subsection 203.04. Reset as necessary. Replace traffic control devices damaged 

during removal, storage, and resetting. 

633.10 Acceptance. Material for permanent traffic control devices will be evaluated under

Subsections 106.02 and 106.03. 

Installation of permanent traffic control devices will be evaluated under Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Steel structures will be evaluated under Section 555. 

Minor concrete will be evaluated under Section 601. 

Measurement

633.11 Measure the Section 633 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring sign panels by the square foot, measure front face. Measure each sign panel in a multiple 

configuration. 

When measuring sign systems by the square foot, measure front face of each sign panel.

When measuring sign systems by the each, measure each system as one regardless of the number of sign 

panels.

When measuring removing and resetting permanent traffic control devices, measure after they are reset.

When measuring rumble or mumble strips by the linear foot or mile, measure the length of rumble or 

mumble strip constructed parallel to the roadway centerline. Do not subtract for gaps in rumble or mumble 

strips.

Do not measure signs, retroreflective sheeting, and object markers installed on road closure gates. 

Do not measure supports for sign systems. 

Payment

633.12 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 633 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 634

759

Section 634. — PERMANENT PAVEMENT MARKINGS

Description

634.01 This work consists of applying markings and markers on finished pavement. 

Pavement markings are designated as follows: 

Type A – Solventborne pavement markings 

Type B – Waterborne pavement markings

Type C – High-build waterborne pavement markings

Type D – Epoxy pavement markings 

Type H – Thermoplastic pavement markings

Type J – Preformed pavement marking tape

Type L – Methyl methacrylate pavement markings

Material 

634.02 Conform to the MUTCD and the following Section: 

Traffic signing and marking material 718

Construction Requirements

634.03 General. Where existing and final marking locations are identical, stake the limits of existing 

markings before starting pavement work.

Submit manufacturer’s SDS and product data sheets at least 7 days before applying markings. A field 

demonstration may be required to verify the adequacy of the material. 

Ship marking material containers plainly marked with the following information as appropriate for the 

material being provided: 

(a) Manufacturer’s name and address;

(b) Name of product; 

(c) Lot and batch numbers; 

(d) Color; 

(e) Net mass and volume of contents;

(f) Date of manufacture;

(g) Date of expiration; 

(h) Statement of contents;
Section 634

760

(i) Mixing proportions (if mixing of components is required); and

(j) Safety information.

Establish marking patterns and locations according to the MUTCD and as shown in the plans. 

In curve widening areas, establish the edge line markings at the limits of the traveled way and the 

centerline markings equal distance between the edge lines.

Remove loose particles, dirt, tar, grease, and other deleterious material from the surface to be marked. 

Where markings are placed on rigid pavement less than 1-year old, clean the pavement of laitance and 

curing compounds. 

Remove temporary markings the same day permanent markings are applied. Remove temporary and 

conflicting makings according to Subsection 635.14 before applying permanent markings.

Wait at least 14 days before applying markings on new asphalt pavements or new asphalt surface 

treatments. Apply markings to a clean, dry surface and according to the manufacturer’s recommendations. 

Produce markings that are clean-cut and uniform in appearance by day and night. 

Current state-approved marking material may be used if approved. 

Apply glass beads at the rate, type, and timing according to the manufacturer’s recommendations and 

immediately following marking application to ensure adhesion.

Protect markings from traffic until dried to a no-tracking condition. Remove tracking marks, spilled 

marking material, markings in unauthorized areas, and defective markings.

634.04 Solventborne Pavement Markings (Type A). Apply markings when pavement and air 

temperatures are at 35 °F and rising. Do not heat the markings above 120 °F. Spray markings to a 15-mil 

minimum wet film thickness or at a rate of 107 square feet per gallon.

On new asphalt pavements or new asphalt surface treatments, apply two coats of markings and glass beads. 

Apply second coat after first coat is track free.

634.05 Waterborne Pavement Markings (Type B). Apply markings when pavement and air 

temperatures are 50 °F and rising. 

Do not heat the markings above 120 °F. Spray markings at a 15-mil minimum wet film thickness or at a 

rate of 107 square feet per gallon.

On new asphalt pavements or new asphalt surface treatments, apply two coats.

634.06 High-Build Waterborne Pavement Markings (Type C). Apply markings when pavement and 

air temperatures are 50 °F and rising. 

Spray markings at 25-mil minimum wet film thickness or at a rate of 71 square feet per gallon.

634.07 Epoxy Pavement Markings (Type D). Apply epoxy when pavement and air temperatures are 

35 °F and rising. Heat components according to the manufacturer’s recommendations. Apply to a 25-mil 

minimum dry film thickness or at a rate of 71 square feet per gallon.
Section 634

761

634.08 Thermoplastic Pavement Markings (Type H). Apply thermoplastic when pavement and air 

temperatures are 50 °F and rising. Heat thermoplastic according to the manufacturer’s recommendations.

Apply an epoxy resin primer and sealer according to the thermoplastic manufacturer’s recommendations 

if placing markings on pavements more than 2-years old, oxidized, or having exposed aggregates. Allow 

the primer and sealer to dry. 

For edge lines, apply thermoplastic to a 60-mil dry film thickness. For other lines, apply thermoplastic to 

a 90-mil dry film thickness.

634.09 Preformed Pavement Marking Tape (Type J). Use preformed marking tape containing 

retroreflective beads. Install to form a durable, weather resistant bond to the pavement. Apply preformed 

markings according to the manufacturer’s recommendations.

634.10 Methyl Methacrylate Pavement Markings (Type L). Apply a two-component methyl 

methacrylate marking at a minimum thickness of 60 mils for longitudinal markings and 120 mils for 

transverse markings and symbols. Apply markings when pavement and air temperatures are between 40 °F 

and 105 °F. Apply according to the manufacturer’s recommendations. 

634.11 Pavement Markers. Install raised and recessed pavement markers when the pavement and air 

temperatures are 50 °F and rising. Apply pavement markers with an epoxy resin adhesive according to the 

manufacturer’s recommendations when the pavement is dry. Space the markers according to the MUTCD 

and as shown in the plans. 

634.12 Acceptance. Material for permanent pavement markings and markers will be evaluated under 

Subsections 106.02 and 106.03. 

Applying permanent pavement markings and markers will be evaluated under Subsections 106.02 and 

106.04. 

Measurement

634.13 Measure the Section 634 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When two coats of markings are required, measure each coat.

When measuring pavement markings by the linear foot or mile, measure the length of line applied along 

the centerline of each line applied regardless of color. Measure broken and dotted pavement lines from 

end to end of the line including gaps. Measure solid pavement lines from end to end of each continuous 

line. Measure line quantities based on a 4-inch-wide line. For line widths greater than 4 inches, adjust the 

measured length of line in the ratio of the required width to 4 inches.

When measuring pavement markings by the square foot, measure the number of square feet of line, 

symbol, or letter marking based on the marking area shown in the plans. If not shown, measure the area 

of each marking in place to the nearest square foot.
Section 634

762

Payment

634.14 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 634 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05.
Section 635

763

Section 635. — TEMPORARY TRAFFIC CONTROL 

Description

635.01 This work consists of providing, installing, maintaining, relocating, and removing temporary 

traffic control devices and services as ordered for the control and protection of public traffic through the 

project.

Advance warning arrow board, barricade, and warning light types are designated in the MUTCD. 

Material 

635.02 Conform to the MUTCD and the following Section and Subsections: 

Emulsified asphalt 702.02

Temporary plastic fence 710.08

Traffic signing and marking material 718

Construction Requirements

635.03 Qualifications. At least 30 days before starting work, submit the following for approval:

(a) Flaggers. Appropriate certifications from ATSSA, the National Safety Council, a state department 

of transportation, or other approved organization; 

(b) Pilot car operators. Appropriate certifications; and

(c) TCS. Certifications according to Subsection 156.02. 

635.04 General. Provide, install, and maintain temporary traffic control devices adjacent to and within 

the project according to the MUTCD, temporary traffic control plan, and Section 156. Install and maintain 

traffic control devices as follows:

(a) Provide and install temporary traffic control devices before the start of construction operations.

(b) Install only those temporary traffic control devices needed for each stage or phase. 

(c) Relocate temporary traffic control devices as necessary.

(d) Immediately replace devices that are lost, stolen, destroyed, or inoperative.

(e) Provide and maintain temporary traffic control devices that meet the acceptable standard described 

in ATSSA, Quality Guidelines for Work Zone Traffic Control Devices. Modify the ATSSA standards 

as follows:

(1) Repair or remove and replace marginal devices within 48 hours. 

(2) Repair or remove and replace unacceptable devices immediately.

(f) Remove temporary traffic control devices upon contract completion or when approved. 
Section 635

764

(g) Provide crashworthy temporary traffic control devices.

635.05 Barricades. Use barricades of the type and size specified and according to the MUTCD.

635.06 Cones and Tubular Markers. Use cones or tubular markers of the height specified and according 

to the MUTCD.

635.07 Construction Signs. Install posts according to Subsection 633.04. Portable sign supports may be 

used instead of sign posts if approved. Submit ballasting for approval. Do not install sign supports on 

sidewalks, bicycle facilities, or areas designated for pedestrian or bicycle traffic.

Remove or completely cover unnecessary signs. 

Use crashworthy posts within the traversable area adjacent to traffic.

635.08 Drums. Use plastic drums that are at least 36 inches high and at least 18 inches in diameter.

635.09 Traffic Control Supervisor. Perform services described in Subsection 156.08. 

635.10 Flaggers. Use certified flaggers according to Subsection 635.03. Do not use flags alone. 

635.11 Pilot Cars. Use certified pilot car operators according to Subsection 635.03. Mount a 

high-intensity, rotating, flashing, or oscillating light on the roof of the pilot car.

635.12 Portable Traffic Barriers. Use temporary barriers that are crashworthy. Lifting holes no larger

than 4 inches or lifting loops are allowed. Mount white or yellow retroreflectors, as applicable, to the top 

or side of the barrier on 25-foot centers. Mount the retroreflectors at a uniform height at least 24 inches 

above the road surface. Flexible barrier delineators or barrier delineation tape may be used instead of 

retroreflectors if approved.

635.13 Temporary Guardrail. Construct temporary guardrail according to Section 617. 

Mount white or yellow retroreflectors, as applicable, to the top or side of the guardrail on 25-foot centers. 

Mount the retroreflectors at a uniform height at least 24 inches above the road surface.

635.14 Temporary Pavement Markings and Delineation. Before opening a pavement surface to traffic, 

remove conflicting pavement markings. Make the removal pattern uneven to not perpetuate the outline of 

the removed pavement markings. Lightly coat removal areas on asphalt surfaces with emulsified asphalt.

Place and maintain temporary pavement markings that are neat, crack free, true, straight, and unbroken. 

If temporary signs and pavement markers are substituted for temporary pavement markings, install 

temporary signs and pavement markers according to the MUTCD and as shown in the plans. 

For temporary pavement markings, use the following:

(a) Preformed retroreflective tape. Apply according to the manufacturer’s recommendations. 

Remove loose preformed retroreflective tape before placing additional pavement lifts.

(b) Pavement markers. Do not use pavement markers during seasonal suspensions. If chip seals, 

slurry seals, or tack coats are used after marker placement, protect the markers with an approved 
Section 635

765

protective cover, and remove it after the asphalt material is sprayed. Install according to the 

manufacturer’s recommendations. 

(c) Traffic paint. Do not apply traffic paint to the final surface. Apply traffic paint as the temporary 

pavement marking if no work will be performed on the project for at least 30 days. Apply waterborne 

traffic paint according to Section 634. 

Remove temporary pavement markings before placing additional pavement lifts or permanent pavement 

markings unless approved. Remove temporary markers after 14 days and apply permanent pavement 

markings unless approved. 

635.15 Warning Lights. Use warning lights of the types shown in the plans or according to the MUTCD. 

Install warning lights with a minimum mounting height of 30 inches to the bottom of the lens. Secure 

lights to the top of the traffic control device they are supplementing. Use batteries recommended by the 

light manufacturer. Mount large batteries below windshield height and preferably on the ground. Replace 

batteries when they no longer provide satisfactory performance. 

Use Type C steady-burn warning lights for delineation on barricades or drums. Use Type A low-intensity 

flashing warning lights on the first 2 barricades or drums in the merging or shifting taper series. Use Type 

B high-intensity flashing warning lights on the first two advance warning signs. 

635.16 Shadow Vehicle. Use a 19,800±990 pound shadow vehicle equipped with a truck-mounted 

attenuator attached to the rear of the vehicle, an exterior flashing yellow dome light, and an arrow board. 

Use the shadow vehicle to provide physical protection to workers from traffic approaching from the rear 

during moving operations. 

If using a shadow vehicle, submit a plan for using a shadow vehicle and associated lane closures to traffic.

635.17 Pavement Patch. Use an approved hot asphalt mix or commercially available cold asphalt mix to 

repair potholes and rough spots in the traveled way before reopening travel lanes to traffic. If cold asphalt 

mix is used, remove and replace with approved hot asphalt mix before placing succeeding hot asphalt lifts.

635.18 Crash Cushions. Use a crashworthy temporary crash cushion according to the manufacturer’s 

recommendations.

635.19 Traffic Signal System. Use a traffic signal system according to MUTCD Parts 4 and 6. Provide 

the names and telephone numbers of at least two emergency contacts who can be reached 24 hours a day, 

and who are available to arrive on site within 4 hours of notification to repair or replace malfunctioning 

temporary signal equipment. In addition, provide emergency flaggers who can be reached 24 hours a day, 

and who are available to perform traffic control operations within the timeframes specified below until 

the temporary signal system is operable.

If the traffic signal malfunctions during construction operations, immediately start traffic control 

operations using flaggers until the system is returned to normal signal operation. Complete traffic signal 

repairs within 6 hours of the malfunction. 

If the traffic signal malfunctions during a period when no construction activity is taking place, start traffic 

control operations using flaggers as soon as possible, but no later than 2 hours after the initial notification. 
Section 635

766

Continue temporary flagging operations until the system is returned to normal signal operation. Complete 

traffic signal repairs within 12 hours of notification.

635.20 Temporary Plastic Fence. Use temporary plastic fence according to Section 619 and the MUTCD 

where applicable.

635.21 Portable Rumble Strip. Use transverse or longitudinal rumble strips according to the MUTCD 

Part 6.

Before placing portable rumble strips, clean the roadway free of dust, sand, and other materials that may 

cause slippage. Use portable rumble strips that can be installed without adhesives or bolts and have a 

minimum weight of 105 pounds, and a non-slip textured surface on the rumble strip face.

635.22 Steel Plates. Use 1-inch or thicker steel plates that can safely carry traffic. Secure the plates to the 

pavement to prevent movement.

635.23 Advance Warning Arrow Board. Conform to the MUTCD Part 6.

635.24 Portable Changeable Message Sign. Conform to the MUTCD Part 6. Ensure that the portable 

changeable message sign (PCMS) display panel is raised to a fully upright position and is fully visible to 

motorists. Reduce the intensity of the lights when using PCMS at night. Use approved messages. Limit 

messages to two phases unless approved. Use a display time for each phase between 2 and 3 seconds.

635.25 Acceptance. Material for temporary traffic control devices will be evaluated under 

Subsections 106.02 and 106.03. 

Vehicles for pilot cars and shadow vehicles will be evaluated under Subsections 106.02 and 106.04. 

Placement of temporary traffic control devices will be evaluated under Subsections 106.02 and 106.04. 

Temporary traffic control services will be evaluated under Subsection 106.02. 

Temporary guardrail will be evaluated under Section 617. 

Temporary plastic fence will be evaluated under Section 619.

Waterborne traffic paint will be evaluated under Section 634. 

Measurement

635.26 Measure the Section 635 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

When measuring temporary traffic control pay items, measure only one time even if relocated or replaced.

When measuring barricades by the linear foot, measure barricades by the width.

When measuring construction signs by the square foot, measure front face sign panel. Do not measure 

posts and temporary supports. 
Section 635

767

When measuring moving portable traffic barriers, do not measure movement of portable traffic barriers

for work access or the convenience of the Contractor.

When measuring temporary pavement markings by the linear foot or mile, measure along the centerline 

of the roadway. Measure temporary pavement markings as a single measurement, inclusive of all 

markings, from end to end regardless of color, material type, or number of lines. Do not deduct for standard 

gaps between stripes.

When measuring temporary pavement markings by the square foot, measure the number of square feet of 

symbols or letter markings based on the marking area shown in the plans or, if not shown, the area of each 

marking measured in place to the nearest square foot.

Measure temporary pavement markers used at the option of the Contractor instead of temporary pavement 

markings as equivalent temporary pavement markings and not as temporary pavement markers. 

When measuring pavement marking removal, measure the actual line removed. Do not measure gaps. 

When measuring moving crash cushion by the each, do not measure movement of crash cushion for work 

access or the convenience of the Contractor.

When measuring replacement barrels or cartridges for crash cushions by the each, measure barrels or 

cartridges damaged by public traffic.

Measure flaggers for each hour a person is performing the work. Do not measure time required to set up 

and take down required signage. 

Do not measure flagging performed by the Traffic Control Supervisor. 

Do not measure flaggers used in place of a malfunctioning or inoperable temporary signal system. 

Payment

635.27 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 635 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

(a) Progress payments for temporary traffic control devices and markings will be paid as follows:

(1) 50 percent of the pay item amount will be paid after installation.

(2) An additional 25 percent of the pay item amount will be paid after 50 percent of the total work 

is completed in the contract.

(3) The remaining portion of the pay item amount will be paid after the temporary traffic control 

devices and markings are removed from the project.

(b) Progress payments for temporary traffic control by the lump sum will be paid as follows:

(1) 25 percent of the pay item amount will be paid after initial construction signs are in place and 

needed devices onsite for use.
Section 635

768

(2) An additional 65 percent of the pay item amount will be prorated based on total work completed 

in the contract.

(3) The remaining portion of the pay item amount will be paid after the construction signs and 

devices are no longer needed and have been removed from the project. 

(c) Progress payments for pay items paid for by the hour, or day, will be paid at 100 percent of the pay 

item amount.
Section 636

769

Section 636. — TRAFFIC SIGNAL, TRAFFIC COUNTER, LIGHTING,

AND ELECTRICAL SYSTEMS

Description

636.01 This work consists of installing, modifying, relocating, or removing traffic signals, traffic counter, 

flashing beacons, highway lighting, sign illumination, communication conduits, and electrical systems or 

provisions for future systems.

Material 

636.02 Conform to the following Subsections: 

Backer rod 712.01(f)

Electrical material 721.01

Joint sealant and crack fillers 712.01(a)

Lighting material 721.02

Underground precast concrete utility structures 725.09(d)

Construction Requirements

636.03 Regulations and Codes. Provide material and workmanship conforming to the standards of the 

National Electrical Code (NEC), local safety code, UL, NEMA, Insulated Cable Engineers Association 

(ICEA), and IMSA.

Obtain permits, arrange for inspections, and pay fees necessary to obtain electrical service.

Provide luminaires with crashworthy supports. 

Notify the CO, local traffic enforcement agency, utility companies, or railroad company at least 7 days 

before operational shutdown to coordinate connections or disconnections to an existing utility or system. 

636.04 General. At least 14 days before starting system installation work, submit a list of proposed 

equipment and material according to Subsection 104.06. Include the manufacturer’s name, size, and 

identification number of each item. Supplement the list with drawings and wiring diagrams showing 

locations and details of equipment and wiring. 

Obtain approval for the exact location of the systems. 

Remove structures and obstructions according to Section 203. Salvage material that meets requirements 

for reuse in the work. Excavate and backfill according to Section 209. Construct minor concrete according 

to Section 601. Install signs according to Section 633. 

If roadways are to remain open to traffic, maintain the existing systems in operation until final connection 

to the modified circuit to minimize traffic disruptions.

636.05 Conduit. Cut conduit so the ends are smooth. Connect conduit sections with couplings to butt the 

ends of both conduits squarely against each other inside the couplings. Provide a metal expansion and 

deflection fitting where conduit crosses a structural expansion joint.
Section 636

770

Install conduits continuous between outlets with at least couplings to allow pulling conductors. End 

conduit with bell fittings or bushings. Provide pull wires for conduits designated for future cable 

installation.

Remove and replace crushed, deformed, or damaged conduit. Maintain conduits clean and dry and protect 

ends of conduit with plugs, caps, or fittings. 

Size pull boxes to provide for termination of the conduit and connection of the conductors. 

636.06 Traffic Signal and Lighting Systems. Provide systems conforming to the MUTCD or state 

adopted supplements to the MUTCD for the state in which the system is located. Design systems to operate 

according to IMSA or NEMA or both. 

636.07 Traffic Counter and Traffic Counter Components. Obtain approval of traffic counter and traffic 

counter components before installation. 

Mount a fan inside the cabinet and position to direct the majority of airflow over the traffic counter and 

modem. Mount a fan thermostat at the top of the cabinet and minimize its interference with other cabinet 

components. Run the fan until the cabinet temperature decreases 20 degrees below the turn-on 

temperature.

Before powering-on equipment within the cabinet provide a copy of the following: 

(a) Voltages for solar power supplies; and

(b) Telephone number, IP address, or both, for communication devices. 

If using solar-powered panels, include a minimum 20-watt solar panel (that can produce at least 36 watt 

hours per day) and a minimum 12-volt, C100 36-ampere-hour, gel type battery that can power the cabinet 

electrical components for at least 25 days. 

Frame the solar panel with bronze anodized extruded aluminum. Mount a weatherproof connection on the 

back of the solar panel to connect the output cable to the solar panel cable. Ensure all cell modules have 

been approved for application in NEC Class I, Division 2, Group D hazardous location. 

Mount and orient the cabinet to provide an unobstructed, direct line of sight to the roadways that contain 

count station and vehicle detection equipment when cabinet door is opened. Install traffic counter and 

communications devices inside cabinet.

Identify and label loop wires inside each pull box in which the loop wires enter. Maintain consistent wiring 

identification and labeling when entering the cabinet and with connection to the traffic counter. Use water 

resistant material for wiring identification and labeling. Obtain approval for loop wire assignments at all 

locations. 

636.08 Rectangular Rapid-Flashing Beacons. Provide and install rectangular rapid-flashing beacons 

according to the MUTCD.

636.09 Traffic Loop. Do not install loops when the pavement is wet. Saw cut, wire, and seal loop wires 

on the same day. Do not allow vehicular traffic to pass over an open saw cut unless protected. 
Section 636

771

Wet cut clean, smooth, well-defined, 3⁄8-inch wide saw cuts at a depth to allow 2 to 21⁄2 inches of cover 

without damaging the adjacent pavement. Drill 11⁄2-inch diameter loop corners matching the saw cut depth. 

For the lead-in channel, saw clean, smooth, well-defined, 5/8-inch-wide cuts providing a minimum cover 

of 2 inches. Ensure saw cuts are straight with less than 1⁄2-inch error in a 10-foot line. Saw cut the lead-in 

to the pull box as close as possible to the edge of pavement. Thoroughly clean the saw cut of foreign 

material with compressed air and water blasting. Dry the joint with compressed air.

Install the loop wire in one continuous length at the bottom of the cut using a 3/16- to 1⁄4-inch thick rounded, 

smooth wood paddle. Install without kinks, curls, or other damage to the wire or its insulation. Replace 

damaged wires. Hold the loop wire in place with 1-inch lengths of 1⁄2-inch backer rod spaced at 2-foot 

intervals.

For the number of loop wire turns, conform to Table 636-1. 

Table 636-1 

Required Number of Loop Wire Turns

Required Number of Loop 

Wire Turns

Number of Turns

≤ 200 3

>200 to 500 4

>500 to 700 5

If the loop wire crosses a crack or joint, use a plastic sleeve that extends 4 inches on each side of the crack 

or joint. Provide extra loop wire in the sleeve for joint expansion and contraction. 

Twist the loop lead-in wires 6 twists per foot from the loop to the pull box. Do not twist different loop 

pairs together. Color code the wires of each loop using colored vinyl electrical tape for identification of 

separate loops inside each pull box, as shown in Table 636-2. Coil 18 inches of lead-in slack in the pull 

box for each loop. 

Table 636-2 

Loop Labeling Convention

Loop # of Identifiers Color

Loop 1 1 Red

Loop 2 1 White

Loop 3 1 Green

Loop 4 1 Blue

Loop 5 2 Red

Loop 6 2 White

Loop 7 2 Green

Loop 8 2 Blue

Before applying sealant, test the loop and lead-in for continuity and resistance by applying a 1000-volt 

megohmmeter between each end of the loop lead-in and the nearest reliable electrical ground. If no 

available ground exists, establish a ground for the measurement. Record the location and megohmmeter 

readings and submit readings and test equipment data to the CO. Replace the loop if the insulation 

resistance measure to earth ground is greater than 100 megohms at 500 volts direct current, the inductance 

is less than 50 microhenries or more than 800 microhenries, wire resistance is less than 1.75 ohms per 

700 feet, or the loop quality factor is less than 5 at 50 kilohertz. Install inductive loops with dedicated saw 

cuts and separate PVC conduits for each sensor lead-in cable from the edge of pavement to the first pull 

box. 
Section 636

772

Apply sealant to the saw cuts with the backer rods in place. Do not produce air bubbles when applying 

sealant. Remove excess sealant and finish level with the pavement. Follow the manufacturer’s 

recommendations for sufficient time for the sealant to harden before allowing traffic to cross the loops.

Repeat the resistance and continuity test after sealant is applied. Report the second test for comparison 

with the first test report.

Preformed inductive loops with 3 to 5 turns of #14 AWG cable with an insulation of XLPE (cross-linked 

polyethylene) encased in PVC pipe may be used as an alternative for use in new construction. 

Loop dimensions and spacing, based on lane width are shown in Table 636-3. 

Table 636-3 

Loop Dimensions and Spacing

Lane Width, feet Loop Dimension, feet Spacing to Centerline, feet

12 6 x 6 3 

11 5 x 5 3 

10 5 x 5 2.5

636.10 Testing and Demonstration Period for Traffic Counters. Before energizing portions of the 

system, demonstrate that the conductor system is clear and free of short circuits, open circuits, and 

unintentional grounds. Repair or replace faulty circuits.

After energizing the system, demonstrate that all electrical components work properly. Repair or replace 

faulty electrical components.

Conduct an on-site verification test according to ASTM E2300, Type I-2 with a 10 percent tolerance. For 

each loop tested, provide two human observers to count for the minimum duration of 15 minutes and at 

least 50 vehicles. If the test would likely last greater than 30 minutes to attain the 50-vehicle threshold, 

then test vehicles driven over the loops being tested should be considered. Conduct the test at an approved 

date and time.

Upon completion of construction at a location as shown in the plans the site will be placed in full scale 

operation for a 30-day demonstration period. Repair defects or complete necessary adjustments during the 

demonstration period. If failures occur during this demonstration period, perform repairs within 2 days. If 

necessary repairs are not completed within 3 days of notification, stop the demonstration period and 

resume only after such repairs and replacement of materials have been made, inspected, and approved.

636.11 Warranties, Guarantees, and Instruction Sheets. If installations are permanent, deliver the 

manufacturer’s warranties, guarantees, instruction sheets, and parts lists at the final inspection.

Within each cabinet, store one laminated copy of the cabinet wiring diagram and the field wiring diagram 

showing loops, pull boxes, and conduit runs inside two one-gallon re-sealable storage bags, one inside the 

other. Provide an electronic copy of each document to the CO. 

636.12 Relocations. Use material equivalent to existing material, unless present codes require different 

or improved material. Existing material may be salvaged and reused if material and installation methods 

used meet the requirements of applicable codes and ordinances. 
Section 636

773

636.13 Acceptance. Material for traffic signal, traffic counter, lighting and electrical systems will be 

evaluated under Subsections 106.02 and 106.03. 

Installation of traffic signal, traffic counter, lighting and electrical systems will be evaluated under 

Subsections 106.02 and 106.04. 

Excavation and backfill will be evaluated under Section 209. 

Installation of signs will be evaluated under Section 633.

Minor concrete will be evaluated under Section 601. 

Removal of structures and obstructions will be evaluated under Section 203. 

Measurement

636.14 Measure the Section 636 pay items listed in the bid schedule according to Subsection 109.02 and 

the following as applicable:

For relocations, do not measure additional line or connections necessary to place the fixture at the new 

location. 

Payment

636.15 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 636 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for lump sum pay items will be prorated based on total work completed under this 

Section. 
Section 637

774

Section 637. — FACILITIES AND SERVICES

Description

637.01 This work consists of providing, installing, maintaining, and removing facilities and services for 

the exclusive use of Government personnel. 

Construction Requirements

637.02 General. Provide the facilities and services starting no later than 14 days before starting on-site 

construction activities and ending no sooner than 21 days after on-site construction activities have 

concluded for all contract work. Provide notice for removal or termination date for facilities and services.

Submit a list of facilities, proposed facility locations, services, furnishings, and equipment for approval 

before committing to or signing any agreements or leases for these items.

Comply with applicable ordinances, safety codes, rules, and regulations. 

If facilities or services become defective, are damaged, stolen, or for other reasons do not function as 

intended; repair or provide a replacement within 8 hours after being notified. Repairs and replacements 

are subject to approval. 

Pay bills, including taxes and fees, for facilities and services by the payment due date.

Remove facilities and services when directed.

637.03 Facilities. Perform site work to accommodate the placement or construction of facilities. Conform 

to Subsection 107.10(d). 

Provide and maintain facilities according to Tables 637-1 and 637-2. If not otherwise specified, provide 

furnishings of standard size, character, and condition for their function. Provide batteries and light bulbs 

necessary for the provided furnishings. 

Provide safe, secure, sanitary, weatherproof buildings or trailers in good condition. Provide services 

according to Subsection 637.04. 

Restore the ground to its original condition upon removal of facilities. 

(a) Field office. Provide one of the following: 

(1) Office trailer. Provide a portable office trailer. Locate the office trailer on or adjacent to the 

project site, or as directed. Locate the trailer so that it can be accessed 24 hours a day, 7 days a 

week. Provide exterior lighting to illuminate the area surrounding the Government field office at

night. Equip the lights with photocell sensor devices and motion detectors to activate the lights. 

(2) Commercial office space. Provide office space at a commercial development adjacent to or 

near the project site.

(b) Residential housing. If the unit is part of a larger building, separate units with partitions and 

provide separate outside doors with locks. 
Section 637

775

Table 637-1 

Minimum Requirements for Field Facilities and Associated Services

Property Field

Office, Each

Residential

Housing, 

Each

Floor space, square feet 400 880

Locking outside door, deadbolt with 2 sets of keys 1 1 

Steps with slip-proof tread and handrails ✓(1) ✓(1)

Windows with locks 2 3 

Total window area, square feet 30 60

Ceiling height, 7 feet ✓ ✓

Rooms including toilet room 4 5(2)

Room size, except toilet room, square feet 100 100

Closet, 45-cubic foot − 2 

Shelves, 12-inch depth, square feet 12 12

Electrical lighting ✓ ✓

Heat and air conditioning, maintain temperature of 72±7 °F(3) ✓ ✓

Adequate electrical outlets ✓ ✓

Surge protectors 3 3 

Adequate electricity

(120 and 240 V, 60 cycle as applicable) ✓ ✓

Adequate potable water supply ✓ ✓

Drinking water cooler with water supply ✓ −

Sink with faucets for both hot and cold water ✓ ✓

Adequate hot and cold water supply − ✓

Shower/bath facilities − ✓

Parking for three vehicles on gravel, or paved surface ✓ ✓

6-foot-high chain link fence with gate around building and parking area ✓ −

(1) As required by local code.

(2) Includes two bedrooms.

(3) If window air conditioning is provided, provide a separate unit for each room 
Section 637

776

Table 637-2 

Minimum Facility Furnishings

Property Field

Office, Each

Residential

Housing, 

Each

Table, wood or like, 96 inches L x 30 inches W x 30 inches H 3 −

File cabinet, 2-drawer, fire resistant, metal, with lock and keys 1 −

File cabinet, 4-drawer, metal 1 −

Desk, wood or like, 60 inches L x 30 inches W x 30 inches H(1) 2 −

Desk lamp(1) 2 −

Office chair(1) 5 −

Storage cabinet, 72 inches L x 36 inches W x 18 inches H 1 −

Fire extinguisher 1 2 

Refrigerator, 18-cubic foot 1 1 

Range and oven, standard 36-inch − 1 

Microwave oven, 1.1 cubic foot, 1100 watt 1 1 

Kitchen table with 4 chairs, wood or like, 

60 inches L x 36 inches W x 30 inches H, minimum − 1 set

Sofa, 90 inches L x 38 inches W x 34 inches H, minimum − 1 

Coffee table, 36 inches L x 18 inches W x 16 inches H, minimum − 1 

Recliner chair − 2 

End table, 28 inches L x 17 inches W x 20 inches H, minimum − 3 

Table lamp, 26 inches H, minimum − 3 

Queen bed with frame, mattress, and box spring as necessary − 2 

Nightstand, 20 inches L x 20 inches W x 25 inches H, minimum − 4 

Nightstand lamp, 26 inches H, minimum − 4 

Dresser, six-drawer, wood or like − 2 

Television, 40-inch − ✓

Laundry (washer and dryer) − ✓

Vacuum cleaner, bagless, 12amp − ✓

(1) Meet accepted industry standards for ergonomics.

(c) Storage facility. Provide a storage facility with a minimum floor space of 100 square feet, that is 

secure, enclosed, covered, and protected from the elements. Secure the storage facility with a padlock 

or other approved device. Provide keys, lock combinations, or gate codes necessary for entry to the 

CO. Provide one of the following: 

(1) Stand-alone facility. Provide a stand-alone structure or storage container located adjacent to 

the Government field office, or as directed. Position the facility, or make improvements to the site, 

so that vehicles can park within 50 feet of the facility for loading and unloading. 

(2) Commercial facility. Provide a drive-up storage facility at a commercial development located 

within 15 roadway miles of the project.

(d) Vehicle. Provide a light duty, 4x4 wheel drive, gasoline powered pickup truck which is 7 model 

years old or newer and with less than 65,000 miles. Deliver the vehicle to the project site, field office, 
Section 637

777

or alternate location as directed. Do not include branding, stickers, or advertisements on the vehicle. 

Maintain the vehicle to provide safety and reasonable comfort for the operator with all factory 

equipment in working order. Provide fuel and perform required maintenance on the vehicle, including 

regular cleanings. 

Provide and maintain current vehicle registration and collision and comprehensive insurance. Secure 

vehicle insurance according to State and Local rules and regulations.

Equip the vehicle with tools, equipment, and a roadside emergency kit. Store equipment in a suitable 

container within the vehicle. Include the following:

(1) Automotive strobe light, amber;

(2) Full-size spare tire and jack;

(3) Jumper cables;

(4) Flares and reflective triangles;

(5) Fire extinguisher;

(6) First aid kit;

(7) Basic tool kit or multitool;

(8) Duct tape; 

(9) Blanket; 

(10) Flashlight with extra batteries;

(11) Shovel; 

(12) Axe or pulaski; and 

(13) Ice scraper and snow brush. 

637.04 Services. Provide utilities and services necessary to operate field offices and residential housing 

facilities according to Table 637-3 and the following. 

(a) Electricity. Provide electrical service from the local utility. Obtain approval to use generators if 

electricity cannot be provided to the facility by the utility.

(b) Water. Provide continuous potable water supply. 

(c) Natural gas, propane, or heating oil. Provide service from a local utility or provider if required 

for appliances and furnishings. 

(d) Sewer. Provide service from the local utility if required.
Section 637

778

(e) Portable toilet. Provide portable toilets if sewer or septic hookups are unavailable for field office 

trailers. Provide one portable toilet with weekly service and cleanings. Locate portable toilet adjacent 

to the field office, as directed. Provide hand sanitizer and toilet paper. Provide a padlock if requested.

(f) Trash and waste disposal. Provide trash and waste disposal service weekly.

(g) Drinking water. Provide a bottled water dispenser, that can cool and dispense chilled water. 

Provide purified drinking water for use with the water dispenser.

(h) Snow removal. Perform snow removal if directed. Plow parking areas and access roads to the 

provided facilities. Shovel sidewalks and walkways. 

(i) Landscape maintenance. Perform landscape maintenance if directed.

(j) Pest control. Perform pest control if directed.

(k) High-speed internet. Provide dedicated commercial high-speed internet service with no 

bandwidth limitations, data caps, or throttling that meets the following:

(1) Fiber Optic Service (FIOS), Cable Internet Service, or Digital Subscriber Line (DSL), with 

minimum speeds of:

(a) Download speed of 25,000 kilobits per second;

(b) Upload speed of 10,000 kilobits per second;

(2) Equipped with a modem and a router with a firewall or a router and a firewall appliance;

(3) Router with Internet Protocol Version 6 (IPv6) capability, Wi-Fi Protected Access II (WPA2) 

or higher encryption, Simple Network Management Protocol (SNMP) Monitoring, Dynamic Host 

Configuration Protocol (DHCP), and at least Category 6 Registered Jack 45 (RJ45) LAN office 

drop cables; and

(4) Supports simultaneous internet access of at least 3 workstations connected by Category 6 

Registered Jack 45 (RJ45) LAN office drop cables.

If the required service options are not available, alternate internet access service options, including 

Satellite Internet, a dedicated Transmission System 1 Line (T1), or mobile hotspot (MiFi) may be 

submitted for approval.

(l) Telephone. Provide telephone if directed. Provide local and long-distance telephone service. 

Provide two cordless telephones with the following capabilities:

(1) Touch tone, speaker phone, speed dial, hold button, and conference calling features; and 

(2) One digital telephone answering machine or voicemail service that can answer, record, store, 

and play back telephone messages and has storage capacity of at least 30 minutes in length.

(m) Television. Provide cable or satellite television service.
Section 637

779

Table 637-3 

Services Provided for Facilities

Service Field

Office, Each

Residential

Housing, 

Each

Electricity (120 and 240 V, 60 cycle as applicable) ✓ ✓

Water ✓ ✓

Natural gas, propane, and heating oil(1) ✓ ✓

Sewer(1) ✓ ✓

Portable toilet(2) ✓ −

Trash and waste disposal ✓ ✓

Drinking water ✓ −

Snow removal(3) ✓ ✓

Landscape maintenance(3) ✓ ✓

Pest control(3) ✓ ✓

High-speed internet ✓ ✓

Telephone ✓ ✓

Television − ✓

(1) If required for provided appliances or furnishings.

(2) If indoor flush toilets are not available.

(3) Provide service if directed.

637.05 Acceptance. Facilities and services will be evaluated under Subsections 106.02 and 106.04. 

Measurement

637.06 Measure the Section 637 pay items listed in the bid schedule according to Subsection 109.02. 

Payment

637.07 The accepted quantities will be paid at the contract price per unit of measurement for the 

Section 637 pay items listed in the bid schedule. Payment will be full compensation for the work 

prescribed in this Section. See Subsection 109.05. 

Progress payments for facilities and services by the lump sum or by the each will be paid as follows:

(a) 75 percent of the pay item amount will be paid after installation and acceptance for occupancy.

(b) The remaining portion of the pay item amount will be paid after the facilities and services are 

removed. 
780

DIVISION 700

MATERIAL
Section 701

781

Section 701. — CEMENTITIOUS MATERIAL

701.01 Hydraulic Cement. Do not mix cement brands or types. 

(a) Portland cement. Conform to AASHTO M 85.

(b) Blended hydraulic cement. Conform to AASHTO M 240. 

701.02 Reserved. 

701.03 Pozzolans.

(a) Fly ash. Conform to AASHTO M 295, Class C, 

Class F, or Class N. Available alkalies as equivalent 

Sodium Oxide (Na2O)

1.5 percent maximum

(b) Slag cement. Conform to AASHTO M 302, Grade

100 or Grade 120. Total alkalies as equivalent Na2O 

1.0 percent maximum

(c) Silica fume (microsilica). Conform to 

AASHTO M 307. Total alkalies as equivalent Na2O 

1.0 percent maximum

(d) High-reactivity pozzolans. Conform to 

AASHTO M 321. Total alkalies as equivalent Na2O 

1.0 percent maximum 

701.04 Grout. 

(a) Neat hydraulic cement grout. 

(1) Ground anchors, micropiles, and soil nails. Provide a pumpable mixture of portland cement, 

sand, water, and admixtures. Use hydraulic cement conforming to Subsection 701.01. If sand is 

added, provide sand conforming to Subsection 703.01. Provide water conforming to 

Subsection 725.01(a). Provide the minimum water content necessary for placement and a 

maximum water to cementitious material ratio of 0.45 by mass.

Chemical admixtures that control bleed or retard set may be used provided the additives conform 

to Subsection 711.03 and are mixed according to the manufacturer’s recommendations. Do not use 

admixtures containing more than trace (from impurities, not as an intended constituent) quantities 

of chlorides, fluorides, aluminum, zinc, or nitrates. 

The maximum water-soluble chloride ion content of the grout is 0.06 percent by mass of cement 

when tested according to ASTM C1218. 

Provide grout conforming to the following minimum compressive strengths:

(a) Ground anchors 3500 psi at 7 days 

(b) Micropiles 2500 psi at 7 days and 5000 psi at 28 days 
Section 701

782

(c) Soil nails 1500 psi in 3 days and 3000 psi in 28 days 

(2) Miscellaneous applications. Provide a grout consisting of a mixture of hydraulic cement, 

water, and admixtures. Do not exceed a water to cementitious material ratio of 0.44. Do not exceed 

20 percent of the cement by mass if fly ash is used. Admixtures to reduce water content, improve 

the flowability, control bleeding, or control shrinkage may be added according to the 

manufacturer’s recommendations. Provide admixtures free of chlorides, fluorides, sulphites, and 

nitrates.

(b) Non-shrink grout. Conform to ASTM C1107 and the following as specified: 

(1) Provide a minimum compressive strength of 5000 pounds per square inch in 3 days. 

(2) Provide a minimum compressive strength of 3000 pounds per square inch in 3 days. 

(c) Grout for post-tensioned structures. Conform to the requirements of the PTI, Guide 

Specification for Grouting of Post-Tensioned Structures. 

701.05 Mortar. 

(a) General mortar. Conform to ASTM C270. Use masonry cement Type M or S according to 

ASTM C91. 

(b) Packaged repair mortar. Conform to ASTM C928, Type R1 and the following:

(1) Relative dynamic modulus of elasticity, ASTM C666, 

Method A 

95 percent minimum

(2) Drying shrinkage, ASTM C157, except as modified by 

ASTM C882

0.07 percent maximum

(c) Latex-modified mortar. Conform to ASTM C1438, Type II.
Section 702 

783

Section 702. — ASPHALT MATERIAL AND ADDITIVES

702.01 Asphalt Binder. Conform to AASHTO M 226, AASHTO M 320, or AASHTO M 332. 

702.02 Emulsified Asphalt. Conform to AASHTO M 140 or AASHTO M 208. 

(a) Polymer-modified cationic emulsified asphalt for chip seals. Conform to AASHTO M 316. 

(b) Polymer-modified emulsified asphalt for micro surfacing. Conform to ISSA A143, except use 

AASHTO T 59, Section 7, Emulsified Asphalt Residue by Evaporation to determine percent residue.

(c) Penetrating emulsified asphalt for prime coat. Test according to AASHTO T 59, except as 

modified by Table 702-1. 

Table 702-1 

Penetrating Emulsion for Prime Coat

Property Minimum Maximum

Requirements for Emulsion

Viscosity, saybolt furol at 122 °F, sec 15 150

Settlement, 24 hours, % − 1

Residue by evaporation, % 62 −

Requirements for Residue

Penetration, 77 °F, 100 g, 5 sec, AASHTO T 49 40 200

(d) Engineered emulsion. Conform to the following:

(1) Residue by distillation 60 minimum 

(2) Sieve test 0.10 maximum 

(3) Test on residue from distillation:

(a) Penetration, 77 °F, 100g, 5s percent Target from mix design ±25 

(b) Ductility, 77 °F, 5 cm/min, cm 40 minimum 

(e) Polymer-modified emulsified asphalt membrane. Conform to Table 702-2. Follow 

AASHTO T 59 test method except where noted. 
Section 702

784

Table 702-2 

Polymer-Modified Emulsified Asphalt Membrane for

Ultrathin Bonded Wearing Course

Property Minimum Maximum

Requirements for Emulsion

Viscosity, saybolt furol at 77°F, sec 20 100

Storage stability, 24-hour, %(1) - 1 

Particle charge test positive - 

Sieve test, %(2) - 0.05

Residue by evaporation, % 63 - 

Requirements for Residue

Penetration, 77°F, 100 g, 5 sec AASHTO T 49 60 150

Elastic recovery, %, 50°F, 20 cm elongation,

5 cm/min, AASHTO T 301 58 - 

Ash content, AASHTO T 111 - 1 

(1) After standing undisturbed for 24 hours, the surface shows no white, milky colored 

substance, but is a smooth homogeneous color throughout.

(2) Use distilled water in all wetting and washing operations rather than a sodium oleate 

solution (two percent).

702.03 Hot-Applied Asphalt Aggregate-Filled Mastic. Conform to ASTM D8260. 

702.04 Asphalt Mastic. Conform to AASHTO M 243. 

702.05 Antistrip Additive. Conform to the following: 

(a) Type 1. Provide commercially produced, heat stable liquid products that when added to an asphalt 

have the chemical and physical properties to prevent separation of the asphalt from aggregates.

(b) Type 2. Provide cement conforming to Subsection 701.01 or fly ash conforming to 

Subsection 701.03(a). 

(c) Type 3. Provide lime conforming to AASHTO M 303. 
Section 703

785

Section 703. — AGGREGATE

703.01 Fine Aggregate for Concrete. Provide sand conforming to AASHTO M 6, Class B, except as 

modified or supplemented by the following: 

(a) Material passing No. 200 sieve, AASHTO T 11 3.0 percent maximum

(b) ASR. Test the aggregate for alkali silica reaction and conform to one of the following: 

(1) ASR, ASTM C1260 after casting 0.10 percent maximum at 16 days 

(2) ASR, ASTM C1260 0.11 percent to 0.20 percent at 

16 days after casting

Include one of the following examinations: 

(a) Petrographic examination of aggregates,

ASTM C295, performed within 1 year from time

of submittal 

Favorable report for use

(b) Petrographic examination of hardened

concrete, ASTM C856, performed on ASTM 

C1260 specimens after test

(c) Examinations according to AASHTO R 80 

for field performance history, limiting the alkali 

content of the concrete, or using supplementary 

cementitious materials or blended cements

Favorable report for use

Favorable study results or adequate 

prevention levels achieved

(3) ASR with cementitious after casting material, 

ASTM C1567, performed on approved mix design 

mass percent combinations. Do not use lithium 

compounds as mitigation measures. 

0.10 percent maximum at 16 days

(4) ASR, ASTM C1293 less than 0.04 percent at 12 months

(5) ASR with cementitious material, ASTM C1293, 

performed on approved mix design mass percent 

combinations. 

less than 0.04 percent at 24 months 

For lightweight fine aggregate, conform to AASHTO M 195. 

703.02 Coarse Aggregate for Concrete. Conform to AASHTO M 80, Class A, except as modified or 

supplemented by the following: 

(a) Los Angeles abrasion, AASHTO T 96 40 percent maximum

(b) Grading, AASHTO M 43 All sizes

(c) ASR Subsection 703.01(b)
Section 703

786

For bridge decks or surface courses, do not use aggregates known to polish or carbonate aggregates 

containing less than 25 percent by mass of insoluble residue as determined by ASTM D3042. 

For lightweight coarse aggregate, conform to AASHTO M 195. 

703.03 Underdrain Backfill. Provide aggregate for the following installations.

(a) Underdrain pipe with geotextile. Provide aggregate backfill conforming to AASHTO M 80, 

Class E and AASHTO M 43, Size Number 3, 4, 5, 57, 67, or 7. 

(b) Underdrain pipe without geotextile. Provide aggregate backfill conforming to AASHTO M 6, 

except the soundness test is not required. 

703.04 Reserved. 

703.05 Subbase, Base, and Surface Course Aggregate. 

(a) General. Provide hard, durable particles or fragments of crushed stone, crushed slag, or crushed 

gravel conforming to the following:

(1) Los Angeles abrasion, AASHTO T 96 35 percent maximum

(2) Soundness of aggregate using sodium sulfate AASHTO T 104, 5 cycles

(a) Coarse aggregate 12 percent loss maximum

(b) Fine aggregate 12 percent loss maximum

(3) Durability index (coarse), AASHTO T 210 35 minimum

(4) Durability index (fine), AASHTO T 210 35 minimum 

(5) Fractured faces, AASHTO T 335 70 percent minimum

(6) Without organic matter and lumps or balls of clay.

(b) Subbase or base course aggregate. In addition to Subsection 703.05(a), conform to the 

following:

(1) Gradation Table 703-1

(2) Liquid limit, AASHTO R 58 and AASHTO T 89 25 maximum
Section 703

787

Table 703-1 

Target Value Ranges for Subbase, Base, and Surface Course Gradation

Sieve 

size

Percent by Mass Passing Designated Sieve (AASHTO T 27 & T 11)

Grading Designation(1)

Subbase Base Surface

A B C D E F G H 

21⁄2 in 100 – – – – – – – 

2 in 97 to 100 100 100 – – – – – 

11⁄2 in – 97 to 100 – – – – – – 

1 in 65 to 79 – 80 to 100 100 100 – 100 – 

3⁄4 in – – 64 to 94 86 to 100 86 to 100 100 – 100

1⁄2 in 45 to 59 – – – – – 70 to 80 – 

3⁄8 in – – 40 to 69 51 to 82 51 to 82 62 to 90 – – 

No. 4 28 to 42 40 to 60 31 to 54 36 to 64 36 to 64 36 to 74 40 to 50 41 to 71

No. 10 – – – – – – 25 to 40 – 

No. 40 9 to 17 – – 12 to 26 12 to 26 12 to 26 15 to 25 12 to 28

No. 200 4.0 to 8.0 4.0 to 12.0 4.0 to 7.0 4.0 to 7.0 10 max(2) 4.0 to 7.0 8.0 to 14.0 9.0 to 16.0

(1) Contractor specified target values. See Table 703-2 for allowable deviations.

(2) Statistical procedures do not apply. 

(c) Surface course aggregate. In addition to Subsection 703.05(a), conform to the following: 

(1) Gradation Table 703-1

(2) Liquid limit, AASHTO R 58 and T 89, Method A 35 maximum 

(3) Plasticity index, AASHTO T 90 

(a) Grading G 10±3 

(b) Grading H 8±4 

Table 703-2 

Allowable Deviation

Based on Target Value for Aggregates

Percent by Mass Passing Allowable

Minimum Maximum Deviation

90.0 100 (1)

70.1 89.9 4 

60.1 70.0 5 

55.1 60.0 6 

45.1 55.0 7 

40.1 45.0 6 

30.1 40.0 5 

21.1 30.0 4 

8.1 21.0 3 

0 8.0 2 

(1) Statistical procedures do not apply.
Section 703

788

703.06 Crushed Aggregate. Provide hard, durable particles or fragments of crushed stone or gravel 

conforming to the size and quality requirements for crushed aggregate material normally used locally in 

the construction and maintenance of highways by Federal or state agencies. Provide crushed aggregate 

with a maximum size of 1 inch as determined by AASHTO T 27 and AASHTO T 11. Provide well-graded 

crushed aggregate, free of organic matter, lumps or balls of clay, and other deleterious material.

703.07 Asphalt Concrete Aggregate. Provide hard, durable particles or fragments of crushed stone, 

crushed slag, or crushed gravel conforming to the following:

(a) Los Angeles abrasion, AASHTO T 96 35 percent maximum

(b) Soundness of aggregate using sodium sulfate, AASHTO T 104 (5 cycles): 

(1) Coarse aggregate 12 percent loss maximum

(2) Fine aggregate 12 percent loss maximum

(c) Fractured faces, AASHTO T 335 90 percent minimum

(d) Fine aggregate angularity, AASHTO T 304, Method A 40.0 percent minimum

(e) Flat and elongated particles, ASTM D4791 (1:5 ratio, plus 

3⁄8-inch sieve, calculated by mass, weighted average)

10 percent maximum

(f) Sand equivalent, AASHTO T 176, Alternative Method 

No. 2, Reference Method

45 minimum

(g) Gradation. See Table 703-3

For the surface course, do not use aggregates known to polish or carbonate aggregates containing less than 

25 percent by mass of insoluble residue when tested according to ASTM D3042. 
Table 703–3 

Asphalt Concrete Aggregate Gradation

Sieve Size

Nominal Maximum Aggregate Size – Percent Passing(1)

Grading Designation(2)

1 inch 3⁄4 inch 1⁄2 inch 3⁄8 inch No. 4

Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum

11⁄2 in 100 – – – – – – – – – 

1 in 90 100 100 – – – – – – – 

3⁄4 in – 90 90 100 100 – – – – – 

1⁄2 in – – – 90 90 100 100 – – – 

3⁄8 in – – – – – 90 90 100 100 – 

No. 4 – – – – – – – 90 95 100

No. 8 19 45 23 49 28 58 32 67 70 80

No. 16 – – – – – – – – – – 

No. 30 – – – – – – – – – – 

No. 50 – – – – – – – – – – 

No. 200 1.0 7.0 2.0 8.0 2.0 10.0 2.0 10.0 4.0 10.0

(1) Size, grade and combine the aggregate fractions in mix proportions that result in a composite blend conforming to the specified gradation. Nominal maximum size is 

one sieve size greater than the first sieve to retain more than 10 percent of the combined aggregate. Test according to AASHTO T 27 and AASHTO T 11

(2) Contractor specified target values. Provide target values for all sieves designated in Table 703-3. See Table 703-2 for allowable deviations.
Section 703

790

703.08 Open-Graded Asphalt Friction Course Aggregate. Provide hard, durable particles or fragments 

of crushed stone, crushed slag, or crushed gravel conforming to the following: 

(a) Los Angeles abrasion, AASHTO T 96 35 percent maximum

(b) Soundness of aggregate using sodium sulfate, AASHTO T 104 (5 cycles) 

(1) Coarse aggregate 12 percent loss maximum

(2) Fine aggregate 12 percent loss maximum

(c) Fractured faces, AASHTO T 335 (two or more) 75 percent minimum

(d) Gradation Table 703-4

Table 703-4 

Target Value Ranges for 

Open-Graded Friction Course Aggregate Gradation

Sieve Size

Percent by Mass Passing Designated Sieve

(AASHTO T 27 & T 11)

Grading Designation(1)

A B 

1⁄2 in – 100

3⁄8 in 100 95 to 100

No. 4 30 to 45 50 to 70

No. 8 5 to 15 5 to 15

No. 200 2.0 to 5.0 2.0 to 5.0

(1) Contractor specified target values. See Table 703-2 for allowable deviations.

703.09 Chip Seal Aggregate. Provide hard durable particles or fragments of crushed gravel, crushed 

stone, crushed slag, or lightweight aggregates. Use only one type of aggregate on the surface treatment. 

Conform to the following:

(a) Gradation Table 703-5

(b) Clay lumps and friable particles, AASHTO T 112 1.0 percent maximum

(c) Flat and elongated particles, ASTM D4791 (1:3 ratio, plus 

3⁄8-inch sieve, calculated by mass, weighted average) 

10 percent maximum

(d) Fractured faces, AASHTO T 335 90 percent minimum

(e) Los Angeles abrasion, AASHTO T 96 40 percent maximum

(f) Soundness of aggregate using sodium sulfate,

AASHTO T 104 (5 cycles) 

12 percent loss maximum
Section 703

791

Table 703-5 

Target Value Ranges for 

Single and Double Course Chip Seal Aggregate Gradation

Sieve Size

Percent by Mass Passing Designated Sieve

(AASHTO T 27 & T 11)

Grading Designation(1)

A B C D 

1 in 100

3⁄4 in 90 to 100 100

1⁄2 in 0 to 35 90 to 100 100

3⁄8 in 0 to 12 0 to 35 85 to 100 100

No. 4 − 0 to 12 0 to 35 85 to 100

No. 8 − − 0 to 8 0 to 23

No. 200(2) 0.0 to 1.0 0.0 to 1.0 0.0 to 1.0 0.0 to 1.0

(1) Contractor specified target values. See Table 703-2 for allowable deviations.

(2) The allowable deviation is (plus or minus) 0.5.

703.10 Slurry Seal and Micro Surfacing Aggregate. Provide hard durable particles or fragments of 

crushed gravel or crushed stone. 

(a) Slurry seal aggregate. Conform to ISSA A105 and the following: 

(1) Gradation Table 703-6

(2) Los Angeles abrasion, AASHTO T 96, Grading D 35 percent maximum

(3) Sand equivalent, AASHTO T 176, Alternate 

Method No. 2, Reference Method 

45 minimum

(4) Soundness of aggregate using sodium sulfate fine,

AASHTO T 104 (5 cycles)

15 percent loss maximum

(b) Micro surfacing aggregate. Conform to ISSA A143 and the following:

(1) Gradation Table 703-6

(2) Los Angeles abrasion, AASHTO T 96, Grading D 30 percent maximum 

(3) Sand equivalent AASHTO T 176, Alternate

Method No. 2, Reference Method 

65 minimum

(4) Soundness of aggregate using sodium sulfate 

fine, AASHTO T 104 (5 cycles) 

15 percent loss maximum
Section 703

792

Table 703-6 

Micro Surfacing and Slurry Seal Aggregate Gradation

Sieve Size

Percent by Mass Passing Designated Sieve 

(AASHTO T 27 & T 11)

Grading Designation

I II III

3⁄8 in − 100 100

No. 4 100 90 to 100 70 to 90

No. 8 90 to 100 65 to 90 45 to 70

No. 16 65 to 90 45 to 70 28 to 50

No. 30 40 to 65 30 to 50 19 to 34

No. 50 25 to 42 18 to 30 12 to 25

No. 100 15 to 30 10 to 21 7 to 18

No. 200 10.0 to 20.0 5.0 to 15.0 5.0 to 15.0

703.11 Reserved. 

703.12 Blotter. Provide sound durable particles of gravel or crushed stone conforming to the following:

(a) Material passing 3⁄8-inch sieve, AASHTO T 27 100 percent

(b) Liquid limit, AASHTO R 58 and T 89, Method A 25 maximum 

(c) Without organic matter and clay balls.

703.13 Aggregate for Aggregate-Topsoil Course. Conform to AASHTO M 80, Class E and 

AASHTO M 43, Size Number 57. 

703.14 Sand. Provide clean material conforming to AASHTO M 6, Class B.

703.15 Flowable Backfill Aggregate. Provide hard, clean, durable, nonplastic, nonorganic, nonreactive 

aggregate conforming to Table 703-7. 

Table 703-7 

Flowable Backfill Aggregate

Sieve Size

Percent by Mass Passing

Designated Sieve

(AASHTO T 27 & T 11)

1 in 100

No. 200 0.0 to 10.0

703.16 Shotcrete Aggregate. Provide hard, clean, durable, nonplastic, nonorganic, nonreactive aggregate 

conforming to the following: 

(a) Fine aggregate. Conform to AASHTO M 6, Class B, except as modified or supplemented by the 

following:
Section 703

793

(1) Material passing No. 200 sieve, AASHTO T 3.0 percent maximum

(2) Sand equivalent value, AASHTO T 176, Alternate 

Method No. 2, Reference Method 

75 minimum

(3) ASR Subsection 703.01(b)

(b) Coarse aggregate. Conform to AASHTO M 80, Class A, except as modified or supplemented by 

the following:

(1) Los Angeles abrasion, AASHTO T 96 40 percent maximum

(2) ASR Subsection 703.01(b)

(c) Gradation. Combine fine and coarse aggregates to meet the designated gradation in Table 703-8. 

Table 703-8 

Shotcrete Gradation Limits for Combined Aggregates

Sieve Size

Percent by Mass Passing Designated Sieve

(AASHTO T 27 & T 11)

Grading Designation

A B

1⁄2 in – 100

3⁄8 in 100 90 to 100

No. 4 95 to 100 70 to 85

No. 8 80 to 98 50 to 70

No. 16 50 to 85 35 to 55

No. 30 25 to 60 20 to 35

No. 50 10 to 30 8 to 20

No. 100 2.0 to 10.0 2.0 to 10.0

703.17 Granular Rock Backdrain. Provide hard, durable, crushed, rock conforming to the following: 

(a) Los Angeles abrasion, AASHTO T 96 50 percent maximum

(b) Apparent specific gravity, AASHTO T 85 2.50 minimum

(c) Absorption, AASHTO T 85 4.0 percent maximum

(d) Durability index (coarse), AASHTO T 210 50 minimum

(e) Gradation Table 703-9

(f) Fractured faces, AASHTO T 335 90 percent minimum 
Section 703

794

Table 703-9 

Granular Rock Backdrain Gradation

Sieve Size

Percent by Mass Passing

Designated Sieve

(AASHTO T 27 & T 11)

6 in 100

4 in 0 to 25

No. 200 0.0 to 5.0

703.18 Ultrathin Bonded Wearing Aggregate. Provide hard, durable particles or fragments of crushed 

stone, crushed slag, or crushed gravel conforming to the following:

(a) Los Angeles abrasion, AASHTO T 96 35 percent maximum 

(b) Soundness of aggregate using sodium sulfate, AASHTO T 104 (5 cycles)

(1) Coarse aggregate 12 percent loss, maximum 

(2) Fine aggregate 12 percent loss, maximum 

(c) Flat and elongated particles, ASTM D4791, 1:3 ratio, plus 

3⁄8-inch sieve, calculated by mass, weighted average

25 percent maximum 

(d) Fractured faces, AASHTO T 335 (two or more) 90 percent minimum 

(e) Sand equivalent value, AASHTO T 176, Alternate 

Method No. 2, Reference Method 

45 minimum 

(f) Gradation Table 703-10

Table 703-10 

Target Value Ranges for 

Ultrathin Bonded Wearing Course Aggregate Gradation

Sieve Size Percent by Mass Passing Designated Sieve

(AASHTO T 27 & T 11)

1⁄2 in 100

3⁄8 in 85 to 100

No. 4 22 to 40

No. 8 19 to 32

No. 16 15 to 23

No. 30 10 to 18

No. 50 8 to 13

No. 100 6 to 10

No. 200 4 to 7
Section 703

795

703.19 Polyester Polymer Concrete Aggregate. Provide aggregate for PPC conforming to the following:

(a) Use natural sand for the fine aggregate.

(b) Crushed particles retained on the No. 8 sieve, 

AASHTO T 335

45 percent maximum

(c) Aggregate absorption (weighted average),

AASHTO T 84 and T 85 

1 percent maximum 

(d) Aggregate moisture content, AASHTO T 255 

 

less than 50 percent of aggregate 

absorption 

(e) Gradation Table 703-11

Table 703-11 

Polyester Polymer Concrete Aggregate 

Gradation Limits

Sieve Size

Percent by Mass Passing

Designated Sieve

(AASHTO T 27 & T 11)

3⁄8 in 100

No. 4 62 to 85

No. 8 45 to 67

No. 16 29 to 50

No. 30 16 to 36

No. 50 5 to 20

No. 100 0 to 7

No. 200 0 to 3

703.20 Geosynthetic Reinforced Soil Open-graded Backfill. Provide hard, crushed, durable particles or 

fragments of rock or gravel conforming to the following:

(a) Gradation AASHTO M 43, size number 

6, 67, 68, 7, 78, 8, or 89 

(b) Fractured faces AASHTO T 335 (two or more) 75 percent minimum 

(c) Soundness of aggregate using sodium sulfate, 

AASHTO T 104 (5 cycles) 

15 percent loss maximum 

(d) Los Angeles abrasion, AASHTO T 96 50 percent maximum
Section 704

796

Section 704. — SOIL

704.01 Soil and Soil-aggregate Materials. Provide suitable materials conforming to Table 704-1. 

Table 704-1 

Soil Gradation and Classification Requirements

Gradation and 

Classification 

Requirements

Material Designation

Foundation 

Fill

Bedding 

Material

Common 

Backfill

RSS

Backfill

Plastic 

Pipe 

Backfill

Structural

Backfill

Unclassified 

Borrow

Maximum 

particle size, in 2 1⁄2 3 11⁄2 3 24

Soil 

classification, 

AASHTO M 145

A-1-a – 

A-1 

A-2 

A-3 

A-1 

A-2-4 

A-2-5 

A-3 

– 

A-1 

A-3 

A-2-4 

Material passing 

No. 200 sieve,

AASHTO T 27 

& T 11

6.0 

maximum

10 

maximum – – 5.0 maximum – 

Plasticity index, 

AASHTO T 90 – – – – 6 maximum – 

Other 

Requirements – – Wellgraded Well-graded – – 

704.02 Select Borrow. Provide a suitable, well-graded material conforming to the following:

(a) Gradation Table 704-2

(b) Liquid limit, AASHTO T 89, Method A 30 maximum 

Table 704-2 

Select Borrow Gradation

Sieve Size

Percent by Mass Passing

Designated Sieve

(AASHTO T 27 & T 11)

3 in 100

1 in 70 to 100

No. 4 30 to 70

No. 200 0.0 to 5.0
Section 704

797

704.03 Select Granular Backfill. 

(a) General. Provide suitable, sound, durable, granular material conforming to the following:

(1) Gradation Table 704-3

(2) Angle of internal friction on the portion passing the 

No. 10 sieve, AASHTO T 236 

34 degree minimum

AASHTO T 236 is not required for material with more than 40 percent retained on the No. 4 sieve. 

If required, compact samples to 95 percent of the maximum density at +/-2 percent of the optimum 

moisture content determined according to AASHTO T 99, method A or B without oversized 

material corrections. Perform testing at confining stresses of 1, 2, 4, and 8 kips per square foot.

(3) Soundness of aggregate using sodium sulfate,

AASHTO T 104 (5 cycles) 

15 percent loss maximum

(4) Plasticity index, AASHTO T 90 6 maximum 

(5) Los Angeles abrasion, AASHTO T 96 50 percent maximum

Table 704-3 

Select Granular Backfill Gradation

Sieve Size

Percent by Mass Passing Designated Sieve

(AASHTO T 27 & T 11)

Backfill with Geosynthetic 

Reinforcement Backfill with Metallic Reinforcement

4 in – 100

11⁄2 in 100 – 

No. 40 0 to 60 0 to 60

No. 200 0.0 to 15.0 0.0 to 15.0

(b) MSE walls with metallic reinforcements. Conform to Subsection 704.03(a) and the following:

(1) Resistivity, AASHTO T 288 3000 Ω centimeter minimum

(2) pH, AASHTO T 289 5.0 to 10.0 

(3) Sulfate content, AASHTO T 290 200 ppm maximum 

(4) Chloride content, AASHTO T 291 100 ppm maximum 

Tests for sulfate and chloride content are not required if resistivity is greater than 

5000 ohm centimeters.

(c) MSE walls with geosynthetic reinforcements. Conform to Subsections 704.03(a) and 

704.03(b)(2). 
Section 705

798

Section 705. — ROCK

705.01 Gabion and Revet Mattress Rock. Provide angular stone from a rock quarry or cut that is hard, 

durable, free of organic and other unsuitable material, and resistant to weathering and water action. Do 

not use crushed river rock or rock with rounded surfaces. Conform to the following: 

(a) Durability index (coarse), AASHTO T 210 50 minimum

(b) Density of a filled basket 100 lb/ft3 minimum

(c) Gradation. Provide rock with breadth and thickness at least one-third its length.

(1) Baskets 1 foot or greater in the vertical dimension.

(a) Maximum dimension 8 inches 

(b) Minimum dimension 4 inches 

(2) Baskets less than 1 foot in the vertical dimension. 

(a) Maximum dimension 6 inches 

(b) Minimum dimension 3 inches 

(d) Los Angeles abrasion, AASHTO T 96 50 percent maximum

705.02 Rock for Riprap. Provide hard, durable, angular rock that is resistant to weathering and water 

action, and free of organic and other unsuitable material. Angular rock is characterized by sharp, clean 

edges at the intersections of relatively flat surfaces. Do not use shale, rock with shale seams, or other 

fissile or fissured rock that may break into smaller pieces in the process of handling and placing. Conform 

to the following:

(a) Apparent specific gravity, AASHTO T 85 2.40 minimum

(b) Absorption, AASHTO T 85 4.0 percent maximum 

(c) Soundness of aggregate using sodium sulfate,

AASHTO T 104 (5 cycles) 

12 percent loss maximum 

(d) Los Angeles abrasion, AASHTO T 96 50 percent maximum 

(e) Rock particle intermediate dimension (width) and minimum 

dimension (thickness) 

1⁄3 longest dimension (length)

minimum

(f) Gradation, FLH T 521 Table 705-1
Section 705

799

Table 705-1 

Gradation Requirements for Riprap(1)

Class

Percent of Rock

Equal or Smaller

by Count, DX

Range of Intermediate

Dimensions,

inches(2)

Range of Rock Mass,

pounds(3)

1 

100 9 to 15 59 to 270

85 7 to 11 28 to 110

50 5 to 8 10 to 42

15 3 to 6 2 to 18

2 

100 15 to 21 270 to 750

85 11 to 15 110 to 270

50 8 to 11 42 to 110

15 6 to 8 10 to 42

3 

100 21 to 27 750 to 1600

85 15 to 19 270 to 560

50 11 to 14 110 to 220

15 8 to 10 42 to 81

4 

100 27 to 33 1600 to 2900

85 19 to 23 560 to 990

50 14 to 17 220 to 400

15 9 to 12 59 to 140

5 

100 33 to 39 2900 to 4850

85 23 to 28 990 to 1800

50 17 to 20 400 to 650

15 11 to 15 110 to 270

6 

100 39 to 45 4850 to 7400

85 28 to 32 1800 to 2650

50 20 to 23 650 to 990

15 13 to 17 180 to 400

7 

100 45 to 54 7400 to 12,800

85 32 to 38 2650 to 4450

50 23 to 28 990 to 1800

15 15 to 20 270 to 650

8 

100 54 to 66 12,800 to 23,400

85 38 to 47 4450 to 8450

50 28 to 35 1800 to 3500

15 19 to 25 560 to 250

9 

100 66 to 78 23,400 to 38,600

85 47 to 55 8450 to 13,500

50 35 to 41 3500 to 5600

15 22 to 30 870 to 2200

10

100 78 to 90 38,600 to 59,300

85 55 to 64 13,500 to 21,300

50 41 to 48 5600 to 9000

15 26 to 36 1450 to 3800

(1) Gradation includes spalls and rock fragments to provide a stable, dense mass.

(2) The intermediate dimension is the longest straight-line distance across the rock that is perpendicular to 

the rock’s longest axis on the rock face with the largest projection plane.

(3) Rock mass is based on a specific gravity of 2.65 and 85 percent of the cubic volume as calculated using 

the intermediate dimension. 
Section 705

800

705.03 Rock for Masonry Structures. Provide sound, durable rock of the texture and color specified. 

Provide rock without reeds, rifts, seams, laminations, and minerals that may cause discoloration or 

deterioration from weathering.

Unless otherwise specified, provide rock fragments with the following dimensions:

(a) Minimum thickness 5 inches 

(b) Minimum width 12 inches or 11⁄2 times the 

thickness, whichever is greater 

(c) Minimum length 11⁄2 times the width 

(d) Rocks with volume ≥1 cubic foot 50 percent minimum

When headers are required, provide headers with lengths at least the width of bed of the widest adjacent 

stretcher plus 12 inches. 

705.04 Rock for Special Rock Embankments. Provide angular rock that is hard, durable, resistant to 

abrasion and weathering, and that is free of weak cleavages that may cause the rock to disintegrate during 

handling and placing. 

(a) Mechanically-placed embankments. Provide rock conforming to Table 705-2. 

Table 705-2 

Range of Mechanically-Placed Rock

Percent of Rock

Fragments by

Mass

Range of Intermediate

Dimensions,

inches(1)

Range of Rock Mass,

pounds(2)

50 > 29 > 2000

50 10 to 29 90 to 2000

(1) The intermediate dimension is the longest straight-line distance across the rock that is 

perpendicular to the rock’s longest axis on the rock face with the largest projection plane.

(2) Rock mass is based on a specific gravity of 2.65. 

(b) Hand-placed embankments. Provide rock conforming to Table 705-3. 

Table 705-3 

Range of Hand-Placed Rock

Percent of Rock

Fragments by

Mass

Range of Intermediate

Dimensions,

inches(1)

Range of Rock Mass,

pounds(2)

75 > 14 > 165

25 10 to 14 90 to 165

(1) The intermediate dimension is the longest straight-line distance across the rock that is 

perpendicular to the rock’s longest axis on the rock face with the largest projection plane.

(2) Rock mass is based on a specific gravity of 2.65.
Section 705

801

705.05 Rock for Buttresses.

(a) General. Provide angular rock that is hard, durable, free of organic and other unsuitable material, 

and resistant to weathering and water action. Conform to the following: 

(1) Rock breadth and thickness At least one-third of the rock length 

(2) Apparent specific gravity, AASHTO T 85 2.40 minimum 

(3) Absorption, AASHTO T 85 4.0 percent maximum

(4) Durability index (coarse), AASHTO T 210 52 minimum

(b) Mechanically-placed buttresses. In addition to Subsection 705.05(a), provide rock conforming 

to Table 705-2. 

(c) Hand-placed buttresses. In addition to Subsection 705.05(a), provide rock conforming to 

Table 705-3. 

705.06 Rock for Rockeries. Provide hard, angular, and durable rock that consists of a solid mass without 

open fractures, foliation, or other planes of weakness that are generally cubical, tabular, or rectangular in 

shape. Do not provide crushed river rock or rock with rounded surfaces. Conform to the following:

(a) Apparent specific gravity, AASHTO T 85 2.50 minimum 

(b) Absorption, AASHTO T 85 4.0 percent maximum

(c) Los Angeles abrasion, AASHTO T 96 50 percent maximum

(d) Durability index (coarse), AASHTO T 210 52 minimum

(e) Soundness of aggregate using sodium sulfate, 

AASHTO T 104 (5 cycles) 

12 percent loss maximum

(f) Size and shape 

(1) Rock length See plans

(2) Rock breadth and thickness At least one-third of rock length

(3) Rock dimension 18 in minimum

(4) Cap rock mass 200 lb minimum

705.07 Rock Mulch. Provide hard, durable native rock that is resistant to weathering and free of excess 

moisture, muck, frozen lumps, roots, sod, or other deleterious material conforming to the following: 

(a) Maximum particle size 6 in

(b) Minimum particle size 2 in 
Section 705

802

(c) Apparent specific gravity, AASHTO T 85 2.40 minimum 

(d) Absorption, AASHTO T 85 4.0 percent maximum

(e) Soundness of aggregate using sodium 

sulfate, AASHTO T 104 (5 cycles)

12 percent loss maximum

(f) Los Angeles abrasion, AASHTO T 96 50 percent maximum

705.08 Filter Rock. Provide hard, durable, angular rock that is resistant to weathering and water action 

and free of organic or other unsuitable material. Angular rock is characterized by sharp, clean edges at the 

intersections of relatively flat surfaces. Do not use shale, rock with shale seams, or other fissile or fissured 

rock that may break into smaller pieces in the process of handling and placing. Conform to the following:

(a) Apparent specific gravity, AASHTO T 85 2.40 minimum 

(b) Absorption, AASHTO T 85 4.0 percent maximum

(c) Soundness of aggregate using sodium 

sulfate, AASHTO T 104 (5 cycles)

12 percent loss maximum

(d) Los Angeles abrasion, AASHTO T 96 50 percent maximum

(e) Rock particle intermediate dimension 

(width) and minimum dimension (thickness) 

1⁄3 longest dimension (length) 

minimum

(f) Gradation Table 705-4

Table 705-4 

Gradation Requirements for Filter Rock

Percent of Rock by 

Mass

Range of Intermediate 

Dimensions, inches(1)

Range of Rock Mass,

pounds(2)

20 6 to 8 21 to 49

30 5 to 6 12 to 21

40 3 to 5 2.6 to 12

10 2 to 3 0.8 to 2.6

(1) The intermediate dimension is the longest straight-line distance across the rock that is 

perpendicular to the rock’s longest axis on the rock face with the largest projection plane.

(2) Rock mass is based on a specific gravity of 2.65.

705.09 Wall Facing Fill. Provide hard, durable, angular, or fractured rock without organic or other 

unsuitable material. Do not use shale, rock with shale seams, or other fissile or fissured rock that may 

break into smaller pieces in the process of handling and placing. Conform to the following: 

(a) Gradation. Provide rock with width and thickness at least one-third its length with a 6-inch 

maximum dimension. Ensure that 95 percent of wall facing fill particles minimum dimension exceeds 

welded wire facing opening with remaining 5 percent exceeding one-half of the welded wire facing 

opening.

(b) Soundness of aggregate using sodium 

sulfate, AASHTO T 104 (5 cycles) 

15 percent loss maximum
Section 705

803

(c) Los Angeles abrasion, AASHTO T 96 50 percent maximum 

(d) A minimum of 75 percent of individual particles exhibit an angular, rough, or broken surface either 

naturally occurring or created by crushing, blasting, or other means. The surface is well defined by 

sharp natural angles or fractured edges and consist of one half or more of the projected area, when 

viewed normal to that face.
Section 706

804

Section 706. — CONCRETE PIPE

706.01 Non-Reinforced Concrete Pipe. Conform to AASHTO M 86 for the diameters and strength 

classes specified.

706.02 Reinforced Concrete Pipe. Conform to AASHTO M 170 for the diameters and strength classes 

specified. For precast reinforced concrete end sections, conform to cited specifications to the extent they 

apply. 

706.03 Perforated Concrete Pipe. Conform to AASHTO M 175, Type 1 or Type 2 and AASHTO M 86 

for the diameters and strength classes specified.

706.04 Reinforced Arch-Shaped Concrete Pipe. Conform to AASHTO M 206 for the diameters and 

strength classes specified.

706.05 Reinforced Elliptically-Shaped Concrete Pipe. Conform to AASHTO M 207 for the diameters, 

placement design (horizontal or vertical), and strength classes specified.

706.06 Reinforced D-Load Concrete Pipe. Conform to AASHTO M 242 for the diameters specified.

706.07 Precast Reinforced Concrete Box Sections. Conform to ASTM C1577 for the design earth cover, 

size, and the circumferential reinforcement area specified. Meet the design requirements for AASHTO, 

LRFD Bridge Design Specifications with HL-93 live load. Clearly mark the following information on the 

inner surface of each box section by indentation, waterproof paint, or other approved means: 

(a) Box span and rise; 

(b) Date of manufacture;

(c) Name of manufacturer;

(d) Submittal number; and

(e) Date certified by manufacturer.

706.08 Gaskets for Concrete Pipe. 

(a) Elastomeric seals. Conform to ASTM C1619, Class C. 

(b) Resilient connectors. Conform to ASTM C923. 

706.09 Supplemental Concrete Pipe Ties. Conform to ASTM A307 or ASTM F1554 and galvanize tie 

hardware.
Section 707

805

Section 707. — METAL PIPE

707.01 Ductile Iron Culvert Pipe. Conform to ASTM A716 for the sizes specified. 

707.02 Metallic-Coated Corrugated Steel Pipe. Provide pipe, special sections (such as elbows, branch 

connections, and prefabricated flared end sections) and coupling bands conforming to AASHTO M 36 

and either AASHTO M 218, AASHTO M 274, or AASHTO M 289 for the dimensions, classification 

type, and thicknesses specified.

Fabricate underdrain pipe from steel sheets with a minimum thickness of 0.052 inch. Use any class of 

perforation specified in AASHTO M 36. 

707.03 Aluminum-Alloy Corrugated Pipe. Provide pipe, special sections (such as elbows, branch 

connections, and prefabricated flared end sections) and coupling bands conforming to AASHTO M 196 

for the dimensions, classification type, and thicknesses specified.

Fabricate underdrain pipe from aluminum sheets with a minimum thickness of 0.048 inch. Use any class 

of perforation.

707.04 Asphalt-Coated Pipe. Provide pipe, special sections (such as elbows, branch connections, and 

prefabricated flared end sections), and coupling bands conforming to this Section as applicable for the 

kinds of pipes to be coated. 

Coat the pipe with asphalt material conforming to AASHTO M 190 for the type of coating specified. Coat 

special sections (such as elbows, branch connections, and end sections) and coupling bands according to 

AASHTO M 190. Coat flared end sections with an asphalt coating conforming to AASHTO M 190, 

Type A or a field applied asphalt mastic coating conforming to AASHTO M 243. 

707.05 Steel Structural Plate Structures. Provide structures and assembly fasteners for connecting 

plates conforming to AASHTO M 167 for the sizes and types specified. 

707.06 Aluminum-Alloy Structural Plate Structures. Provide structures and assembly fasteners for 

connecting plates conforming to AASHTO M 219 for the sizes and types specified. 

707.07 Asphalt-Coated Structural Plate Structures. Provide structures conforming to either 

Subsection 707.05 or 707.06 as applicable. Coat with an asphalt coating conforming to AASHTO M 190, 

Type A or a field applied asphalt mastic coating conforming to AASHTO M 243. 

If the asphalt coating is applied to the plates before field erection, identify each plate’s nominal metal 

thickness by painting the data on the inside surface of the plates after coating. Other methods of plate 

identification may be used if approved. 

707.08 Polymer-Coated Steel Pipe. Provide pipe, special sections (such as elbows and branch 

connections) and coupling bands conforming to AASHTO M 245, Grade 250/250 and AASHTO M 246, 

Grade 250/250, for the dimensions, classification type, and class, if applicable, specified. 
Section 707

806

707.09 Corrugated Metal Units. Conform to AASHTO M 36 for steel corrugated units. Conform to 

AASHTO M 196 for aluminum corrugated units. See the plans for the diameter, shape, specific pipe 

classification and, if applicable, class. For coatings, conform to the following: 

(a) Bituminous-coated corrugated units AASHTO M 190, Type A 

(b) Polymer-precoated corrugated units AASHTO M 245, Grade 

250/250 

707.10 Metallic-Coated Slotted Drain Pipe. Provide pipe conforming to AASHTO M 36 and either 

AASHTO M 218, AASHTO M 274, or AASHTO M 289 for the dimensions, thicknesses, classification 

type, class, if applicable, and coating type specified.

Fabricate the pipe with either angle slots or grate slots and as shown in the plans. 

Provide grate assemblies for the grate slot drain conforming to ASTM A1011, SS Grade 36. Galvanize 

slot angles and grate slot assemblies according to AASHTO M 111.

707.11 Metallic-Coated Spiral Rib Pipe. Provide pipe, special sections (such as elbows and branch 

connections), and coupling bands conforming to AASHTO M 36, Type IR and Type IIR, AASHTO 

M 218, AASHTO M 274, or AASHTO M 289 for the dimensions, thicknesses, and coating type specified.

707.12 Aluminum-Alloy Spiral Rib Pipe. Provide pipe, special sections (such as elbows and branch 

connections) and coupling bands conforming to AASHTO M 196, Type IR and Type IIR for the 

dimensions and thicknesses specified.

707.13 Concrete-Lined Corrugated Steel Pipe. Provide pipe, special sections (such as elbows and 

branch connections), and coupling bands conforming to Subsection 707.02 for the dimensions and 

thicknesses specified. Fully line the pipe and special sections with concrete according to ASTM A849, 

Class C.

707.14 Invert-Paved Corrugated Steel Pipe. Provide pipe, special sections (such as elbows and branch 

connections), and coupling bands conforming to Subsection 707.02 for the dimensions and thicknesses 

specified. Pave the invert of the pipe and special sections with concrete or asphalt material according to 

ASTM A849, Class A or Class C.

707.15 Cast Iron Soil Pipe and Fittings. Conform to ASTM A74, Class SV for the designated sizes. 

707.16 Seamless Copper Water Tube and Fittings. Conform to ASTM B88, Type L for the designated 

sizes.

707.17 Gaskets for Metal Pipe. 

(a) O-ring gaskets for flexible metal pipe. Conform to ASTM C1619, Class C. 

(b) Continuous flat gaskets for flexible metal pipe with flat bands or bands with projections.

(1) Conform to ASTM D1056.

(2) Gasket thickness 1⁄2 in greater than the nominal depth of pipe 

corrugations
Section 707

807

(c) Continuous flat gaskets for flexible metal pipe with corrugated bands. 

(1) Conform to ASTM D1056. 

(2) Gasket thickness 3⁄8 in

707.18 Gaskets for Ductile Iron Pipe. Conform to ASTM A746. 
Section 708

808

Section 708. — PLASTIC PIPE

708.01 Smooth Wall Polyethylene Pipe. 

(a) General use. Provide perforated and nonperforated 12- to 42-inch diameter pipe conforming to 

ASTM F714 and minimum cell Class PE335434C according to ASTM D3350. 

(b) Water systems (4 inches and over). Provide pipe conforming to the requirements of 

ANSI/AWWA C906. Fabricate from high-density polyethylene PE3408 conforming to a minimum 

cell Class 345464 C, D or E according to ASTM D3350. 

708.02 Corrugated Polyethylene Pipe. 

(a) General use. Provide perforated and nonperforated 12- to 48-inch diameter pipe conforming to 

AASHTO M 294.

(b) Culvert and storm drains. Provide Type S pipe conforming to AASHTO M 294. 

708.03 Profile Wall (Ribbed) Polyethylene Pipe. Provide perforated and nonperforated 18- to 48-inch 

diameter pipe conforming to ASTM F894 and minimum cell Class 334433C or 335434C according to 

ASTM D3350. 

708.04 Corrugated Polyethylene Drainage Tubing. Provide perforated and nonperforated 3- to 10-inch 

diameter tubing conforming to AASHTO M 252. 

708.05 Corrugated Polypropylene Pipe. 

(a) Culvert and storm drains. Provide 12- to 48-inch diameter pipe conforming to AASHTO M 330, 

Type S or Type D. 

(b) Sanitary sewers. Provide pipe conforming to ASTM F2764/F2764M. 

708.06 Smooth Wall Polyvinyl Chloride Pipe.

(a) General use. Provide perforated and nonperforated 4- to 15-inch diameter pipe conforming to 

AASHTO M 278 and minimum cell Class 12454 or Class 12364 according to ASTM D1784. 

(b) Sanitary sewers. Conform to ASTM D3034. 

(c) Water systems.

(1) PVC pipe (4 inches and over). Provide pipe and fittings conforming to the requirements of 

ANSI/AWWA C900 or ANSI/AWWA C905 and listed by UL. Provide joints conforming to the 

requirements of ASTM D3139 and using a restrained rubber gasket conforming to ASTM F477. 

(2) PVC pipe (under 4 inches). Provide pipe and fittings conforming to ASTM D2241. Select 

PVC 1120, PVC 1220, or PVC 2120 with a minimum wall thickness equal or greater than a 

standard dimension ratio (SDR) of 21. Provide pipes bearing the National Sanitation Foundation 

Seal for use to transport potable water. Provide joints conforming to the requirements of ASTM 
Section 708

809

D3139 using a restrained rubber gasket conforming to ASTM F477. Provide solvent cement for 

pipe and fittings conforming to ASTM D2564. 

(d) Horizontal drains. Provide Schedule 80 pipe and couplers conforming to ASTM D1785. Select 

PVC 1120, PVC 1220, PVC 2112, PVC 2116, or PVC 2120. Provide Schedule 80, solvent weld 

fittings conforming to ASTM D2467.

(e) Lined drain holes in rock. Provide Schedule 80 pipe and couplers conforming to ASTM D1785. 

Provide Schedule 80 solvent weld fittings conforming to ASTM D2467. 

Provide slotted pipe with three rows of 0.01-inch slots on 120-degree centers cut around the 

circumference and at least 0.75 square inch of slot opening per linear foot. 

708.07 Profile Wall (Ribbed) Polyvinyl Chloride Pipe. Provide perforated and nonperforated 4- to 

48-inch diameter pipe conforming to AASHTO M 304 and minimum cell Class 12454C or Class 12364C 

according to ASTM D1784. For sanitary sewer applications, conform to ASTM F794 or ASTM F949. 

708.08 Acrylonitrile-Butadiene-Styrene (ABS) Pipe. Conform to ASTM D2680. 

708.09 Gaskets for Plastic Pipe.

(a) Elastomeric seals. Conform to ASTM F477. 

(b) Thermoplastic elastomeric seals. Conform to ASTM F913. 
Section 709

810

Section 709. — REINFORCING STEEL AND WIRE ROPE

709.01 Reinforcing Steel. 

(a) Reinforcing bars. Provide deformed, Grade 60 bars conforming to AASHTO M 31 or AASHTO 

M 322.

(b) Epoxy-coated reinforcing bars. Provide bars conforming to Subsection 709.01(a). For

epoxy-coated prefabricated reinforcing bars, conform to ASTM A934. For epoxy-coated reinforcing 

bars, conform to ASTM A775. 

Inspect the reinforcing bars after the near-white blast cleaning. Reject bars with steel slivers or scabs. 

Provide epoxy-coated reinforcing steel coated at a CRSI-certified epoxy coating plant. 

(c) Corrosion-resistant steel reinforcing bars. Fabricate from one of the following:

(1) Stainless steel reinforcing bars, AASHTO M 334, UNS Designations: S24000, S30400, 

S31603, S31653, S31803, or S32304. 

(2) Low-carbon, chromium steel reinforcing bars, AASHTO M 334, Type 1035 CS. 

(d) Tie bars. Provide deformed, Grade 60 bars conforming to AASHTO M 31. 

(e) Hook bolts. Provide plain, Grade 60 bars conforming to AASHTO M 31 with M14 rolled threads 

or M16 cut threads. Provide a threaded sleeve nut that can sustain a minimum axial load of 15,000 

pounds. 

(f) Dowel bars. Conform to AASHTO M 254, Type A or Type B. Use plain round bars, without 

burring or other deformation restricting free movement in the concrete. Paint one-half of the length of 

each dowel bar with one coat of tar paint. When the paint dries and immediately before placing the 

dowels, lubricate the painted end to prevent concrete from bonding to the painted end. 

For expansion joints, provide a dowel cap that snugly covers 2±1⁄4 inches of the dowel, has a closed 

end, and has a stop to hold the closed end 1 inch from the end of the dowel bar. 

Lubricants for Type B dowels may be medium setting emulsified asphalt or flaked graphite. Lubricants 

are not required for Type A coated dowel bars. 

Provide dowel assemblies that hold dowel bars within 1⁄4-inch tolerance vertically and horizontally 

during concrete placement and allow unrestricted movement of the pavement slab. 

Provide wire conforming to AASHTO M 336 for dowel assemblies. Coat dowel assemblies with the 

same material as the dowel bar. Recoat or repair damaged coatings equivalent to the manufacturer’s

original coating. 

(g) Deformed steel wire. Conform to AASHTO M 336. 

(h) Steel welded wire reinforcement, plain, for concrete. Conform to AASHTO M 336. 
Section 709

811

(i) Cold-drawn steel wire. Conform to AASHTO M 336. 

(j) Welded deformed steel wire reinforcement. Conform to AASHTO M 336. 

(k) Fabricated deformed steel bar or rod mats. Conform to AASHTO M 54. 

(l) Low alloy steel deformed bars. Conform to ASTM A706. 

709.02 Prestressing Steel. Conform to the following:

(a) Low-relaxation, uncoated seven-wire steel strand, AASHTO M 203, Grade 270; 

(b) High-strength steel bars, AASHTO M 275, Type II; or 

(c) Stress-relieved steel wire, AASHTO M 204, Type BA or Type WA. 

709.03 Wire Rope. Provide IWRC or equivalent, EIP stranded steel 6 x 19 or 7 x 19 wire ropes 

conforming to ASTM A1023. 
Section 710

812

Section 710. — FENCING AND MESH FABRICS

710.01 Barbed Wire. Provide galvanized wire or aluminum coated wire conforming to AASHTO M 280.

710.02 Smooth Wire. Provide smooth wire conforming to ASTM A854. 

710.03 Woven Wire. Provide galvanized fabric or aluminum coated fabric conforming to 

AASHTO M 279. 

710.04 Chain Link Fence. Provide fabric, posts, rails, ties, bands, bars, rods and other fittings, and 

hardware conforming to AASHTO M 181. 

Provide 0.177-inch coiled spring steel tension wire conforming to ASTM A641 hard temper with a Class 

3 galvanized coating. Use the same coating on the tension wire as used on the rest of the chain link fence.

710.05 Fence Posts and Bollards. 

(a) Wood. Conform to AASHTO M 168. 

Peel bark, except for red cedar posts and bracing, which do not require peeling. Trim knots flush with 

the surface and season the wood.

For dimension lumber for fences, bollards, or gate posts, use timber that is sound, straight, and 

reasonably without knots, splits, and shakes. Provide S4S finish. 

(b) Steel. Conform to AASHTO M 281, except that chain link fence conforms to AASHTO M 181. 

710.06 Split Rail. Conform to ASTM F537. 

710.07 Fence Gates. For frame gates using chain link fabric, conform to AASHTO M 181. Use the same 

chain link fabric in the gate as in the fence.

710.08 Temporary Plastic Fence. Provide plastic noncorrosive fence fabricated from polyethylene and 

UV stabilized for outdoor weathering. Conform to the following: 

(a) Height 48 in minimum 

(b) Mesh openings 3.15 to 3.35 in 

(c) Color International orange 

(d) Mass 0.16 lb/ft minimum

710.09 Draped Rockfall Protection Fabric.

(a) Double-twist wire mesh. Provide 8x10 double-twist, hexagonal wire mesh conforming to ASTM 

A975, Style 1. 

(b) High tensile strength steel wire mesh. Provide a homogenous high tensile strength steel wire 

mesh consisting of one wire type with a minimum tensile strength exceeding 250,000 pounds per 
Section 710

813

square inch with a zinc and aluminum galvanizing applied at a minimum weight of 0.025 ounces per 

square feet. Provide a mesh with a minimum tensile strength of 10.0 kips per foot.

(c) Wire mesh fastener. Provide wire mesh fasteners specified by the wire mesh manufacturer.

(d) Cable net with wire mesh backing.

(1) Cable net panels. Provide net panels that are constructed from either a 1x3 high tensile steel

wire spiral rope or a 7x19 galvanized aircraft cable (GAC), EIP steel with a minimum nominal 

diameter of 5/16 inch and breaking strength of at least 9800 pounds. Use net panels with a grid size

opening no larger than 12 inches by 12 inches or with a diamond in-circle diameter less than

10 inches. For the net panels made with GAC wire rope, provide wire rope conforming to Federal

Specification RR-W-410 and ASTM A1023.

(2) Wire mesh backing. Provide one of the following mesh fabrics for use as the wire mesh 

backing attached to the cable net wire panels: 

(a) 8x10 double-twist, hexagonal wire mesh conforming to ASTM A975, Style 1; 

(b) Galvanized wire mesh consisting of No. 9 gauge (0.148-inch diameter) commercial quality 

steel wire, 31⁄2 inches by 51⁄2 inches diamond mesh chain link conforming to AASHTO M 181. 

Galvanize the wire according to ASTM A392, Class 1. Galvanize wire before weaving. 

Provide a wire mesh fabric with knuckled selvages; or 

(c) Homogenous high tensile strength steel wire mesh consisting of one type of wire. Provide 

a mesh with wires with a minimum diameter of 0.079 inch, minimum tensile strength of 

250,000 pounds per square inch, and a zinc and aluminum coating applied at a minimum 

weight of 0.40 ounce per square feet. Provide a mesh with a longitudinal minimum tensile 

strength of 3.6 kips per foot, and a mesh diamond in-circle diameter no larger than 4 inches. 

(e) Lacing and seaming wire rope. Conform to Subsection 709.03. 

710.10 Midslope Rockfall Attenuator Materials.

(a) Fence post columns. Provide columns fabricated from wide flange structural members 

conforming to ASTM A992 or AASHTO M 270, Grade 50 or 50S and galvanized following 

fabrication according to AASHTO M 111 or ASTM A123. Provide bars or plates welded to steel posts 

conforming to ASTM A572 Grade 50 or AASHTO M 270, Grade 50 and galvanized after fabrication 

according to AASHTO M 111 or ASTM A123. 

(b) Attenuator net panels. Conform to Subsection 710.09(d)(1). 

(c) Steel post foundation. Provide #3 diameter and #4 deformed, Grade 60 bars conforming to 

AASHTO M 31 or AASHTO M 322 as reinforcing steel bars for the concrete foundations. 

(d) Wire mesh backing. Provide one of the following mesh fabrics for use as the wire mesh attached 

to the attenuator net panels:

(1) Double-twist wire mesh. Provide 8x10 double-twist, hexagonal wire mesh conforming to 

ASTM A975, Style 1; or 
Section 710

814

(2) High tensile strength steel wire mesh. Provide a homogenous high tensile strength steel wire 

mesh consisting of one type of wire. Provide a mesh with wires with a minimum diameter of 

0.079 inch, minimum tensile strength of 250,000 pounds per square inch, and a zinc and aluminum 

coating applied at a minimum weight of 0.40 ounce per square feet. Provide a mesh with a 

longitudinal minimum tensile strength of 3.6 kips per foot, and a mesh diamond in-circle diameter 

no larger than 4 inches. 

(e) Wire mesh fastener. Conform to Subsection 710.09(c). 

(f) Lacing and seaming wire rope. Conform to Subsection 709.03. 
Section 711

815

Section 711. — CONCRETE CURING MATERIAL AND ADDITIVES

711.01 Curing Material. Conform to the following: 

(a) Burlap cloth AASHTO M 182

(b) Sheet material ASTM C171

(c) Liquid membrane forming compounds ASTM C309, Type I-D or Type 2 

711.02 Air-Entraining Admixtures. Conform to AASHTO M 154. 

711.03 Chemical Admixtures. Provide water-reducing, retarding, set-accelerating, and hydration 

stabilizing admixtures, or combinations thereof, conforming to AASHTO M 194. For hydration 

stabilizing admixtures, conform to AASHTO M 194, Type B or Type D. 

711.04 Latex Emulsion. Provide a homogeneous, nontoxic, film forming polymeric emulsion in water 

with stabilizers added at the point of manufacture. Conform to the following:

(a) Color White

(b) Styrene butadiene polymer type stabilizer 68±4 percent styrene

32±4 percent butadiene

(c) Chlorides 0 percent

(d) Polymer particle size 1500 to 2500 Angstroms average

(e) Latex nonionic surfactant 

(f) Solids 46.5 to 49.0 percent

(g) Mass 8.40 to 8.55 lb/gal @ 77 °F 

(h) pH 9.0 to 13.0 

(i) Shelf life 2 years minimum 

(j) Portland cement composition Polydimethylsiloxene

711.05 Concrete Coloring Agents. Conform to ASTM C979. Use only coloring agents composed of 

synthetic or natural inorganic iron oxides. 

711.06 Reinforcing Fibers. 

(a) Fibers for shotcrete. Use deformed steel or fibrillated polyolefin fibers conforming to ASTM 

A820 or ASTM D7508. 
Section 711

816

(b) Fibers for concrete. Use fully oriented, collated, fibrillated, white, 3⁄4-inch long fibers of 

100 percent virgin polyolefin conforming to ASTM D7508. Dose at 1.5 to 3 pounds per cubic yard of 

concrete.

(c) Fibers for UHPC.

(1) Closure pour. Use deformed steel fibers conforming to ASTM A820, minimum tensile 

strength 290,000 pounds per square inch conforming to ASTM A370. 

(2) UHPC overlay. Conform to ASTM A820, Type I cold drawn wire. 
Section 712

817

Section 712. — JOINT MATERIAL

712.01 Sealants, Fillers, and Seals. Conform to the following:

(a) Joint sealants and crack fillers.

(1) Joint and crack sealant, hot-applied, for concrete 

and asphalt concrete pavements

ASTM D6690, Type II or Type III

(2) Crack filler, hot-applied, for concrete and asphalt 

concrete pavements

ASTM D5078

(3) Proprietary asphalt-rubber products, provide the following:

(a) Source and grade of asphalt binder; 

(b) Total quantity of granulated rubber and mass as a percent of asphalt-rubber mixture;

(c) Granulated rubber types and quantity of each type (if blend); 

(1) Mass as a percent of combined rubber; and

(2) Gradation of granulated rubber. 

(d) Type of asphalt modifier, if any;

(e) Quantity of asphalt modifier and mass as a percent of asphalt binder;

(f) Other additives; 

(g) Heating and application temperatures; and

(h) Manufacturer’s recommended application procedures.

(4) Elastomeric joint sealant ASTM C920, Type M, Grade P,

Class 25, use T1 or T2

(5) Flexible cellular joint filler ASTM D1056, Type 2, Class B or 

Class C, Grades 3, 4, or 5

(b) Preformed expansion joint fillers. Provide in a single piece for the depth and width required for 

the joint.

(1) Preformed expansion joint filler for concrete 

(bituminous type)

AASHTO M 33

(2) Preformed sponge rubber expansion joint 

filler for concrete paving and structural 

construction 

AASHTO M 153, Type I
Section 712

818

(3) Preformed cork expansion joint filler for 

concrete paving and structural construction 

AASHTO M 153

(4) Performed expansion joint filler for concrete 

paving and structural construction (non-extruding 

and resilient bituminous types)

AASHTO M 213

(c) Preformed polychloroprene elastomeric joint seal for concrete pavements. Conform to 

ASTM D2628. Use a lubricant conforming to ASTM D2835, which was manufactured within 

9 months of use.

(d) Cold-applied, single component, chemically curing silicone joint sealant for concrete 

pavement (non-sag). Conform to ASTM D5893, Type NS. 

(e) Cold-applied, single component, chemically curing silicone joint sealant for concrete 

pavement (self-leveling). Conform to ASTM D5893, Type SL. 

(f) Backer rod. Conform to ASTM D5249, Type 1. Use a compatible sealant as recommended by the 

rod manufacturer. For size of backer rod, conform to Table 712-2. 

Table 712-2 

Backer Rod Sizes

Joint Width After Preparation, inch Rod Diameter, inch

5

⁄16 3⁄8

3⁄8 1⁄2 

1⁄2 5⁄8

5⁄8 3⁄4 

3⁄4 1 

1 11⁄4

11⁄4 11⁄2

11⁄2 2 

(g) Preformed polychloroprene elastomeric joint seal for bridges. Conform to AASHTO M 297. Use 

an adhesive lubricant conforming to ASTM D4070. 

(h) Pre-compressed foam-supported silicone joint seal.

(i) Provide a joint system comprised of the following: 

(1) Cellular polyurethane foam impregnated with hydrophobic 100 percent acrylic, water-based 

emulsion, factory coated with highway-grade, fuel resistant silicone conforming to Table 712-3. 

(2) Field-applied epoxy adhesive primer conforming to Table 712-4. 

(3) Field-injected silicone sealant bands conforming to Table 712-5. 
Section 712

819

Table 712-3 

Impregnated Foam Requirements

Property Test Method Minimum Requirement

Base material – Cellular, high density, polyurethane foam

Tensile strength ASTM D3574 18 psi

UV and moisture resistance ASTM G155 No changes - 2000 hours, Pass

Density ASTM D545 4 lb./cu. ft.

Elongation ASTM D3574 125%

Temperature service range ASTM C711 -40 to 185 °F

Table 712-4 

Epoxy Adhesive Requirements

Property Test Method Minimum Requirement

Tensile strength ASTM D638 3500 psi

Shear strength ASTM D732 3000 psi

Bond strength ASTM D882 2500 psi

Compressive strength ASTM D695 8000 psi

Table 712-5 

Silicone Sealant Bands Requirements

Property Test Method Requirement

Color Visual Black

Movement capability ASTM C719 ±50%

Elongation ASTM D412 > 600%

Tensile strength ASTM D412 ≥ 100 psi

(j) Asphaltic plug joints. Conform to ASTM D6297 except for Table 1 recommended application 

heating range.
Section 713

820

Section 713. — ROADSIDE IMPROVEMENT MATERIAL

713.01 Topsoil. 

(a) Provided topsoil. Provide fertile, friable, free draining, sandy loam soil that is free of subsoil, 

refuse, stumps, roots, brush, weeds, rocks larger than 1 inch, or other substances detrimental to the 

development of plant growth. Conform to the following: 

(1) Texture

(a) Organic matter, AASHTO T 267 3.0 to 10.0 percent

(b) Sand, AASHTO T 88 20 to 70 percent

(c) Silt, AASHTO T 88 10 to 60 percent

(d) Clay, AASHTO T 88 5 to 30 percent 

(2) pH, AASHTO T 289 6.0 to 8.0 

(b) Conserved topsoil. Conform to Subsection 204.02(c). 

713.02 Agricultural Limestone. Provide calcic or dolomitic ground limestone conforming to the 

standards of the Association of Official Analytical Collaboration (AOAC) International, applicable 

Federal and state rules and regulations, and the following: 

(a) Purity (calcium and magnesium) carbonates 75 percent minimum

(b) Gradation Table 713-1

Table 713-1 

Agricultural Limestone Gradation

Sieve Size

Minimum Percent by Mass

Passing Designated Sieve

(AASHTO T 27)

No. 10 90

No. 40 50

Granulated slag or other approved natural sources of lime may be used provided the application rate is 

adjusted to equal the total neutralizing power of the specified ground limestone. 

713.03 Fertilizer. Provide standard commercial grade dry formulated fertilizer conforming to the 

standards of the AOAC International, applicable Federal and state rules and regulations, and required 

minimum percentages of available nutrients.

Provide the fertilizer in new, clean, sealed, and properly labeled containers with name, mass, and 

guaranteed analysis of contents clearly marked.

Liquid fertilizer containing the minimum percentage of available nutrients may be used. 
Section 713

821

713.04 Seed. Conform to the Federal Seed Act, the Federal Plant Protection Act, and applicable state and 

local seed and noxious weed laws. Do not use wet, moldy, contaminated, or damaged seed. Provide each 

seed type in separate sealed containers. Clearly label each container with the following:

(a) Name and type of seed;

(b) Lot number; 

(c) Net mass;

(d) Percent of purity, germination, and hard seed; 

(e) Percent of maximum weed seed content; 

(f) Seed origin; 

(g) Noxious weeds present;

(h) Other crop seed; 

(i) Inert matter;

(j) Name and address of seed distributor; and

(k) Mixture percent of each component.

Inoculate legume seed with approved cultures according to the manufacturer’s recommendations. 

713.05 Mulch.

(a) Straw. Provide certified weed free straw from oats, wheat, rye, rice, or other grain crops that is 

not discolored, brittle, rotten, or moldy. Provide straw in an air-dry condition suitable for placing with 

mulch blower equipment.

(b) Wood fiber. Provide processed wood fiber from wood chips conforming to the following:

(1) Colored with a green dye non-injurious to plant growth; 

(2) Readily dispersible in water;

(3) Nontoxic to seed or other plant material;

(4) Free of growth or germination inhibiting substances; 

(5) Free of weed seed;

(6) Air dried to a moisture content of 12±3 percent;

(7) Packaged in new containers labeled with the manufacturer’s name; and
Section 713

822

(8) Packaged in a condition appropriate for mixing in a homogeneous slurry suitable for 

application with power spray equipment.

(c) Grass straw cellulose fiber. Provide processed grass straw fiber conforming to the following: 

(1) Colored with a green dye non-injurious to plant growth; 

(2) Readily dispersible in water;

(3) Nontoxic to seed or other plant material;

(4) Free of growth or germination inhibiting substances;

(5) Free of weed seed;

(6) Air dried to a moisture content of 10±0.2 percent;

(7) Air dried to a uniform mass of ±5 percent; 

(8) Packaged in new containers labeled with the manufacturer’s name and air-dry mass; and

(9) Packaged in a condition appropriate for mixing in a homogeneous slurry suitable for 

application with power spray equipment.

(d) Peat moss. Provide a granulated sphagnum peat moss conforming to the following:

(1) Sticks, stones, and mineral matter 0 percent

(2) Partially decomposed stems and leaves of sphagnum 75 percent minimum

(3) Color Brown

(4) Textured from porous fibrous to spongy fibrous 

(5) pH 3.5 to 7.5 

(6) Air-dried

(e) Mature compost. Provide partially decomposed organic material, (such as leaves, grass, shrubs, 

and yard trimmings) cured for 4 to 8 weeks. Maturity is indicated by temperature stability and soil like 

odor. Provide friable, dark brown, weed-free, and pathogen-free mature compost conforming to the 

following:

(1) Carbon/nitrogen ratio 25/1 to 35/1 

(2) Carbon/phosphorus ratio 120/1 to 240/1 

(3) pH 6.0 to 7.8 

(4) Water content 40 percent maximum

(5) Particle size
Section 713

823

(a) Seeding and sodding 1⁄2 inch maximum 

(b) Erosion control 1 inch maximum 

(6) Organic material 50 percent minimum

(7) Synthetic, plastic, metal, or glass material 2 percent maximum

(f) Straw for hydroseeding. Provide clean agricultural straw milled to 1 inch or less in length. Dry 

the fibers to 10 percent moisture for compaction. Bale in heat-sealed plastic bags.

(g) Bonded fiber matrix hydromulch. Provide a mixture of fibers and bonding agent which, when 

hydraulically applied and dried, produce a matrix conforming to the following: 

(1) Does not dissolve or disperse when wetted;

(2) Holds at least 10 ounces of water per ounce of dry matrix; 

(3) Has no germination or growth inhibiting factors; 

(4) Forms no water insensitive crust;

(5) Contains material that is 100 percent biodegradable; and

(6) Is colored with a green dye non-injurious to plant growth. 

(h) Recycled pulp fiber. Provide cellulose fiber mulch products manufactured from natural material 

diverted from the waste-stream of manufacturing processes or produced from recycled material. These 

include newsprint, chipboard, corrugated cardboard, wood chips, and similar material. Process the 

material to eliminate substances that inhibit seed germination and plant growth. Add a colored dye 

that is non-injurious to plant growth and fades rapidly with exposure to light. Provide fiber that readily 

blends with water, grass seed, fertilizer, and other additives to form a slurry suitable for application 

with power spray equipment. Provide a homogeneous mixture conforming to the following:

(1) Synthetic, plastic, metal, or glass material 0 percent

(2) Weed seed 0 percent

(3) Moisture content 15 percent maximum

(4) Ash content 7 percent maximum

(5) Organic matter 90 percent minimum

(6) Boron 250 ppm maximum 

(7) Water-holding capacity 800 to 1200 percent by mass

(8) pH 4.0 to 8.5 
Section 713

824

(i) Wood chips. Provide wood chips from local sources including clearing. Maximum size of chips is 

4 by 2 by 1⁄2 inches. 

713.06 Plant Material. Unless otherwise specified, conform to the American Standard for Nursery Stock. 

(a) Quality of plant material. Provide plants that are excellent representatives of their normal species 

or varieties. Provide nursery grown stock that has been transplanted or root-trimmed two or more times 

according to the kind and size of plant. Provide plants with a normally developed branch system. Do 

not provide plants with disfiguring knots, sun-scald, injuries, abrasions of the bark, dead or dry wood, 

broken terminal growth, or other disfigurements.

Provide trees with reasonably straight stems and well branched and symmetrical branches according 

to their natural habits of growth.

(b) Plant names. For scientific and common plant names, conform to the United States Department 

of Agriculture (USDA) PLANTS Database. Clearly tag and identify plants by name and size.

(c) Grading standards. Conform to the latest edition of the American Standard for Nursery Stock 

ANSI Z60.1. 

(d) Nursery inspection and plant quarantine. Provide plants that are without plant diseases and 

insect pests.

Comply with nursery inspection and plant quarantine rules and regulations of the states of origin and 

destination including Federal rules and regulations governing interstate movement of nursery stock. 

Provide a valid copy of the certificate of inspection with each package, box, bale, or carload shipped 

or otherwise delivered. 

(e) Balled and burlapped plants. Provide plants from the original and undisturbed soil in which the 

plants were grown. Dig balled and burlapped plants to retain as many fibrous roots as possible. Wrap, 

transport, and handle the plants so the soil ball and small fibrous roots remain intact.

713.07 Cellular Confinement Systems. Provide a flexible honeycomb three-dimensional structure 

fabricated from light stabilized polyethylene plastic. Conform to the following: 

(a) Functional longevity 120 months minimum

(b) Cell area 31.0 to 46.5 in2 

(c) Sheet thickness, ASTM D751 48.8 to 49.6 mils 

(d) Density, ASTM D792 0.549 to 0.555 oz/in3

(e) Carbon black content, ASTM D1603 1.5 to 2.5 percent 

(f) Environmental stress-cracking, ASTM D1693 2000 hours minimum

(g) Conform to Table 713-2 for the depth specified.
Section 713

825

Table 713-2 

Cellular Confinement Systems

Property Requirements

Nominal

cell depth, inch 2 3 4 6 8 

Cell joint

Strength, pound 110 minimum 160 minimum 225 minimum 315 minimum 450 minimum

713.08 Miscellaneous Planting Material. 

(a) Stakes for bracing and anchoring. Conform to the American Softwood Lumber Standard 

(Voluntary Product Standard PS 20). Fabricate stakes for bracing and anchoring trees from rough 

cypress, cedar, locust, or other approved wood essentially without knots, rot, crossgrain, or other 

defects that would impair the strength of the stake. Provide stakes with a minimum 2- by 2-inch square 

cross-section and adequate length.

Provide anchor stakes of the same size and quality as bracing stakes. Provide deadman anchors with 

the diameter and length specified. 

(b) Hose. Provide 1-inch diameter hose (rubber and fabric) to be used with wire for bracing and 

anchoring trees.

(c) Wire. Provide 0.15-inch diameter soft annealed galvanized steel wire for bracing and anchoring 

trees.

(d) Wrapping material. Provide 4-inch-wide rolls of waterproof paper (triple lamination 30-30-30) 

or 6-inch-wide rolls of burlap for wrapping trees.

(e) Twine. Provide two-ply twine for trees 3 inches and less in diameter and three-ply twine for trees 

over 3 inches in diameter for tying wrapping material to the trees.

(f) Antidesiccant. If approved, provide a commercially available antidesiccant emulsion to provide a 

film over plant surfaces that is permeable enough to allow transpiration.

(g) Tree wound dressing. Provide a commercially available product with asphalt base and fungicide. 

Provide material that is antiseptic, waterproof, adhesive, and elastic. Do not use material that is 

harmful to living tree tissue (such as kerosene, coal tar, or creosote).

713.09 Sod. Provide living vigorous sod of the type of grass and thickness specified. Provide sod with a 

dense root system that is free of noxious weeds and grasses. Before taking up the sod, cut the top growth 

to less than 3-inch height. 

713.10 Pegs for Sod. Provide square or round pegs of sound wood conforming to the following: 

(a) Length 8 inches minimum

(b) Approximate cross-sectional area 1 square inch
Section 713

826

713.11 Tackifiers. Provide a commercially available product containing no solvents or other diluting 

agents toxic to plant life that is without growth or germination inhibiting factors, nonflammable, nontoxic 

to aquatic organisms, and functional for at least 180 days. 

(a) General purpose tackifier. Provide one of the following:

(1) Plant based tackifier. Provide a natural high molecular weight polysaccharide, a high 

viscosity hydrocolloid that is miscible in water, and labeled as one of the following:

(a) Guar gum. A product derived from the ground endosperm of the guar plant, Cyamopsis 

tetragonolobus, treated with dispersing agents for easy mixing and dilutable at the rate of 1 to 

5 pounds per 100 gallons of water.

(b) Psyllium. A product manufactured from the finely ground mucilloid coating of Plantago 

ovata or Plantago ispaghula seeds; able to dry and form a firm, but rewettable membrane.

(c) Starch. A product manufactured from a nonionic, water-soluble, granular material derived 

from corn, potato, or other plant-based source. 

(2) Polymeric emulsion blend tackifier. Provide a prepackaged liquid or dry powder, anionic 

formulation with a residual monomer content no more than 0.05 percent by mass and labeled with 

one of the following as the primary active ingredient:

(a) Acrylic copolymers and polymers;

(b) Polymers of methacrylates and acrylates;

(c) Copolymers of sodium acrylates and acrylamides; 

(d) Polyacrylamide and copolymer of acrylamide; or 

(e) Hydrocolloid polymers.

(b) Polymer stabilized fiber matrix tackifier. Provide the following:

(1) A liquid formulation with polyacrylamide as the primary active ingredient with the following 

requirements:

(a) Linear, anionic copolymer of acrylamide and sodium acrylate; and

(b) Anionic with a residual monomer content that is no more than 0.05 percent by mass.

(2) Formulated and labeled as one of the following: 

(a) Water-in-oil emulsion. A product containing at least 2.6 pounds per gallon pure 

polyacrylamide that is at least 30 percent active; or

(b) Liquid dispersed polyacrylamide. A product containing at least 4.4 pounds per gallon pure 

polyacrylamide that is at least 35 percent active.

713.12 Fiber Rolls. 
Section 713

827

(a) Excelsior fiber rolls. Provide fiber rolls of curled excelsior fiber rolled into a cylindrical shape 

and encased in a tubular netting. 

(b) Straw fiber rolls. Provide straw fiber rolls that are manufactured from certified weed free straw 

and wrapped in a tubular netting.

(c) Coir fiber rolls. Provide coir fiber rolls that are 100 percent coconut fiber rolled into a cylindrical 

shape and encased in a tubular netting.

(d) Compost fiber rolls. Provide tubular netting filled with mature compost conforming to 

Subsection 713.05(e).

(e) Tubular netting for fiber rolls. Provide biodegradable tubular netting with openings no larger 

than 3⁄8 inch. Provide tubular netting diameter according to the plans. Do not use monofilament netting 

or similar material.

713.13 Gravel Bags. Provide woven fabric bags with a minimum water flow rating of 145 gallons per 

minute per foot as tested by ASTM D4491. Fill the bags with clean coarse aggregate.

713.14 Sandbags. Use clean, silt free material for sand filler. Conform to the following: 

(a) Bag material canvas, geotextile, or burlap 

(b) Volume per bag 1⁄3 ft3 minimum

713.15 Temporary Culvert Pipe. Provide temporary culvert pipe fabricated from corrugated metal, 

plastic, or concrete. Provide temporary culvert pipe placed beneath the traveled way conforming to HS-20 

(M-18) loading rating in AASHTO, LRFD Bridge Design Specifications. 

713.16 Silt Fence.

(a) Geotextile. Conform to Table 7 of AASHTO M 288. 

(b) Posts. Conform to the following: 

(1) Wood posts. Conform to the following: 

(a) 11⁄2 inches by 11⁄2 inches by 4 feet minimum dimensions;

(b) Untreated fir, redwood, cedar, or pine, cut from sound timber with no loose or unsound 

knots; and 

(c) Pointed on end driven in ground. 

(2) Steel posts. Conform to the following:

(a) 48 inches minimum length;

(b) Cross-section shape that can resist failure from lateral loads (T-shaped, U-shaped, or 

L-shaped); and 
Section 713

828

(c) 0.75 pound per foot minimum mass.

(c) Silt fence reinforcement. Provide a wire mesh consisting of 14-gauge steel with mesh spacing of 

6 by 6 inches or prefabricated polymeric mesh of equivalent strength.

713.17 Rolled Erosion Control Products. Provide RECP conforming to Table 713-3 and the following:

(a) Type 1.A, ultra-short-term netting or open weave textiles. Provide a photodegradable synthetic 

mesh or woven biodegradable natural fiber netting. 

(b) Type 1.B, ultra-short-term net-less rolled erosion control blankets. Provide natural or polymer 

fibers mechanically interlocked or chemically adhered together.

(c) Type 1.C, ultra-short-term single-net erosion control blankets. Provide a processed degradable 

natural or polymer fibers mechanically bound together by a single rapidly degrading, synthetic or 

natural fiber netting 

(d) Type 1.D, ultra-short-term double-net erosion control blankets. Provide a processed 

degradable natural or polymer fibers mechanically bound together between two rapidly degrading, 

synthetic or natural fiber nettings. 

(e) Type 2.A, short-term netting or open weave textiles. Provide a photodegradable synthetic mesh 

or woven biodegradable natural fiber netting. 

(f) Type 2.B, short-term net-less rolled erosion control blankets. Provide a natural or polymer 

fibers mechanically interlocked or chemically adhered together.

(g) Type 2.C, short-term single-net erosion control blankets. Provide processed degradable natural 

or polymer fibers mechanically bound together by a single degradable synthetic or natural fiber 

netting. 

(h) Type 2.D, short-term double-net erosion control blankets. Provide processed degradable 

natural or polymer fibers mechanically bound between two degradable, synthetic or natural fiber 

nettings. 

(i) Type 3.A, extended-term open weave textiles. Provide an open weave textile composed of 

processed slow degrading natural or polymer yarns or twines woven into a continuous matrix. 

(j) Type 3.B, extended-term erosion control blankets. Provide an erosion control blanket composed 

of processed slow degrading natural or polymer fibers mechanically bound together between two slow 

degrading synthetic or natural fiber nettings to form a continuous matrix. 

(k) Type 4.A, long-term open weave textiles. Provide an open weave textile composed of processed 

slow degrading natural or polymer yarns or twines woven into a continuous matrix. 

(l) Type 4.B, long-term erosion control blankets. Provide an erosion control blanket composed of 

processed slow degrading natural or polymer fibers mechanically bound together between two slow 

degrading synthetic or natural fiber nettings to form a continuous matrix. 

Do not use monofilament netting or similar material.
Table 713-3 

Rolled Erosion Control Product Type

Property Test

Method 1.A(1) 1.B 1.C 1.D 2.A(1) 2.B 2.C 2.D 3.A 3.B 4.A 4.B

Typical

functional

longevity, 

months(2)

N/A 3 3 3 3 12 12 12 12 24 24 36 36

Maximum "C"

factor(3)

ASTM

D6459(6) 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.05 0.05 0.05 0.05

Maximum

gradient slope(4) N/A 1V:5H 1V:3H 1V:3H 1V:2H 1V:5H 1V:3H 1V:3H 1V:2H 1V:2H 1V:1.5H 1V:1H 1V:1H

Minimum shear 

stress, lb/ft2 (5)

ASTM

D6460(6) 1.00 1.00 1.50 1.75 1.00 1.00 1.50 1.75 2.00 2.00 2.25 2.25

Minimum MD 

material tensile

strength, lb/ft

ASTM

D6818 125 125 60 75 125 125 60 75 100 100 100 100

Minimum TD 

material tensile

strength, lb/ft

ASTM

D6818 10 10 20 40 10 10 20 40 40 40 40 40

Material 

thickness, inch

ASTM

D6525 >0.03 >0.30 >0.25 to <0.50

>0.25 to 

<0.50 >0.03 >0.30 >0.25 to <0.50

>0.25 to 

<0.50

>0.20 to 

<0.40

>0.25 to 

<0.50

>0.20 to 

<0.40

>0.20 to 

<0.50

Ground 

coverage

ASTM

D6567 >3%

>50% 

to 

<90%

>50% to 

<90%

>50% 

to 

<90%

>3%

>50% 

to 

<90%

>50% 

to 

<90%

>50% to 

<90% >40% >50% to <95% >50% >50% to <95%

Material mass, 

oz/yd2

ASTM

D6475 >0.2 >10.0 >8.0 >8.0 >0.2 >10.0 >8.0 >8.0 >11.0 >8.0 >20.0 >8.0

(1) Obtain the C Factor and permissible shear stress for Types 1.A. and 2.A. mulch control nettings with netting used in conjunction with pre‐applied mulch material.

(2) Functional longevities are for guidance only. Actual functional longevities may vary based on site and climatic conditions.

(3) Maximum C Factor from standardized large‐scale rainfall performance testing, ASTM D6459, or approved equivalent.

(4) Maximum recommended gradient for the product for rainfall and slope application.

(5) Minimum shear stress RECP (unvegetated) can sustain without physical damage or excess erosion (greater than 0.5 in soil loss) during a 30‐minute flow event in large‐

scale performance testing, ASTM D6460, or approved equivalent.

(6) Or other approved large-scale test methods.
Section 713 

830

713.18 Turf Reinforcement Mats. Provide turf reinforcement mat composed of UV-stabilized 

non-degradable synthetic fibers, filament, nets, wire mesh, or other elements processed into a permanent, 

three-dimensional matrix conforming to Table 713-4. 

Table 713-4 

Turf Reinforcement Mats

Property(1) Test Method Rolled Erosion Control Product Type

5.A 5.B 5.C 5.D 5.E(2) 5.F(2)

Maximum gradient N/A 1V:1H 1V:1H 1V:0.5H 1V:0.5H 1V:0.5H 1V:0.5H

Performance test 

unvegetated shear 

stress, lb/ft2 (4),(5),(6)

ASTM D6460 >2.0 >2.0 >2.0 >2.0 >2.0 >2.0

Performance test 

vegetated shear stress, 

lb/ft2 (4),(5),(7)

ASTM D6460 >6.0 >8.0 >10.0 >12.0 >12.0 >14.0

Seedling emergence(4) ASTM D7322 >250% >250% >250% >250% >250% >250%

Minimum MD material 

tensile

Strength, lb/ft (3),(4),(8) 

ASTM D6818 150 175 200 325 1500 3000

Minimum TD material 

tensile

Strength, lb/ft (3),(4),(8)

ASTM D6818 150 175 200 225 1500 3000

Material mass, oz/yd2 (4) ASTM D6566 >8.0 >8.0 >8.0 >8.0 >8.0 >8.0

Minimum material 

thickness, inch(4) ASTM D6525 0.25 0.25 0.25 0.25 0.25 0.25

UV stability(4) ASTM D4355

>80%

@500 

hours

≥ 80%

@500 

hours

≥ 80%

@1000 

hours

≥ 80%

@1000 

hours

≥ 90%

@1000 

hours

≥ 80%

@3000 

hours

(1) For turf reinforcement mats containing degradable components, obtain property values on the nondegradable portion of the matting 

alone.

(2) For material Types 5.E and 5.F, property values tested according to ASTM D6818 and D6525 are reported as minimum average 

roll values (MARVs). MARVs are calculated as the typical minus two standard deviations. Statistically, it yields a 97.7 percent degree 

of confidence that any samples taken from QA testing will exceed the value reported.

(3) Minimum average roll values: MD = machine direction only, TD = transverse direction.

(4) Typical values are calculated as the average value. Statistically, it yields a 50 percent degree of confidence that any samples taken 

from QA testing will exceed the value reported.

(5) Acceptable large‐scale testing protocol may include ASTM D6460, or other approved independent testing. Large scale 

performance testing typically involves limited soil types and vegetative stands; therefore, it is recommended that an appropriate factor 

of safety be used in design and product selection.

(6) Required minimum stress turf reinforcement mat (unvegetated) can sustain without physical damage or excess erosion (greater 

than 0.5-inch soil loss) during a successive 30-minute flow event in large-scale.

(7) Required minimum shear stress turf reinforcement mat (fully vegetated) can sustain without physical damage or excess erosion 

(greater than 0.5-inch soil loss) during successive 30-minute flow event in large-scale testing.

(8) Or other approved large-scale test methods.
Section 713

831

713.19 Sediment Filter Bags. Provide rot and mildew resistant bags composed of a non-woven geotextile 

fabric conforming to Table 713-5 and the following: 

(a) Minimum size 150 ft2

(b) Sewn-in sleeve to fit minimum 4-inch pump discharge hose. 

Secure discharge hose with a hose clamp. 

Table 713-5 

Sediment Filter Bag Geotextile Requirements

Property

Test

Method

ASTM

Units Specifications

Mass D3776 oz/yd2 8.0

Minimum grab tensile strength D4632 lb 205

Minimum tensile elongation at break D4632 % 50

Static California Bearing Ratio 

puncture D6241 lb 500 to 700

Minimum trapezoid tear strength D4533 lb 80

Minimum ultraviolet resistance D4355 % 70

Minimum permittivity D4491 sec-1 1.4

Water flow rate D4491 gal/min/ft2 95

Apparent opening size D4751 US Sieve 80 to 100

713.20 Prefabricated Filter Insert. Provide a commercially available prefabricated filter insert that 

provides a highflow bypass and meets the size and dimension of the catch basin or drop inlet. Follow the 

manufacturer’s recommendations. 

713.21 Floating Turbidity Curtains. Provide turbidity curtains that meet the intended application for the 

site conditions (flow, depth, width, wind, and wave activity). Provide turbidity curtains made of tightly 

woven nylon, plastic, or other nondeteriorating material conforming to Table 713-6 and the following: 

(a) Fabric overlap, if more than one width of fabric is required; 

(b) Supporting flotation buoyancy; 

(c) Ballast chain (galvanized); and

(d) Dual galvanized wire rope load lines with a vinyl coating. 
Section 713 

832

Table 713-6 

Floating Turbidity Curtain Material Requirements

Property Test Method

ASTM Units Specifications 

Minimum grab tensile strength: machine direction D4632 lb 370 

Minimum grab tensile strength: cross machine direction D4632 lb 250 

Trapezoid tear strength: machine direction D4533 lb 100 

Trapezoid tear strength: cross-machine direction D4533 lb 60

California Bearing Ratio puncture strength D6241 lb 500

Apparent opening size D4751 US standard 

sieve 70 

4% permittivity D4491 s-1 0.28 

713.22 Plastic Lining. Provide a film or fabric that is serviceable for the duration of the installation.
Section 714

833

Section 714. — GEOSYNTHETIC MATERIAL

714.01 Geotextile. Provide geotextile conforming to the following physical properties based on intended 

use of the geotextile:

(a) Separation geotextile. Conform to AASHTO M 288 Table 1, Class 1 and Table 3. Separation 

geotextiles can be in either the <50 percent elongation category (woven) or the ≥50 percent elongation 

(non-woven) category. 

(b) Stabilization geotextile. Conform to AASHTO M 288 Table 1, Class 1, <50 percent elongation 

(woven) only, and AASHTO M 288 Table 5. 

(c) Geotextile filter. Conform to AASHTO M 288 Table 1, Class 1 and Table 6 for riprap, special

rock embankment, rock buttress, and other high survivability applications. 

Conform to AASHTO M 288 Table 1, Class 2 and Table 2 for underdrains and other subsurface 

drainage applications.

Geotextile filter can be in either the <50 percent elongation category (woven) or the ≥50 percent

elongation (non-woven) category.

(d) Paving geotextile. Provide geotextile conforming to AASHTO M 288, Table 8. 

Do not use woven slit film geotextile. 

714.02 Geocomposite Drain. Provide a prefabricated geocomposite drain composed of a drainage core 

and a nonwoven geotextile that allows in-flow from both sides. Geocomposites that only allow in-flow 

from one side may only be used directly against a concrete surface. Provide geotextile conforming to 

AASHTO M 288 and drainage core manufactured from long chain synthetic polymers composed of at 

least 95 percent by mass of polypropylene, polyester, polyamide, PVC, polyolefin, or polystyrene. Build 

the core up in thickness by columns, cones, nubs, cusps, meshes, stiff filaments, or other configurations. 

Fabricate the core in sheets, panels, or rolls of adequate strength to resist installation stresses and long-term 

loading conditions. Firmly attach the encapsulating geotextile to the core at the manufacturing plant, so 

that folding, wrinkling, or other movement cannot occur during handling or after placement. Use a 

nonwater-soluble adhesive, heat sealing, or other methods recommended by the geotextile manufacturer. 

Do not use adhesive on areas of the geotextile where flow is intended to occur. 

If heat sealing is used, do not weaken the geotextile below the required strength values. Extend the 

geotextile beyond the core length on all sides sufficiently to encapsulate the core and collector pipe.

Conform to Table 714-1. 
Section 714

834

Table 714-1 

Geocomposite Drain Requirements

Property Test Method Units

Specifications(5)

Sheet Drain Strip Drain

Type 1 Type 1 Type 2

Transmissivity 

(flow rate)(1) ASTM D4716 Gal/min/ft 5.0 15.0 20.0

Compressive strength 

at yield ASTM D1621 psi 100 50 50

Applied normal

compressive stress ASTM D4716(4) psi 14.5 1.45 1.45

Hydraulic gradient ASTM D4716(2),(3),(4) dimensionless 1.0 0.1 0.1

Fungi resistance ASTM G21 − No visible growth

(1) If core construction separates the flow channel into two or more discrete sections, only the flow rate on one in-flow 

face is considered in determining the core’s acceptability.

(2) 14-inch-long specimen.

(3) 100-hour seating period.

(4) Rubber membrane between platens and geocomposite.

(5) The property values in this Table are specified as minimum average roll value (MARV) in the weakest principal 

direction as described in ASTM D4759, except for fungi resistance.

714.03 Stabilization Geogrid. Provide biaxial geogrid conforming to AASHTO M 288, Table 12, 

Class 4C.

714.04 Reinforcement Geotextile and Geogrid. Provide reinforcement geotextile and geogrid 

conforming to AASHTO M 288 Tables 9 and 10, and Table 714-2. 

The minimum allowable long-term strength (TTMMMM) for each layer of reinforcement geotextile or geogrid is 

based on: 

where: 

Tult = Ultimate tensile strength of the reinforcement geotextile or geogrid

RF = Reduction Factors = RFID × RFCR × RFD. 

Provide manufacturer test data for RRPPIIII, RRPPCCCC, and RRPPIIvalues by evaluation of independent test results 

by Highway Innovative Technology Evaluation Center (HITEC), AASHTO Product Evaluation & Audit 

Solutions, Innovations, Developments, Enhancement and Advancements (IDEA), or an equivalent thirdparty report. 
Section 714

835

Table 714-2 

Reinforcement Geotextile and Geogrid Strength Requirements

Property

Test

Method

ASTM

Units

Minimum Specifications(1),(2)

Type 1 Type 2 Type 3 Type 4 Type 5 Type 6

Allowable

long-term

strength (Tal) 

D4595

or

D6637(3),(4)

lb/ft 1000 1500 2000 2500 3000 4000

(1) For reinforcement geotextile, also meet the Class 1 strength requirements in AASHTO M 288 Table 1 and the 

ultraviolet stability requirements of AASHTO M 288 Table 10.

(2) The specified strength is in the principal direction of reinforcement, perpendicular to the wall or slope face and 

based on MARV. 

(3) ASTM D4595 is for reinforcement geotextile and ASTM D6637 is for geogrid. 

(4) See the nominal long-term strength (Tal) formula above.

714.05 Geomembrane. Provide geomembrane that consists of textured (roughened) surface polyvinyl 

chloride, HDPE, or linear low density polyethylene with a thickness of 28.5 to 31.5 mils. Glue or weld 

seams of the geomembrane to prevent leakage.

Conform to Table 714-3. 

Table 714-3 

Geomembrane Requirements

Geomembrane Type Test Method

Polyvinyl chloride (PVC) ASTM D7176(1)

HDPE GRI Test Method GM13(2)

Linear low density polyethylene (LLDPE) GRI Test Method GM17(2)

(1) The minimum average asperity height is 10 mils. Ensure 8 of 10 readings are greater 

than or equal to 7 mils and the lowest individual reading is greater than or equal to 5 mils.

(2) Geosynthetic Research Institute.

714.06 Geosynthetic Reinforced Soil Reinforcement Geosynthetic. Provide reinforcement geotextile 

or geogrid conforming to AASHTO M 288, Tables 9 and 10, and Table 714-4. 

Table 714-4 

GRS Reinforcement Geotextile and Geogrid Strength Requirements

Property Test Method

ASTM Units Minimum Specifications(1)

Ultimate tensile

strength(2) (Tult) D4595 lb/ft 4800

Tensile strength at 2% 

strain (T2%) D4595 lb/ft 1320

(1) The specified strength is in the principal direction of reinforcement perpendicular to 

the wall or slope face.

(2) Based on MARV.
Section 715

836

Section 715. — PILING

715.01 Untreated Timber Piles. Conform to AASHTO M 168. Fabricate the piles from the following 

species (or group):

(a) Douglas fir; 

(b) Larch;

(c) Red pine; 

(d) Red oak; or 

(e) Southern pine. 

715.02 Treated Timber Piles. Conform to AASHTO M 133 and AASHTO M 168. Use Douglas-fir or 

southern pine. 

Use the pressure method procedure prescribed in AWPA. Apply the treatment to the piles after millwork 

is completed.

Imprint legible symbols or legend on the end of piles identifying the name of the treating company and 

type and year of treatment according to AWPA Standards M1, Standard for the Purchase of Treated Wood 

Products and M6, Brands Used on Preservative Treated Materials. 

715.03 Steel Pipes. Provide steel pipe piles conforming to one of the following: 

(a) API 5L X52 PSL2; or

(b) ASTM A709, Grade 50, meeting non-fracture critical tension component impact test requirements.

Use Zone 2 if no temperature zone is shown in the plans. 

Provide closure plates for closed end piles conforming to ASTM A572, ASTM A588, or ASTM A690, 

Grade 50. 

715.04 Steel H-Piles. Fabricate the H-piles from structural steel conforming to ASTM A709, Grade 50.

Provide base metal, coil or plate, used for fabrication of steel H-piling meeting ASTM A709 non-fracture 

critical tension component impact test requirements. Use Zone 2 if no temperature zone is shown in the 

plans. 

715.05 Sheet Piles. Conform to AASHTO M 202. 

715.06 Pile Shoes. For timber and steel piles, provide prefabricated cast steel shoes or driving points 

conforming to ASTM A27, Grade 65-35 or ASTM A148, Grade 90-60. 

715.07 Splices. Manufacture splices from structural steel conforming to ASTM A709, Grade 50 for H or 

pipe piles. 
Section 715

837

715.08 Helical Piles. Provide cold-formed welded and seamless carbon steel round or square central shaft 

helical piles conforming to ASTM A500. Provide high strength low alloy structural steel helix plates 

conforming ASTM A572. Use hot-dip galvanized coating conforming to AASHTO M 111 with a 

minimum thickness of 3.9 mils. Provide bolts and assemblies conforming to ASTM F3125 and galvanized 

according to AASHTO M 232. 
Section 716

838

Section 716. — MATERIAL FOR TIMBER STRUCTURES

716.01 Untreated Structural Timber and Lumber. Conform to AASHTO M 168. Provide an inspection 

certification from an agency accredited by the American Lumber Standards Committee for the species 

and grade. Mark pieces with the inspection service, grade designation, species, and inspector identity.

Season and dry structural timber and lumber before fabrication. Do not use material that is twisted, curved, 

or otherwise distorted. 

Do not use boxed-heart pieces of Douglas fir or redwood in outside stringers, floor beams, caps, posts, 

sills, or rail posts. 

716.02 Treated Structural Timber and Lumber. Provide wood according to Subsection 716.01, treated 

according to AASHTO M 133 and AWPA Standards U1 and T1. 

Provide treated timber members with a quality mark approved by the American Lumber Standards 

Committee or equivalent for individual pieces or sealed pallets assuring that treatment conforms to the 

appropriate AWPA standards.

For hand-contact surfaces such as handrails, use timber treated with waterborne copper-based solutions or 

suspensions containing copper that do not contain arsenic or chromium compounds. 

716.03 Structural Glued Laminated Timber. Conform to ANSI A190.1, Product Standard for Structural 

Glued Laminated Timber and ANSI 117, Standard Specifications for Structural Glued Laminated Timber 

of Softwood Species. 

Provide members with industrial appearance grade for wet use conditions. Use only single-piece or 

multiple-piece laminations with bonded edge joints. 

Provide straight or slightly cambered members which are to be loaded perpendicular to the wide face of 

the laminates that are stamped top on the top at both ends of the beam. 

716.04 Wood-Plastic Composite. Provide composite timber decking that can support commercial use 

with the stringer spacing as shown in the plans. Provide boards with a flat, non-grooved texture at the 

bottom face. Conform to ASTM D7568 and the following: 

(a) Ultimate bending strength, ASTM D198 2500 psi minimum 

(b) Ultimate modulus of rupture, ASTM D7031 2500 psi minimum 

(c) Ultimate modulus of elasticity, ASTM D7031 200,000 psi minimum

(d) Fungus resistance, ASTM D1413 No decay 

716.05 Hardware. Provide bolts, drift pins, and dowels conforming to ASTM A307. Provide nuts 

conforming to ASTM A563. 

Provide gray iron castings according to Subsection 717.04(c), and malleable iron castings according to 

Subsection 717.04(d). 
Section 716

839

Provide nails and spikes conforming to ASTM F1667. 

Galvanize iron and steel hardware according to ASTM A153. 
Section 717

840

Section 717. — STRUCTURAL METAL

717.01 Structural Steel. 

(a) Structural carbon steel. Conform to the following:

(1) Primary bridge members AASHTO M 270, Grade 36T or 50ST 

(2) Fracture critical bridge members AASHTO M 270, Grade 36F or 50SF

(3) Hollow structural sections ASTM A500, Grade B or C, ASTM A618,

ASTM A847, or ASTM A1085

(4) Other shapes, plates, and bars AASHTO M 270, Grade 36 or 50S 

(b) High-strength low-alloy structural steel. Conform to the following:

(1) Primary bridge members and welded 

members

AASHTO M 270, Grade 50T or 50WT

(2) Fracture critical bridge members and 

fracture critical welded members

AASHTO M 270, Grade 50F or 50WF

(3) Other shapes, plates, and bars AASHTO M 270, Grade 50 or 50W 

(c) HPS. Conform to the following: 

(1) Primary bridge members AASHTO M 270, Grade HPS 50WT, 

HPS 70WT, or HPS 100WT

(2) Fracture critical bridge members AASHTO M 270, Grade HPS 50WF, 

HPS 70WF, or HPS 100WF

(3) Other shapes, plates, and bars AASHTO M 270, Grade HPS 50W, 

HPS 70W, or HPS 100W

(d) Bolts and nuts. Conform to ASTM F1554, Grade 36 or 55, or ASTM A307 as shown in the plans. 

Provide nuts conforming to ASTM A563 for appropriate grade and size of anchor bolt. Lubricate 

galvanized nuts with a lubricant containing a visible dye.

(e) High-strength bolts, nuts, and washers. Provide bolts conforming to ASTM F3125 or ASTM 

F3148 as specified. If not provided as an assembly (ASTM F3125 Grades F1852 and F2280, or ASTM 

F3148), provide nuts conforming to ASTM A563, Grade DH or DH3, with the S1 Supplementary 

Lubricant Requirement, and provide washers conforming to ASTM F436. Use Type 3 bolts, nuts, and 

washers to connect uncoated weathering steel components. Use Type 1 or 3 in other scenarios. 

Provide fastener assembly coatings conforming to ASTM F3125 Annex A1 or ASTM F3148 Table 1. 

If hot-dip or mechanically galvanized coatings are used, use a lubricated nut dyed blue. 
Section 717

841

Provide fastener assemblies (bolt, nut, and washers) that have been rotation-capacity tested by the 

manufacturer and fastener components that have been assigned a rotation-capacity lot number. 

(f) Rockfall protection hardware. Provide wire rope clips that meet Federal Specification

FF-C-450G, wire rope thimbles that meet Federal Specification FF-T-276C, and shackles and swivels

that meet Federal Specification RR-C-271D. Provide wire rope clips, thimbles, shackles, and swivels

sized for wire rope diameters of 1 inch, 3⁄4 inch, 9/16 inch, 1⁄2 inch, 5/16 inch, and 1⁄4 inch. Galvanize all

other hardware according to AASHTO M 232 or ASTM A153.

(g) Rockfall protection nuts and washers. Provide nuts conforming to ASTM A563 or ASTM A536 

that can develop 100 percent of the minimum ultimate tensile strength (MUTS) of the bar. Provide 

anchor nuts that meet the specified strength requirement while allowing a maximum 5-degree 

misalignment between the nut and the bearing plate. Provide hardened washers conforming to ASTM 

F436, ASTM A536, or ASTM A47, and plate washers conforming to ASTM A572, Grade 50. 

Galvanize nuts and washers after fabrication according to AASHTO M 232, ASTM A153, or 

ASTM F2329. 

(h) Anchor plates. Provide anchor plates conforming to ASTM A572 Grade 50, hot-dipped 

galvanized according to AASHTO M 232, and with the following characteristics: 

(1) Steel plate thickness of at least 1⁄4 inch.

(2) Bent edges to provide load-bearing points extending through the mesh. 

717.02 Steel Forgings. Conform to AASHTO M 102, Classes C, D, F, and G. 

717.03 Pins and Rollers. Provide pins and rollers more than 9 inches in diameter from annealed carbon 

steel forgings conforming to AASHTO M 102, Class C. 

Provide pins and rollers no more than 9 inches diameter from either annealed carbon steel forgings 

conforming to AASHTO M 102, Class C or cold finished carbon steel shafting conforming to AASHTO 

M 169, Grade 1016 to Grade 1030 inclusive, with a minimum Rockwell Scale B hardness of 85. The 

hardness requirement may be waived if the steel develops a tensile strength of 70,000 pounds per square 

inch and a yield point of 36,000 pounds per square inch. 

For pin threads, conform to ANSI B1.1, Unified Inch Screw Threads (UN, UNR, and UNJ Thread Forms),

Class 2A. Thread pin ends with a diameter of at least 13⁄8 inches with 6 threads to the inch. 

717.04 Castings. 

(a) Steel castings. Conform to AASHTO M 103, Grade 70-36.

(b) Chromium alloy steel castings. Conform to AASHTO M 163, Grade CA15.

(c) Gray iron castings. Conform to AASHTO M 105, Class 30B or 35B. 

(d) Malleable iron castings. Conform to ASTM A47, Grade 32510. 
Section 717

842

717.05 Welded Stud Shear Connectors. Conform to AASHTO M 169 and AASHTO, LRFD Bridge 

Construction Specifications, Article 11.3.3, Welded Stud Shear Connectors. 

717.06 Steel Pipe. Provide galvanized steel pipe conforming to ASTM A53, Type F, standard weight 

class, and plain ends for the designation specified.

717.07 Galvanized Coatings. Galvanize steel according to AASHTO M 111. 

717.08 Steel Grid Floors. Conform to AASHTO M 270, Grade 36. Galvanize according to AASHTO 

M 111 unless coating is specified. 

717.09 Bearings. 

(a) Elastomeric bearings, plain or laminated. Conform to AASHTO M 251. 

(b) High load rotational spherical bearings. Conform to ASTM D5977. 

(c) Polytetrafluoroethylene surfaces for bearings. Conform to the following:

(1) PTFE resin. Provide virgin PTFE resin material conforming to ASTM D4894 or ASTM 

D4895. 

(2) Filler material. Provide milled glass fibers, carbon, or other approved inert material.

(3) Adhesive material. Provide epoxy resin adhesive conforming to AASHTO M 235. 

(4) Unfilled PTFE sheet. Provide unfilled PTFE sheet made from PTFE resin. Conform to 

Table 717-1. 

(5) Filled PTFE sheet. Provide filled PTFE sheet made from PTFE resin uniformly blended with 

filler material. Do not exceed 15 percent filler content using fiberglass or 25 percent filler content 

using carbon fibers. For filled PTFE sheets containing glass fibers or carbon, conform to 

Table 717-1. 

(6) Fabric containing PTFE fibers. Provide fabric made from oriented multifilament PTFE 

fluorocarbon and other fibers or from a mixture of PTFE fibers made from twisted, slit PTFE tape 

and other fibers according to the manufacturer’s recommendations. Conform to Table 717-1. 

Table 717-1 

Polytetrafluoroethylene Sheeting

Property ASTM

Method

Sheet

Unfilled

Sheet

with 15 percent

Glass Fibers

Sheet

with 25 percent

Carbon Fibers

Woven

Fabric

Tensile strength, 

minimum

D638 or

D2256 2800 psi 2000 psi 1300 psi 24,000 psi

Elongation, 

minimum

D638 or

D2256 200% 150% 75% 35%

Specific gravity, 

minimum D792 2.16±0.03 2.20±0.03 2.10±0.03 – 

Melting point D4591 623±2 oF 621±18 oF 621±18 oF –
Section 717

843

(7) Interlocked bronze and filled PTFE components. Provide a phosphor bronze plate 

conforming to ASTM B100 with a 0.010 inch thick, porous bronze surface layer conforming to 

ASTM B103 into which is impregnated a lead-PTFE compound. Overlay the surface with 

compounded PTFE at least 0.001 inch thick. 

(8) Lubricants. Use lubricants consisting of a combination of solids that do not react chemically 

or electrolytically with the PTFE and its mating surface and remain stable in the environmental 

conditions expected at the bridge site. 

(9) Surface treatment. For epoxy bonding, factory treat one side of the PTFE sheet with a sodium 

naphthalene or sodium ammonia process.

(10) Stainless steel mating surface. Conform to ASTM A264, Type 304 and the following:

(a) Thickness 0.0598 inch minimum, if maximum dimension is 

12 inches or less 0.0897 inch minimum, if maximum 

dimension exceeds 12 inches

(b) Surface finish 8 μin root mean square maximum

Polish or roll stainless steel mating surfaces as necessary to a finish at least 20 micro-inches.

717.10 Aluminum Alloy for Bridge Rail. For extruded bars, rods, shapes, and tubes, conform to ASTM 

B221, alloy 6061-T6. For rolled or extruded structural shapes, conform to ASTM B308, alloy 6061-T6.

717.11 Aluminum Bolt Heads and Nuts. Conform to American standard heavy hexagon ANSI B18.2. 

For threads, conform to American standard coarse series, Class 2 fit, ANSI specification B1.1, Unified 

Inch Screw Threads (UN, UNR, and UNJ Thread Forms). 

717.12 Aluminum Welding Wire. Conform to Table 717-2. 

Table 717-2 

Aluminum Welding Wire

Alloy Series Specification Wire

3xxx and 6xxx

AWS A5.10

ER 4043

3xxx, 5xxx, and 6xxx ER 5356

5xxx and 6xxx ER 5556 or ER 5183
Section 718

844

Section 718. — TRAFFIC SIGNING AND MARKING MATERIAL

718.01 Retroreflective Sheeting. Conform to ASTM D4956, including supplementary requirements. 

Clean and degrease the face of the metal panels using methods recommended by the manufacturer before 

applying retroreflective sheeting. Wipe plastic panels clean with a slightly dampened cloth before 

applying retroreflective sheeting. Provide retroreflective sheeting conforming to Table 718-1. 

Table 718-1 

Retroreflective Sheeting Types

Application Description Sheeting Types

Permanent Roadside signs

Type III, IV, VIII, IX, or XI prismatic

retroreflective sheeting.

Use fluorescent yellow-green sheeting for signs 

associated with school buses, schools, and related 

supplementary plaques.

Permanent Multilane or overhead 

guide signs

Type III or Type IV prismatic retroreflective 

sheeting for the background and Type IX or Type 

XI retroreflective sheeting for the legend.

Permanent Parking lot and nonroadway signs

Types I and Type II retroreflective sheeting may be 

used.

Temporary Signs

Type III, IV, VIII, IX, or XI prismatic 

retroreflective sheeting.

Use fluorescent sheeting for orange signs.

For roll-up signs, use fluorescent Type VI 

retroreflective sheeting.

Temporary Barricades Type III, IV, IX, or XI retroreflective sheeting.

Temporary Cones and tubular 

markers Type III or Type VI retroreflective sheeting.

Temporary Drums Type III or Type VI retroreflective sheeting.

Temporary Flagger paddles Type III, IV, VIII, IX, or XI retroreflective 

sheeting.

Temporary Vertical panels Type III, IV, VIII, IX, or XI retroreflective 

sheeting.

718.02 Legends and Borders. Form letters, numerals, and other units to provide a continuous stroke 

width with smooth edges. Make the surface flat and free of warp, blisters, wrinkles, burrs, and splinters. 

Do not fabricate letters, numerals, arrows, symbols, or borders using a red screen ink process. 

Conform to one of the following techniques: 

(a) Type L-1 (screen process). Apply letters, numerals, arrows, symbols, borders, and other features 

on the sign background by direct or reverse screen process. Apply messages and borders of a color 

darker than the sign background by the direct process. Apply messages and borders of a color lighter 

than the sign background by the reverse screen process.

Apply screen inks for use on the various types of retroreflective sheeting. Apply ink that has the same 

durability and color as specified for that type of retroreflective sheeting. Apply black screen ink until 

opaque on retroreflective sheeting. 

Provide a uniform color and tone, with sharply defined edges of legends and borders. Do not allow 

running, streaking, or sagging. 
Section 718

845

Air dry or bake the signs after screening to provide a smooth hard finish.

(b) Type L-2 (transparent films). Apply letters, numerals, arrows, symbols, borders, and other 

features on the sign background with colored transparent films. Select durable, electronically cuttable 

films coated with a transparent pressure-sensitive adhesive protected by a removable liner. Use 

transparent films recommended by the manufacturer within the color requirements specified for the 

retroreflective sheeting.

(c) Type L-3 (direct applied characters). Cut letters, numerals, arrows, symbols, borders, and other 

features from black opaque or retroreflective sheeting of the color specified. Apply characters to the 

sign background. Use the same sheeting manufacturer for both the sign legend, border, and 

background. 

Use colors specified in the plans or the MUTCD, Standard Highway Signs, Including Pavement Markings 

and Standard Alphabets and material conforming to Subsection 718.01. 

718.03 Panels. Package sign panels in protective material and transport in a vertical position. Provide sign 

panels that show the manufacturer’s name and date of manufacture on the back. Conform to the following: 

(a) Plywood. Provide exterior Grade B-B high-density overlay plywood or better conforming to NIST 

Voluntary Product Standard PS 1, Structural Plywood. Use 1⁄2-inch thick plywood for sign panels with 

a facial area 24 by 24 inches or less and the horizontal dimension no greater than the vertical 

dimension. Use 3⁄4-inch thick plywood for larger panels. 

(b) Steel. Provide continuous coated (galvanized) 0.08-inch sheet steel blanks conforming to 

ASTM A653 and zinc coating designation G90. 

Provide panels with a substantially plane surface. Do not use twisted or buckled panels. 

(c) Aluminum. Provide panels conforming to ASTM B209, alloy 6061-T6 or 5052-H38. 

Fabricate temporary panels and permanent panels smaller or equal to 30 by 30 inches from 

0.080-inch-thick aluminum sheets. Fabricate larger permanent panels from 0.125-inch-thick 

aluminum sheets. 

Provide blanks without laminations, blisters, open seams, pits, holes, or other defects that may affect 

their appearance or use. Use blanks with uniform thickness and that are commercially flat.

Join extruded aluminum panel sections with panel nuts, bolts, and washers to achieve the desired sign 

size. Use 6- and 12-inch plate heights to achieve the sign panel vertical dimensions in increments of 

6 inches. Do not include more than one 6-inch plate per sign. 

(d) Plastic.

(1) Non-reinforced plastic. Provide polycarbonate material that is ultraviolet stabilized for 

outdoor weathering and will accept adhesives, coatings, and retroreflective sheeting material.

Fabricate panels smaller or equal to 24 by 24 inches from 0.08-inch-thick plastic blanks. Fabricate 

larger panels from 0.125-inch-thick plastic blanks.
Section 718

846

Provide panels that are flat and free of buckles, warps, and other defects. Do not allow a gap 

between adjacent panels greater than 5⁄8 inch where multiple panels adjoin. Attach reinforcement 

stiffeners on the back of panels larger than 24 by 24 inches rigidity and mounting on supports. 

(2) Reinforced plastic (fiberglass). Provide panels made from fiberglass reinforced thermoset 

polyester acrylic modified laminate sheets. Provide sign panels ultraviolet stabilized for outdoor 

weathering ability that will accept adhesives, coatings, and retroreflective sheeting material.

Provide sign panels free of visible cracks, pinholes, foreign inclusions, or surface wrinkles that 

would affect implied performance, alter the specific dimensions of the panel, or otherwise affect 

the sign panels serviceability.

Fabricate fiberglass reinforced panels conforming to the following mechanical and physical 

properties:

(a) Average tensile strength, ASTM D638 10,000 psi minimum

(b) Average tensile modulus, ASTM D638 1,200,000 psi minimum

(c) Average flexural strength, ASTM D790 20,000 psi minimum

(d) Average flexural modulus, ASTM D790 1,200,000 psi minimum

(e) Average compression strength, ASTM D695 32,000 psi minimum

(f) Average compression modulus, ASTM D695 1,400,000 psi minimum

(g) Punch shear, ASTM D732 13,000 psi minimum

(h) Thickness 0.13±0.004 in

(i) Size, dimension less than 12 ft, ASTM D3841 ±0.12 in 

(j) Squareness per 12 ft of length, ASTM D3841 ±0.12 in 

(k) Surfaces, top and bottom Smooth 

(l) Color, visually uniform gray, Munsell color system N7.5 to N8.5 

(m) Coefficient of linear thermal expansion, ASTM D696 0.000004 in/in/°F maximum

(n) Flame resistance (extent of burning), ASTM D635 1 in maximum

(o) Weather resistance, ASTM D3841 Grade 1 or 2 

(e) Extruded aluminum. Provide panels conforming to ASTM B221, aluminum alloy 6063T6. 

Conform to Subsection 718.03(c) for panel thickness and fabrication. The maximum allowable 

deviation from flat on the face is 0.05 inch per foot. 
Section 718

847

718.04 Sign Posts. Provide sign posts that are straight, smooth, and without defects affecting strength, 

durability, or appearance. Conform to the following: 

(a) Wood. Provide posts conforming to AASHTO M 168. Treat the posts according to Category 4A 

of the AWPA Standard U1-UC4A, Ground Contact, General Use for waterborne preservative 

treatments ammoniacal copper arsenate (ACA), ammoniacal copper zinc arsenate (ACZA), or 

chromated copper arsenate (CCA). 

(b) Galvanized metal. Conform to the following: 

(1) U-channel steel. Provide flanged, channel, galvanized steel posts conforming to ASTM A499, 

Grade 60 and the following: 

(a) Punching. Starting 1 inch from the top and extending the full length of the post, drill or 

punch 3⁄8-inch holes on 1-inch centers along the centerline of the bottom of the U. Remove 

burrs and sharp edges. 

(b) Galvanizing after punching AASHTO M 111

(2) Square tubular steel. Provide square tubular galvanized steel posts conforming to ASTM 

A1011, Grade 55 and the following: 

(a) Punching. Starting 1 inch from the top and extending the full length of the post, drill or 

punch 7/16-inch holes on 1-inch centers along the centerline of all four sides, in true alignment 

and opposite each other directly and diagonally. Remove burrs and sharp edges. 

(b) Galvanizing after punching ASTM A123 or ASTM B695 

(c) Aluminum. Provide standard shapes and thicknesses conforming to ASTM B221, alloy 6061-T6, 

6351-T5, 6063-T6, or 6005-T5.

(d) Corrosion resistant (weathering) steel. Provide posts conforming to ASTM A588 or ASTM 

A242. Zinc-coat the embedded portion of the corrosion resistant steel post according to ASTM A123.

718.05 Delineator and Object Marker Posts. Conform to the following: 

(a) Wood. Provide 4- by 4-inch wood posts conforming to Subsection 718.04(a).

(b) Steel. Provide flanged U-channel steel posts weighing at least 2 pounds per foot and conforming 

to ASTM A36. Galvanize according to AASHTO M 111. 

(c) Aluminum. Provide standard shaped 1⁄8-inch thick aluminum posts conforming to ASTM B221, 

alloy 6063-T6.

(d) Plastic. Provide flexible delineator posts made with high-impact resistant polymer material.

718.06 Hardware. Provide galvanized steel or aluminum alloy lag screws, washers, clip angles, wood 

screws, shear plates, U-bolts, clamps, bolts, nuts, and other fasteners. 

For high-strength steel bolts, nuts, and washers, conform to Subsection 717.01(e). Galvanize steel 

hardware according to AASHTO M 232. 
Section 718

848

For aluminum alloy bolts, nuts, and washers, conform to Subsections 717.10 and 717.11 as applicable.

For neoprene or nylon washers, provide 1⁄8-inch thick by 1-inch minimum outside diameter with maximum 

allowable applied torque of 480 inch-pounds. 

718.07 Delineator and Object Marker Retroreflectors. Provide retroreflectors that are ready for 

mounting. 

(a) Acrylic plastic lens. Provide an acrylic plastic lens with a minimum dimension of 3 inches with 

prismatic optical elements and a smooth, clear, transparent face. Fabricate the back from similar 

material and fuse it to the lens around the entire perimeter to form a homogenous unit. Seal the units 

against the intrusion of foreign material. Conform to Table 718-2 regardless of the orientation angle.

Table 718-2 

Minimum Coefficient of (Retroreflective)

Luminous Intensity (RI)

(1)

Candelas per Foot-candle

Observation

Angle

Entrance

Angle White(2) Yellow Red

0.1° 0° 115 70 30

0.1° 20° 45 25 12

(1) See ASTM E808.

(2) Crystal, clear, or colorless are acceptable color designations. 

Mount the retroreflector unit in a housing fabricated from 0.063-inch ASTM B209, aluminum alloy 

3003-H-14 or similar, or from 0.064-inch cold rolled and hot-dip galvanized steel. Provide antitheft 

attachment hardware.

(b) Retroreflective sheeting. Provide a prismatic retroreflective sheeting with a minimum dimension 

of 3 inches and with a Class 1 or Class 2 adhesive backing conforming to Subsection 718.01. Attach 

the sheeting to an aluminum or plastic support panel (target plate) of the size and dimension specified.

718.08 Solventborne Pavement Markings. Provide VOC-compliant solventborne paint with a VOC of 

1.25 pounds per gallon or less. Provide yellow pigment without lead, chrome, or other heavy metals as 

defined by the EPA.

718.09 Waterborne Pavement Markings. Provide an acrylic water-based, ready-mixed paint 

conforming to AASHTO M 348. 

(a) Composition. Provide a paint composed of resin solids of 100 percent acrylic polymer with the 

exact formulation determined by the manufacturer. Conform to the following: 

(1) Pigment, ASTM D3723 45 to 55 percent by mass

(2) Lead, chromium, cadmium, or cobalt, 

ASTM D3335 and ASTM D3718 

0 percent by mass

(3) VOC, EPA Method 24 20.0 oz/gal maximum
Section 718

849

(4) Density of paint, ASTM D1475 12.0 lb/gal minimum

(b) Viscosity. ASTM D562 80-95 Krebs units 

(c) Drying time.

(1) Dry to no pickup, ASTM D711 10 minutes maximum

(2) Drying to no track, ASTM D713 90 seconds maximum

(d) Flexibility. ASTM D522, using the 1⁄4-in cylindrical mandrel No cracking or flaking

(e) Contrast ratio. ASTM D2805, contrast ratio at 319 square 

feet per gallon spreading rate

0.96 minimum

(f) Color. 

(1) White, ASTM D1729 Match FHWA standard highway white 

(2) Yellow, ASTM D1729 Match FHWA standard highway yellow 

(g) Daylight reflectance (without glass bead).

(1) White, ASTM D6628 84 percent relative to magnesium oxide standard

(2) Yellow, ASTM D6628 55 percent relative to magnesium oxide standard

(h) Bleeding ratio. ASTM D868. Determine reflectance according to 

ASTM E1347 immediately after drying. Divide the average of three 

reflectance readings of the paint over the bleeding surface by the 

average of three readings over the non-bleeding surface to determine the 

bleeding ratio.

0.96 minimum

(i) Freeze-thaw stability. ASTM D2243 Initial viscosity ±5 Krebs units maximum

718.10 High-Build Waterborne Pavement Markings. Conform to Subsection 718.09, except conform 

to Section 634 for film thickness.

718.11 Epoxy Pavement Markings. Provide a 2-component, 100 percent solids type system for hot-spray 

application conforming to the following:

(a) Pigments. Component A. Percent by mass. 

(1) White.

(a) Titanium dioxide (TiO2), ASTM D476, Type IV 18 percent minimum

(b) Epoxy resin, ASTM D1652 75 to 82 percent
Section 718

850

(2) Yellow.

(a) Chrome yellow (PbCrO4), ASTM D126 23 percent minimum

(b) Epoxy resin, ASTM D1652 70 to 77 percent

(3) Non-lead yellow.

(a) Titanium dioxide (TiO2), ASTM D476, 

Type II and Type III 

14 percent minimum

(b) Organic yellow 7 to 8 percent

(c) Epoxy resin, ASTM D1652 75 to 79 percent

(b) Epoxy content. Component A. Mass per epoxy 

equivalent, ASTM D1652

Manufacturer’s target value ±50

(c) Amine value. Component B, ASTM D2074 Manufacturer’s target value ±50 

(d) Toxicity. Toxic or injurious fumes at application temperature None 

(e) Color. 15-mil film thickness specimen (cured).

(1) White, ASTM D1729 Match FHWA standard highway 

white

(2) Yellow, ASTM D1729 Match FHWA standard highway 

yellow

(f) Directional reflectance. (Without glass beads)

(1) White, ASTM E1347 84 percent relative to magnesium 

oxide standard

(2) Yellow, ASTM E1347 55 percent relative to magnesium 

oxide standard

(g) Drying time. 15-mil film thickness with glass beads (cured).

(1) Laboratory at 72 °F, ASTM D711 30 minutes maximum to 

no-pick-up condition

(2) Field at 77 °F, viewed from 50 ft, ASTM D713 10 minutes maximum to 

no-tracking condition

(h) Abrasion resistance. Wear index with a CS-17 wheel under 

a 35.3 oz load for 1000 cycles, ASTM D4060 

82 maximum

(i) Hardness. Type D hardness with 72-hour cure at 72 °F, 

ASTM D2240

75 to 100
Section 718

851

718.12 Thermoplastic Pavement Markings. Conform to AASHTO M 249.

718.13 Preformed Pavement Marking Tape. Conform to the following: 

(a) ASTM D4505, Reflectivity Level I; 

(b) Class 1, 2, or 3; and 

(c) Skid Resistance Level A or B.

718.14 Glass Beads. Conform to AASHTO M 247. Treat glass beads with an adherence coating according 

to the manufacturer’s recommendations.

718.15 Pavement Markers. Provide markers of uniform composition, without surface irregularities, 

cracks, checks, chipping, peeling, spalling, crazing, and other physical damage interfering with 

appearance, application, or durability. Provide precast markers in the form of a single-based spheroidal 

segment ending in a rounded or squared shoulder. 

(a) Non-plowable. Conform to ASTM D4280. 

(b) Plowable. Conform to ASTM D4383. 

(c) Non-reflective. Provide ceramic, plastic, or thermoplastic markers that are 4±1⁄8 inches in diameter 

at the base, 11/16±1⁄16 inch in height, and where the base of the marker does not deviate from a flat plane 

by more than 1⁄16 inch. 

718.16 Temporary Pavement Markings. 

(a) Preformed retroreflective tape. Provide 4-inch-wide tape conforming to ASTM D4592, Type I 

(removable). 

(b) Pavement markers. Provide temporary pavement markers conforming to ASTM D4280 or 

flexible pavement markers no more than 2 inches high, with retroreflective tape on both faces of the 

vertical section, that can retroreflect light from opposite directions, and has an adhesive on the base. 

(c) Traffic markings. Conform to Subsection 718.08 or 718.09 as applicable. 

718.17 Epoxy Resin Adhesives. Provide epoxy resin adhesives conforming to AASHTO M 237 for 

bonding traffic markers to rigid and asphalt concrete pavements. 

718.18 Methyl Methacrylate Pavement Markings. Conform to the following: 

(a) Adhesion to pavement. ASTM D4541 150 psi

(b) Hardness. Type D hardness with 24-hour 

cure at 72 °F, ASTM D2240 

50 minimum

(c) No track time. ASTM D711 30 minutes maximum

(d) Skid resistance. ASTM E303 45 British Pendulum Number minimum
Section 718

852

(e) Color. 

(1) White, ASTM D1729 Match FHWA standard highway white 

(2) Yellow, ASTM D1729 Match FHWA standard highway yellow 
Section 719

853

Section 719. — COATING MATERIAL

719.01 General. Provide a contrasting color for each coat of the coating system. Provide color chips from 

the coating supplier. 

(a) Packaging. Provide coatings in strong, substantial containers, plainly marked with the following: 

(1) Trade name or trademark;

(2) Coating type, color, formulation, lot number, and date of manufacture; 

(3) Net mass;

(4) Volume including the percent of solids and the percent of VOC; 

(5) Storage requirements and shelf life;

(6) Mixing instructions and equipment cleanup instructions; and 

(7) Name and address of the manufacturer.

(b) VOC content. Conform to the following VOC limits for both shop- and field-applied coatings:

(1) Clear (unpigmented) coatings 3.7 lb/gal maximum

(2) Other coatings 2.9 lb/gal maximum

(c) Lead content. Provide coatings with zero lead content. 

(d) Other properties. Provide coatings that:

(1) Do not show excessive settling in a freshly opened full container; 

(2) Easily redisperse with a paddle to a smooth, homogeneous state free of curdling, livering, 

caking, color separation, lumps, and skins; 

(3) Do not skin within 48 hours in a three-quarter filled, closed container;

(4) Brush on easily; 

(5) Possess good leveling properties; 

(6) Show no running or sagging tendencies when applied to vertical surfaces; 

(7) Dry to a smooth uniform finish, without roughness, grit, unevenness, and other surface 

imperfections;

(8) Show no streaking or separation when flowed on clean glass; and 

(9) Show no thickening, curdling, gelling, or hard caking after 6 months of storage in a full, sealed 

container stored at a temperature of 70 oF.
Section 719

854

719.02 Coating for Iron and Steel Structures. Provide a coating system conforming to AASHTO R 31, 

and that appears in one of the following: 

(a) AASHTO Product Evaluation & Audit Solutions; or 

(b) North East Protective Coating Committee. 

719.03 Coating for Aluminum Structures. Provide a coating system conforming to American 

Architectural Manufacturers Association 2605 specifications.

719.04 Coating for Other Structural Material. Provide coatings on the Master Painters Institute (MPI) 

approved products lists as shown in Table 719-1. 

Table 719-1 

Coating for Other Structural Material

Substrate Coating

Primer Intermediate Finish

Lumber & Timber MPI #5 MPI #5 or #6 MPI #10

Masonry Block MPI #4 MPI #10 or #11 MPI #10 or #11

Concrete MPI #108 or #177 – – 

Other Metals MPI #107 or #134 MPI #5 or #6 MPI #5 or #6

719.05 Penetrating Stain for Concrete. Provide coatings on MPI Approved Products List #58. 
Section 720

855

Section 720. — STRUCTURAL WALL AND STABILIZED

EMBANKMENT MATERIAL

720.01 Mechanically-Stabilized Earth Wall Material.

(a) Segmental retaining wall units. Conform to ASTM C1372 and the following: 

(1) Net area compressive strength, ASTM C140 4000 psi minimum

(2) Freeze-thaw durability, ASTM C1262 1 percent maximum weight loss after 

100 cycles for five of five specimens 

tested in saline solution or 1.5 percent 

maximum weight loss after 150 

cycles for four of 5 specimens tested 

in water 

(3) Absorption, ASTM C140 5 percent maximum

(4) Height, nominal 8 in

(5) Connection and alignment devices or mechanisms Manufacturer’s recommendations 

(b) Wire facing and backing mat. Fabricate from welded wire fabric conforming to 

AASHTO M 336. Galvanize according to AASHTO M 111, Coating Grade 85. 

(c) Clevis connector. Fabricate from welded wire conforming to AASHTO M 336. Galvanize 

according to AASHTO M 111, Coating Grade 85. 

(d) Connector bars. Fabricate from cold-drawn steel wire conforming to AASHTO M 336. Galvanize 

according to AASHTO M 111, Coating Grade 85. 

(e) Fasteners. Provide 1⁄2-inch diameter, heavy hexhead bolts, nuts, and washers conforming to 

ASTM F3125, A563, and F436. Galvanize according to AASHTO M 232. 

(f) Hardware cloth. Fabricate with maximum 1⁄4-inch square mesh openings from woven or welded 

galvanized steel wire fabric conforming to ASTM A740.

(g) Reinforcing mesh. Fabricate from welded wire conforming to AASHTO M 336. Galvanize 

according to AASHTO M 111, Coating Grade 85. 

(h) Reinforcing strips. Fabricate from high-strength, low-alloy structural steel conforming to 

ASTM A572, Grade 65, Type 3. Galvanize according to AASHTO M 111, Coating Grade 85. 

(i) Tie strip. Fabricate from hot-rolled steel conforming to ASTM A1011, Grade 50. Galvanize 

according to AASHTO M 111, Coating Grade 85. 
Section 720

856

720.02 Gabion and Revet Mattress Material. Fabricate gabion baskets and revet mattresses from either 

welded wire mesh or twisted wire mesh. Conform to the following:

(a) Welded wire mesh ASTM A974

(b) Twisted wire mesh ASTM A975
Section 721

857

Section 721. — ELECTRICAL AND ILLUMINATION MATERIAL

721.01 Electrical Material. 

(a) Conduit. Conform to the following:

(1) Nonmetallic conduit, duct, couplers, connectors, and fittings. For above ground and 

underground use without concrete encasement, provide rigid PVC, heavy wall conduit conforming 

to UL 651, Schedule 40, 80, Type EB and A Rigid PVC Conduit and Fittings. Conform to ASTM 

D2564 for solvent cement to join conduit. 

(2) Metallic conduit, duct, couplers, connectors, fittings, and nipples. Provide rigid galvanized 

steel conduit conforming to UL 6, Electrical Rigid Metal Conduit - Steel. Provide rigid, full-mass 

sherardized or galvanized threaded fittings.

(3) Coated Metallic conduit, duct, couplers, connectors, fittings, and nipples. Provide rigid 

galvanized steel conduit conforming to UL 6, Electrical Rigid Metal Conduit - Steel. Uniformly 

coat the conduit on the outside with an asphalt mastic conforming to AASHTO M 243 or a 20-mil 

PVC coating. Provide rigid, full-mass sherardized or galvanized threaded fittings. 

(4) Flexible metallic conduit. Provide a watertight metallic conduit conforming to UL 360, 

Liquid-tight Flexible Metal Conduit. Provide insulated throat, grounding, malleable iron watertight 

fittings.

(5) Flexible nonmetallic conduit. Provide a watertight nonmetallic conduit conforming to 

UL 1660, Liquid-tight Flexible Nonmetallic Conduit. Provide insulated throat, grounding, 

malleable iron watertight fittings.

(6) Conduit bodies, boxes, and fittings. Provide watertight, galvanized steel conforming to UL 

514B, Conduit, Tubing, and Cable Fittings. 

(b) Pull boxes, frames, and covers. Fabricate boxes formed in concrete with cast iron or welded sheet 

steel having a minimum thickness of 0.188 inch. Galvanize, inside and out, according to AASHTO 

M 232. 

(c) Wire and cable. 

(1) Lighting. Provide either ozone resistant cross-linked polyethylene (XLP) or PVC insulated 

cable, with or without a nylon jacket conforming to the following: 

(a) Polyethylene. Insulated Cable Engineers Association (ICEA) S-95-658/NEMA WC70, 

Non-Shielded Power Cables Rated 2000 V or Less, ICEA S-96-659/NEMA WC71, NonShielded Power Cables Rated 2001-5000 V, ICEA S-93-639/NEMA WC74, Shielded Power 

Cable 5,000-46,000 V; or 

(b) PVC. UL 83, Thermoplastic-Insulated Wires and Cables.

(2) Electrical. Provide soft drawn or annealed copper conductors conforming to ASTM B3 and 

stranding conforming to ASTM B8. 
Section 721

858

Provide stranded wire for #10 AWG and larger. Provide #6 AWG minimum solid copper ground 

wires.

Provide type thermoplastic high-heat resistant, nylon-coated wire (THHN) or thermoplastic heat 

and water-resistant nylon-coated (THWN) #14 AWG, stranded, single-conductor loop wire 

according to the IMSA Specification 51-7. 

Provide type THHN or THWN, stranded, single-conductor lead-in cable according to IMSA 

Specification 50-2. 

Follow the manufacturer’s recommendations in the selection of the wire insulation cable color 

inside the cabinet.

(d) Circuit breakers and panels. Conform to UL 489, Molded-Case Circuit Breakers, Molded-Case 

Switches and Circuit-Breaker Enclosures and UL 67, Panelboards. Provide molded case thermal 

magnetic trip type breakers. Provide panel enclosures conforming to NEMA 250, Enclosures for 

Electrical Equipment (1,000 V Maximum), Type 3R and lockable with padlocks. 

(e) Safety disconnect switches. Provide heavy-duty safety disconnect switches conforming to NEMA 

250, Enclosures for Electrical Equipment (1,000 V Maximum), Type 3R and UL 98 Enclosed and 

Dead-Front Switches.

(f) Grounding and bonding equipment. Provide 5⁄8-inch diameter, 8-foot long, copper-clad steel 

ground rods, ground clamps, grounding and bonding bushings, and lock nuts conforming to UL 467, 

Grounding and Bonding Equipment.

(g) Contactors and control transformers. Provide a magnetic 60-ampere, two-pole contactor with a 

120-volt coil, equipped with control switches for automatic actuation conforming to UL 508, 

Industrial Control Equipment. Provide cadmium-sulfide type photocell controls for 120 or 240-volt 

operation as applicable rated at 1000 watts resistive load or 1800 volt-amperes inductive load; 

adaptable for pole-top mounting in a plug-in, locking-type receptacle conforming to UL 773, Plug-In 

Locking Type Photocontrols for Use with Area Lighting; and with a built-in surge protective device 

for protection from induced high-voltage and follow-through currents.

Provide single-phase, 240/480-volt primary, 120/240-volt secondary, dry type, 60 hertz, 1 KVA 

transformers for indoor or outdoor use, conforming to UL 506, Specialty Transformers. 

(h) Secondary lightning arrester. Provide a secondary lightning arrester rated for a maximum 

operating voltage of 650 volts RMS with a bracket for mounting on the control cabinet backboard.

(i) Service poles. Provide treated southern yellow pine, treated Douglas fir, butt-treated western red 

cedar, or butt-treated northern white cedar service poles that are at least 30 feet long. Treat the poles 

according to Subsection 716.02.

(j) Meter cabinet. Conform to local power company requirements.

(k) Control enclosure. Provide a watertight outdoor cabinet conforming to NEMA 250, Enclosures 

for Electrical Equipment (1,000 V Maximum), Type 3R, fabricated from 0.125-inch-thick ASTM 

B209 aluminum alloy 5052-H-32, with continuous welded seams, rounded corners, hinge with 

stainless steel pin, stainless steel external hardware, and backboard for mounting apparatus.
Section 721

859

Provide loop surge protection devices conforming to Table 721-1 at the terminal block on all lead-ins. 

Table 721-1 

Surge Protection Device Minimum Requirements

Property Rating

Operating voltage 75 voltage direct current (VDC)

Clamping voltage 130 VDC

Peak surge current 250 Ampere

Technology Silicon breakover device

Operating temperature -40 °F to 185 °F

Weight 3 oz

Dimensions 1.2 in cube

Provide a surge protection power strip, 120-volt with RJ-11 or RJ-45 surge protection. Connect 

incoming phone line and modem phone line to power bar RJ-11 or RJ-45 ports. 

Provide a tube axial compact type, 120-volt, corrosion resistant cabinet fan with a minimum 100 cubic 

foot per minute capacity, minimum 100,000 hour design life, maximum 40 decibel operating noise, 

and a five-year duty cycle. Fuse the fan at 125 percent of the motor’s ampere capacity. Ensure the 

fan’s magnetic field does not affect the performance of the surrounding traffic counting equipment.

Provide an inline type, single pole, 120-volt, 10-ampere cabinet fan thermostat that is adjustable in 

10-degree increments from 70 °F to 200 °F, and with a turn-on setting that is adjustable from 90 °F to 

120 °F.

(l) Splices and crimps. Use UL listed splices and crimp type connectors and terminals. Use 

waterproof connections in damp or wet locations. 

721.02 Lighting Material. Conform to the following: 

(a) Poles. Provide 11 gauge round steel conforming to ASTM A595 or aluminum shafts conforming 

to ASTM B429, alloy 6063-T6, tapered uniformly at 0.14 inch per foot. Provide hand holes with no 

rough edges and a reinforcing frame and cover designed to maintain the required pole strength. Weld 

a 23⁄8- to 3.0-inch outside diameter vertical tenon, fabricated from the same material as the pole, and 

welded at the top and on the same axis as the pole.

Provide pole sections in minimum 15-foot lengths. Provide pole sections less than 70 feet in height in 

two sections or less, between 70 and 100 feet in three sections or less, and over 100 feet in four sections 

or less.

Provide poles that can sustain the following loadings: 

(1) A horizontal load of 500 pounds applied 18 inches from the shaft top, in any direction, without 

failure of any component part, and a maximum allowable vertical deflection of 7.5 percent of the 

shaft length.

(2) A horizontal load of 50 pounds applied at the luminaire attachment point and normal to the 

pole bracket member plane, with a vertical load of 30 pounds on the luminaire supporting arm, 

and a maximum allowable horizontal deflection of 10 percent of the luminaire supporting arm’s 

horizontal length.
Section 721

860

(3) A vertical load of 100 pounds applied at the luminaire attachment point, and a maximum 

allowable vertical deflection of 5.5 percent of the pole arm’s horizontal length.

(4) A vertical load of 250 pounds applied at the luminaire attachment point, and no collapse or 

rupture of any portion of the structure. 

(5) The pole arm and luminaire mass with a maximum allowable deflection from vertical at the 

top of the pole of 1 percent of the total shaft length.

Prime the poles inside and out according to the fabricator’s recommendation. Use epoxy modified 

enamel for the finish coat.

(b) Pole arms. 

(1) Material. Provide steel or aluminum. Use the same material as the pole.

(2) Type. Provide bracket type, truss or single member arms. Provide single member arms with a 

minimum diameter of 2 inches and the same taper as the pole.

(3) Connection. Provide a weather resistant connection to the pole and a smooth raceway for 

wiring. Provide fittings for connection to the pole. 

(c) Anchor bases. Provide a one-piece base dimensioned for adequate pole mounting and structural 

support with holes for anchor bolts and tapped holes for anchor bolt covers. Fabricate anchor bases 

from material similar to the pole material and conform to the following:

(1) Steel casings AASHTO M 103, Grade 65-35 

(2) Steel plate ASTM A36

(3) Aluminum castings ASTM B26

(d) Bolts, nuts, and washers. 

(1) Steel anchor bolts. Conform to ASTM F1554, Grade 55 or Grade 105. 

(2) Hex head bolts. Conform to the following: 

(a) 120 ksi yield anchor bolts ASTM F3125 

(b) 105 ksi yield anchor bolts ASTM A354, Grade BC

(3) Nuts. Conform to ASTM A563. Provide nuts appropriate for the strength of the anchor bolt. 

(4) Washers. Provide flat, circular washers conforming to ASTM F436. 

Galvanize the top 12 inches of anchor bolts and associated hardware according to AASHTO M 232. 

(e) Anchor bolt covers. Provide a bolt cover for each anchor bolt and 1⁄4-inch stainless steel, 

phillips-head or hex-head screws to attach the cover to the base or pole.
Section 722

861

(f) Luminaires. Provide luminaires that operate on a 240-volt series circuit. Provide the following 

types of luminaires:

(1) Conventional highway luminaires. Provide material for a complete installation including:

(a) Aluminum housings with refractor holder and slipfitter;

(b) Thermal shock-resistant glass prismatic refractors with gaskets and clips;

(c) Aluminum detachable reflectors with ethylene propylene terpolymer gaskets; and

(d) Internal regulator or auto regulator type ballast, with a power factor greater than 90 percent 

that will start lamps at a minimum ambient temperature of -20 °F or equivalent Light-Emitting 

Diode (LED). 

Comply with ANSI specifications. 

(2) Sign lighting luminaires. Provide material for a complete installation including:

(a) Die-cast aluminum housings with mounting bracket and door assembly; 

(b) Thermal, shock-resistant, borosilicate glass refractors with gaskets;

(c) Aluminum reflectors; and

(d) 120/240-volt, 60 hertz constant-wattage ballasts with a power factor greater than 90 percent 

that will start lamps at a minimum ambient temperature of -20 °F or equivalent LED.
Section 721 

862

Section 722. — ANCHOR MATERIAL

722.01 Anchorage Devices. Galvanize anchorage device components according to AASHTO M 232. 

722.02 Anchor Tendons. Provide material conforming to the following:

(a) Prestressing steel. Conform to one of the following:

(1) Wire, uncoated stress-relieved for prestressed concrete ASTM A421

(2) Steel strand, uncoated seven-wire stress-relieved for 

prestressed concrete 

AASHTO M 203

(3) Steel strand, uncoated, seven-wire, compacted, 

stress-relieved for prestressed concrete

ASTM A779

(4) Uncoated high-strength steel bar for prestressed concrete AASHTO M 275

(b) Couplers. Provide couplers that can develop 95 percent of the minimum specified ultimate tensile 

strength of the tendon. 

(c) Sheathing. Conform to one of the following: 

(1) Free-stressing length.

(a) Polyethylene plastic tubing. Conform to ASTM D1248, Types II, III, or IV with a minimum 

wall thickness of 60 mils. 

(b) Hot-melt extruded polypropylene tubing. Conform to ASTM D4101, cell classification 

PP 210 B5554211 with a minimum wall thickness of 60 mils. 

(c) Hot-melt extruded polyethylene tubing. Conform to ASTM D3350 and ASTM D1248 Type 

III high-density with a minimum wall thickness of 60 mils. 

(d) Steel tubing. Conform to ASTM A500 with a minimum wall thickness of 0.20 inch. 

(e) Steel pipe. Conform to ASTM A53, Schedule 40 minimum. 

(f) Plastic pipe. Conform to ASTM D1785, Schedule 40 minimum. 

(2) Bonded length.

(a) High-density corrugated polyethylene tubing. Conform to AASHTO M 252 with a 

minimum wall thickness of 30 mils. 

(b) Corrugated, polyvinyl chloride tubes. Conform to ASTM D1784, Class 13464-B.

(c) Fusion-bonded epoxy. Conform to ASTM A775 with a minimum film thickness of 15 mils. 
Section 722

863

(d) Corrosion inhibiting compounds. Use grease conforming to PTI, Recommendations for 

Prestressed Rock and Soil Anchors. 

(e) Centralizers and spacers. Fabricate centralizers and spacers from material, except wood, that are 

not deleterious to the prestressing steel.

(f) Anchorages. Provide material conforming to PTI, Recommendations for Prestressed Rock and Soil 

Anchors. 

For strand tendons, provide anchorages that allow lift-off testing without the jack engaging the strand.

Provide steel plates conforming to ASTM A36 or ASTM A588 for bearing plates. Provide grout tube 

holes in the bearing plates.

722.03 Rock Bolts and Rock Dowels. 

(a) Bars. Provide continuously threaded steel reinforcement bars that conform to ASTM A615 

Grade 75 deformed bars. The bending requirements of ASTM A615 do not apply. 

Provide rock dowels with a minimum No. 7 bar size. 

For rock bolts, Grade 150 threaded steel reinforcement bars meeting the requirements of ASTM A722 

Type II, or AASHTO M 275 Type II that can be post-tensioned to the design loads, performance test 

loads, and proof loads specified are also allowed.

(b) Hardware. Provide the following:

(1) Bearing plates. Provide bearing plates that conform to PTI, Recommendations for Prestressed 

Rock and Soil Anchors for the respective application. 

(2) Nuts and couplers. Provide nuts and couplers that exceed 100 percent of the MUTS of the 

bar. Provide nuts and couplers meeting ASTM A563, AASHTO M 169 or ASTM A108, 

ASTM A536, or ASTM A29. 

(3) Washers. Provide washers conforming to ASTM F436. Provide spherical and beveled washers 

conforming to ASTM A536 and ASTM A47. 

(4) Centralizers. Fabricate centralizers from materials that are not deleterious to steel bars. Do 

not use wood. 

(c) Corrosion protection. Provide anchor bars and hardware with hot-dip galvanizing for corrosion 

protection as applicable. Use hot-dip galvanizing conforming to AASHTO M 232, ASTM A153, or 

ASTM F2329 with a minimum thickness of 3.4 mils. Provide corrosion protection for steel anchor 

bars and hardware, from delivery of materials through complete installation, repairing damaged 

galvanizing according to Section 563. 

(d) Rock bolt bond breakers. Provide a grease that conforms to PTI, Recommendations for 

Prestressed Rock and Soil Anchors. 

Provide sleeved bond breakers for rock bolts fabricated from plastic tube or pipe having the following 

properties: 
Section 722

864

(1) Resistant to chemical attack from aggressive environment, grout, or corrosion inhibiting 

compound; 

(2) Resistant to aging by ultra-violet light;

(3) Non-detrimental to rock bolts; 

(4) Resistant to damage caused by abrasion, impact, crushing, and bending during handling and 

installation;

(5) Enables rock bolts to elongate during testing; and 

(6) Resistant to distortion caused by heat generated by the curing of the grout. 

Table 722-1 

Wall Thickness Requirements for Sleeved Bond Breakers

Type Nominal, inch Minimum, inch

HDPE and 

Polypropylene

0.060 0.050

PVC 0.040 0.035

722.04 Soil Nails.

(a) Tendon. Provide deformed bars conforming to one of the following: 

(1) Deformed bars, Grade 60 or Grade 75 ASTM A615

(2) Deformed bars ASTM A722

Provide new, straight, continuous, undamaged bars. Provide, bare, epoxy-coated, or encapsulated bars.

(b) Coupler. Provide couplers that can develop the full, ultimate tensile strength of the tendon as 

certified by the manufacturer.

(c) Fusion bonded epoxy coating. Apply epoxy coating conforming to ASTM A775, except for the 

bend test requirements. Electrostatically apply the coating to a minimum thickness of 12 mils. The 

coating at the wall anchorage end of epoxy-coated bars may be omitted over the length provided for 

threading the nut against the bearing plate. 

(d) Encapsulation. Provide corrugated polyethylene pipe conforming to AASHTO M 252 or 

corrugated polyvinyl chloride pipe conforming to ASTM D1784, Class 13464. 

722.05 Anchor Nails. Provide 11⁄4-inch diameter, high strength steel, hollow-core, self-drilling, anchor 

nails with corrosion protection that conforming to ASTM A615 and come supplied with a 3-inch diameter 

sacrificial bit. Provide nails with corrosion protection conforming to ASTM A153 for hot-dip galvanizing. 

Provide nails that are groutable and can be post tensioned to a design load of at least 10,000 pounds and 

an ultimate strength of at least 55,000 pounds. 
Section 722

865

722.06 Micropile Materials. 

(a) Tendon. Provide deformed bars conforming to one of the following: 

(1) Deformed bars, Grade 60 and Grade 80 AASHTO M 31

(2) Deformed bars AASHTO M 275

Provide new, straight, continuous, and undamaged bars. 

(b) Coupler. Provide couplers that can develop the full, ultimate tensile strength of the tendon as 

certified by the manufacturer.

(c) Fusion bonded epoxy coating. Apply epoxy coating conforming to ASTM A775, except for the 

bend test requirements. Electrostatically apply the coating to a minimum thickness of 12 mils. Do not 

epoxy coat bearing plates and nuts encased in the concrete footing unless footing reinforcement is 

epoxy coated. 

(d) Encapsulation. Provide corrugated polyethylene pipe conforming to AASHTO M 252 or 

corrugated polyvinyl chloride pipe conforming to ASTM D1784, Class 13464. 

(e) Sheathing. Provide watertight smooth polyvinyl chloride sheathing conforming to ASTM D1784, 

Class 13464-B.

722.07 Rockfall Protection Anchor Materials. 

(a) Hollow-core self-drilling anchors. Provide 1.25-inch hollow-core, threaded, deformed steel bar, 

self-drilling anchors conforming to ASTM A513 and A519. Include a sacrificial drill bit at least 3-inch 

diameter.

(b) Wire rope anchors. Provide ASTM A1023 galvanized, stranded carbon steel wire ropes. Provide 

double-legged wire rope anchors in the sizes and with minimum breaking strengths to provide the 

working loads specified. Provide 6x19 classification IWRC made from EIP steel with a 

factory-installed swage-eye terminal on the distal end of the wire rope, possessing ferrules, thimbles, 

or wire clips as required by the manufacturer.

(c) Threaded bar ground anchors. Provide 1-inch diameter deformed continuously threaded bars. 

Provide a minimum Grade 60 steel deformed continuously threaded bars and couplers conforming to 

ASTM A615 and ASTM A775 or AASHTO M 111. 
Section 723

866

Section 723. — DAMPPROOFING AND WATERPROOFING MATERIAL

723.01 Dampproofing Material. 

(a) Primer. Conform to ASTM D41. 

(b) Asphalt. Conform to ASTM D449. 

723.02 Waterproofing Material.

(a) Primer. If preformed membrane sheets are used, provide primers of a type recommended by the 

manufacturer.

If elastomeric spray-applied membranes are used, provide primers conforming to the manufacturer’s 

recommendations. Provide a primer with an adhesion to concrete that is at least 150 pounds per square 

inch when tested according to ASTM D7234. 

(b) Preformed membrane sheet. Provide either a rubberized asphalt type or a modified bitumen type. 

A rubberized asphalt type consists of a rubberized asphalt sheet reinforced with a polyethylene film 

or mesh. A modified bitumen sheet type consists of a polymer-modified bitumen sheet reinforced with 

a stitch-bonded polyester fabric or fiberglass mesh. 

For surfaces other than bridge decks, conform to Table 723-1. For bridge deck surfaces, conform to 

ASTM D6153, Type III, and Table 723-2. 

Table 723-1 

Preformed Membrane Sheet for Surfaces Other Than Bridge Decks

Property Test

Value

Rubberized

Asphalt Type

Modified

Bitumen Type

Tensile strength, minimum ASTM D882 20 lb/in 20 lb/in

Elongation at break, minimum ASTM D882 150% at

73.4 °F 25%

Water vapor transmission, maximum ASTM E96 0.1 perms 0.1 perms

Pliability ASTM D146(1) No cracks No cracks

Thickness, minimum – 60 mils 60 mils 

Softening point, minimum ASTM D36 165 °F 210 °F

(1) Base ASTM D146 on a 180-degree bend over a 4.0-inch mandrel at 10 °F.
Section 723

867

Table 723-2 

Preformed Membrane Sheet for Bridge Decks

Property Test

Value

Rubberized

Asphalt Type

Modified

Bitumen Type

Tensile strength, minimum ASTM D882 1500 lb/in 1500 lb/in

Elongation at break, minimum ASTM D882 300% 300%

Water vapor transmission 

(permeance), water method,

maximum

ASTM E96 0.1 perms 0.1 perms

Puncture resistance, minimum ASTM E154 200 lb 200 lb

Pliability ASTM D146(1) No cracks No cracks

Thickness – 65 - 120 mils 65 - 120 mils 

Softening point, minimum ASTM D36 200 °F 210 °F

(1) Base ASTM D146 on a 180-degree bend over a 4.0-inch mandrel at 10 °F. 

(c) Mastic. Provide mastic consisting of a rubberized asphalt cold-applied sealing compound for use 

with preformed rubberized sheets. Provide mastic consisting of a blend of bituminous and synthetic 

resins for use with modified bitumen sheet.

(d) Elastomeric spray-applied membrane. Provide cold spray-applied, elastomeric membrane 

conforming to Table 723-3. 

Table 723-3 

Elastomeric Spray-Applied Membrane Performance Requirements

Property Test Value

Solids content – 100%

Gel time, maximum – 10 sec

Tack-free time, maximum – 30 sec

Shore D hardness, minimum ASTM D2240 40

Adhesion to concrete, minimum ASTM D7234 150 psi

Tensile strength, minimum ASTM D638 2000 psi

Tear strength (Die C), minimum ASTM D624 300 lb/in

Elongation, minimum ASTM D638 250%

Crack bridging

(80 mils, 1⁄8 in opening @ -15 °F) ASTM C1305 Pass @ 40 cycles

(e) Elastomeric membrane topcoat. Provide membrane topcoat conforming to Table 723-4. 

Table 723-4 

Elastomeric Membrane Topcoat Performance Requirements

Property Test Value

Solids content – 100%

Gel time, minimum – 30 sec

Tack-free time, minimum – 2 min

Open to traffic – 1 hr

Shore D hardness, minimum ASTM D2240 40

Tensile strength, minimum ASTM D638 2000 psi

Tear strength (Die C), minimum ASTM D624 300 lb/in

Elongation, minimum ASTM D638 250%

Crack bridging

(80 mils, 1⁄8 in opening @ -15 °F) ASTM C1305 Pass @ 40 cycles
Section 723

868

(f) Broadcast topcoat aggregate. Provide washed, clean, durable, angular aggregate with a Mohs 

hardness of at least 6. Provide aggregate conforming to Table 723-5. 

Table 723-5 

Broadcast Topcoat Aggregate Gradation

Sieve Size

Percent by Mass Passing 

Designated Sieve

(AASHTO T 27 & T 11)

No. 8 100

No. 20 10

No. 30 5 

No. 100 1 
Section 724

869

Section 724. — GUARDRAIL

724.01 Rail Elements. 

(a) Metal beam rail. Provide metal beam rail conforming to Task Force 13 (TF13), Guide to 

Standardized Roadside Hardware. 

(1) Galvanized steel. Provide W-beam or thrie-beam rail fabricated from corrugated sheet steel 

conforming to AASHTO M 180 for the designated shape, type, class, and mass of coating 

specified.

(2) Painted steel. Provide W-beam or thrie-beam rail conforming to AASHTO M 180 for the 

designated shape, class, type, and mass of coating specified. 

(3) Corrosion resistant (weathering) steel. Provide W-beam or thrie-beam rail conforming to 

AASHTO M 180, Type IV, Class B.

(b) Box beam rail. Provide steel box beam rail conforming to TF13, Guide to Standardized Roadside 

Hardware. 

(c) Steel-backed timber rail and rub rail. Provide timber conforming to AASHTO M 168. Fabricate 

the timber rail and rub rail from dry, seasoned, and dressed rough sawn southern pine or other species 

having a stress grade of at least 1500 pounds per square inch. Do not use refractory species (such as 

larch or Rocky Mountain Douglas fir). Provide treated timber conforming to AASHTO M 133. 

Provide steel backing elements according to ASTM A242. 

(d) Steel-backed log rail. Provide No. 1 Grade western hemlock, western red cedar, or pine logs that 

are seasoned, straight, and sound. Do not use logs that taper more than 2 inches between the butt and 

tip ends of adjacent logs. Remove bark and at least 80 percent of the inner bark. Do not use logs with 

peeler or incision marks on surfaces that will be visible. Do not use logs with knot clusters. Logs may 

contain sound, tight, well-spaced knots. Do not use logs with season checks, singular or any two 

opposite each other, that exceed the thickness of the member. Provide treated timber conforming to 

AASHTO M 133.

Provide steel backing elements according to ASTM A242. 

724.02 Guardrail Posts. Provide guardrail posts conforming to TF13, Guide to Standardized Roadside 

Hardware. 

(a) Wood. Provide posts that do not have a through check, shake, or end slit in the same plane as, or 

a plane parallel to the bolt hole and extending from the top of the post to within 3 inches or the bolt 

hole. Provide according to AASHTO M 168 and treat according to AASHTO M 133. 

For steel-backed timber guardrail systems, provide posts conforming to Subsection 724.01(c). 

For steel-backed log rail systems, provide posts conforming to Subsection 724.01(d). 
Section 724

870

(b) Steel. Provide posts of the appropriate size shape according to ASTM A6. Zinc-coat the embedded 

portion of corrosion resistant (weathering) steel posts according to ASTM A123. 

724.03 Guardrail Blockouts. Provide guardrail blockouts conforming to TF13, Guide to Standardized 

Roadside Hardware. 

(a) Wood. Treat according to AASHTO M 133. 

(b) Steel. Provide steel conforming to Subsection 724.02(b). 

(c) Plastic or composite. Provide blockouts that are crashworthy. Provide a new homogeneous 

blockout with uniform texture that does not crack, chip, flake, peel, or splinter after fabrication.

724.04 Guardrail Hardware. Provide hardware conforming to TF13, Guide to Standardized Roadside 

Hardware. For angles, channels, wide flanges, and plates not contained in TF13, conform to ASTM A36 

for non-weathering steel and ASTM A242 for corrosion resistant (weathering) steel. For structural tubing 

for short steel posts, conform to ASTM A500 or ASTM A513, Grade 1008. 

Galvanize soil plates and structural tubing according to AASHTO M 111. Do not punch, drill, cut, or weld 

the metal after galvanizing.

Provide a flexible hinged guardrail delineator that allows the reflector to fold down and spring back to an 

upright position after impact. Provide retroreflective sheeting conforming to ASTM D4956, including 

supplementary requirements. Use Type IV or XI reflective sheeting permanently adhered to 0.090-inch 

minimum thick body. Manufacture reflector tabs from 0.15-inch aluminum or plastic. Use an adhesive 

that resists peeling with a force of 5 pounds per inch of width. Use mildew resistant adhesive that has no 

staining effect on retroreflective sheeting.

Provide nuts, bolts, and cables conforming to the following: 

(a) Galvanized nuts and bolts. Provide nuts conforming to ASTM A563, Grade A. Provide bolts 

conforming to ASTM A307, Grade A. 

(b) Corrosion resistant (weathering) nuts and bolts. Provide nuts conforming to ASTM A563, 

Grade C3. Provide bolts conforming to ASTM A449, Type 3. 

(c) Cable. Provide cable conforming to AASHTO M 30, Type II, Class A. 
Section 725

871

Section 725. — MISCELLANEOUS MATERIAL

725.01 Water. Conform to the following:

(a) Water for cementitious materials. Provide water for mixing or curing cement, concrete, mortar, 

or grout that conforms to AASHTO M 157. Potable water of known quality may be used without 

testing according to ASTM C1602. Potable water is safe for human consumption as defined by the 

public health authority having jurisdiction. 

(b) Water for vegetation. Provide water for the planting or care of vegetation that is free of substances 

injurious to plant life (such as oils, acids, alkalies, or salts).

(c) Water for construction. Provide water for earthwork, pavement courses, dust control, and 

incidental construction that is free of substances detrimental to the work.

725.02 Calcium Chloride, Magnesium Chloride, and Lignosulfonate. 

(a) Calcium chloride liquid. Provide a water solution conforming to the following: 

(1) Calcium chloride liquid ASTM D98, Type L 

(2) Calcium chloride by mass 35 percent minimum

(b) Calcium chloride flake. Conform to ASTM D98, Type S, Grades N1, N2, N3, or N4, Class A.

(c) Magnesium chloride liquid. Provide a water solution conforming to the following:

(1) Magnesium chloride by mass 28 percent minimum

(2) Specific gravity, ASTM D1298 1.29 to 1.33 

(d) Lignosulfonate liquid. Provide a water solution with a base cation of ammonia, calcium, or 

sodium. Conform to the following: 

(1) Dry solids 50 percent

Use Pulp and Paper Technical Association of Canada standard test Method H.1, Determination of 

Solids Content of Pulp and Paper Mill Effluents. 

(2) Specific gravity, ASTM D1475 1.20 minimum

(3) pH, ASTM E70 3.0 to 8.0 

725.03 Lime. 

(a) Lime for masonry. Conform to ASTM C207, Type NA. 

(b) Lime for soil stabilization. Conform to AASHTO M 216. 

(c) Lime for asphalt mixtures. Conform to AASHTO M 303. 
Section 725

872

725.04 Reserved. 

725.05 Mineral Filler. Conform to AASHTO M 17. 

725.06 Concrete Building Brick. Conform to ASTM C55, normal weight. 

725.07 Concrete Masonry Units. Conform to one of the following: 

(a) Loadbearing concrete masonry units ASTM C90, normal weight

(b) Concrete masonry units for constructing catch basins and 

manholes 

ASTM C139

(c) Nonloadbearing concrete masonry units ASTM C129, normal weight 

725.08 Paving Brick. Conform to one of the following:

(a) Pedestrian and light traffic paving brick ASTM C902, Class SX,

Type I

(b) Heavy vehicular paving brick ASTM C1272, Type F,

Application PS

725.09 Precast Concrete Units and Accessories. Conform to the following: 

(a) Precast reinforced concrete manhole sections AASHTO M 199

(b) Precast concrete barrier ASTM C825

(c) Concrete grid paving units ASTM C1319

(d) Underground precast concrete utility structures ASTM C858

(e) Precast concrete water and wastewater structures ASTM C913

(f) Solid concrete interlocking paving units ASTM C936

725.10 Frames, Grates, Covers, and Ladder Rungs. Fabricate metal grates and covers to evenly bear 

on the frames. Correct bearing inaccuracies by machining. Assemble units before shipment. Mark pieces 

to facilitate reassembly at the installation site. Uniformly coat castings with a commercial preservative 

according to the manufacturer’s standard practice. Conform to the following:

(a) Gray iron castings AASHTO M 105

(b) Carbon steel castings AASHTO M 103

(c) Structural steel ASTM A36

(d) Galvanizing AASHTO M 111

(e) Malleable iron castings ASTM A47
Section 725

873

(f) Aluminum alloy ladder rung material ASTM B221, alloy 6061-T6

(g) Aluminum castings ASTM B26, alloy 356.0-T6

725.11 Detectable Warning Tape. Provide tape conforming to ASTM D2103.

725.12 Epoxy Resin Adhesives. Provide epoxy resin adhesives conforming to AASHTO M 235. 

725.13 Slurry (Drilling Fluids). 

(a) Mineral slurry. Provide sodium bentonite or attapulgite in potable water. Use a mineral grain size 

that remains in suspension with sufficient viscosity and gel characteristics to transport drilled material 

out of the hole.

(b) Polymer slurry. Provide a slurry compatible with soil type and water chemistry.

725.14 Polymer Concrete and Mortar. Provide a mixture of monomers or resin binders that polymerize 

without the use of portland cement aggregates in the proportions recommended by the polymer 

manufacturer with a minimum compressive strength of 3500 pounds per square inch in 4 hours. Conform 

to the following:

(a) Epoxy mortar. Conform to ACI 503.4, Standard Specification for Repairing Concrete with Epoxy 

Mortars.

(b) Polyester resin grout. Provide polyester resin grout with a minimum ultimate compressive 

strength of 14,000 pounds per square inch, a minimum ultimate tensile strength of 2500 pounds per 

square inch, and a minimum ultimate shear strength of 4500 pounds per square inch when fully cured. 

Conform to ASTM F432, except where noted. 

Provide polyester resin grout consisting of an unsaturated polyester resin, evenly filled with 

nonreactive, inorganic aggregate of suitable size, and a separated catalyst filled with nonreactive 

inorganic filler. Provide resin in cartridge form. Provide cartridge lengths and diameters according to 

the manufacturer recommendations for the specified drill hole and reinforcing bar size. Provide resin 

cartridges readily and individually identified as to their respective gel times.

(c) Polyurethane grout. Conform to Table 725-1. 
Section 725

874

Table 725-1 

Polyurethane Grout Properties

Property Test Method Requirement

Grout density ASTM D1622 3 lb/ft3 minimum

Compressive strength ASTM D1621 30 psi minimum

Compressive modulus ASTM D1621 1700 psi minimum

Dimensional stability ASTM D2126

 - 40 °F 2% maximum

 200 °F 15% maximum

Tensile strength ASTM D1623 60 psi minimum

Tensile modulus ASTM D1623 1700 psi minimum

Shear strength ASTM C273 35 psi minimum

Shear modulus ASTM C273 500 psi minimum

Flexural strength ASTM D790 50 psi minimum

Flexural modulus ASTM D790 950 psi minimum

Water absorption ASTM D2842 2% maximum

Elongation ASTM D1623 1% maximum

Closed cell content ASTM D6226 90% minimum

725.15 Color Coating. Provide a semi-opaque colored toner containing methyl methacrylate-ethyl 

acrylate copolymer resins or equivalent resins, solvents, and color-toning pigments suspended in solution 

by a chemical suspension agent. Provide color-toning pigments consisting of laminar silicates, titanium 

dioxide, and inorganic oxides. Conform to the following: 

(a) Mass per gallon, ASTM D1475 8.3 lb minimum

(b) Solids by mass, ASTM D2369 30 percent minimum

(c) Solids by volume 21 percent minimum

(d) Drying time, ASTM D1640 30 minutes at 70 °F and 50 percent

maximum humidity

(e) Color change, ASTM D822, 1000 hours No appreciable change

(f) Resistance to acids, alkalies, gasoline, and mineral 

spirits, ASTM D543 

Excellent

(g) Water vapor transmission from interior concrete,

ASTM D1653

Transmittable 

(h) Oxidation over time None 

725.16 Galvanic Anodes. Provide galvanic anodes that have at least 100 grams of zinc conforming to 

ASTM B418 Type II. 
Section 725

875

725.17 Polyester Resin Binder. Provide polyester resin binder meeting the following requirements:

(a) Be an unsaturated isophthalic polyester-styrene co-polymer;

(b) Contain at least 1 percent by weight gamma-methacryloxypropyltrimethoxysilane, an organosilane 

ester silane coupler;

(c) Used with a promoter that is compatible with suitable methyl ethyl ketone peroxide and cumene 

hydroperoxide initiators; 

(d) Conform to Table 725-2. 

Table 725-2 

Polyester Binder Resin Properties

Quality Characteristic Test Method Requirement

Viscosity, cP, RV, No. 1 spindle, 20 RPM, at 77 °F(1) ASTM D2196 75 to 200

Specific gravity at 77 °F(1) ASTM D1475 1.05 to 1.10

Elongation, % 35 minimum

 Type I specimen, 0.25±0.03-inch-thick, rate = 0.45 in/min ASTM D638

 Sample conditioning: 18/25/50+5/70 ASTM D618

Tensile strength, psi 2500 minimum

 Type I specimen, 0.25±0.03-inch-thick, rate = 0.45 in/min ASTM D638

 Sample conditioning: 18/25/50+5/70 ASTM D618

Styrene content, % by weight(1) ASTM D2369 40 to 50

PCC saturated surface-dry bond strength, psi, at 24 hours and 70±2 °F California 

Test 551 500 minimum

(1) Perform test before adding initiator.

725.18 High Molecular Weight Methacrylate. Provide a wax-free, low odor, high molecular weight 

methacrylate primer consisting of a resin, initiator, and promoter. Use a promoter recommended by the 

system provider. Use an initiator consisting of a metal drier and peroxide. When supplied separately from 

the resin, do not mix the metal drier directly with the peroxide.

Conform to Table 725-3. 

Table 725-3 

High Molecular Weight Methacrylate Resin Properties

Property Test Method Requirement

Viscosity, cP, Brookfield RV with UL adaptor, 

50 RPM, at 77 °F(1) ASTM D2196 25 maximum

Volatile content, %(1) ASTM D2369 30 maximum

Specific Gravity, at 77 °F(1) ASTM D1475 0.90 minimum

Flash Point, °F(1) ASTM D3278 180 minimum

Vapor Pressure, inches Hg, at 77 °F(1) ASTM D323 0.04 maximum

Tack-free time, minutes, at 77 °F Prepare specimens under

California Test 551 400 maximum

PCC Saturated Surface-Dry Bond Strength, Adhesive, 

psi, at 24 hours and 70±1 °F(2) California Test 551, Part 5 700 minimum

(1) Perform test before adding initiator.

(2) PPC at 12 percent resin content by weight of the dry aggregate. 
Section 725

876

725.19 Fiber-Reinforced Polymer. Fabricate polymer structures from high-strength E-glass and 

isophthalic polyester resin unless otherwise specified. Apply weathering and ultraviolet light protection 

by addition of a 10-mil polyester veil to the laminate construction.

Conform to Table 725-4. 

Table 725-4 

FRP Performance Requirements

Property Test Method Requirement, psi

Tensile strength ASTM D638 30,000 minimum

Compressive strength ASTM D6641 30,000 minimum

Shear strength ASTM D2344 4500 minimum

Flexural strength ASTM D790 30,000 minimum

Young’s modulus ASTM D638 2,500,000 minimum

725.20 Penetrating Sealant. Provide a silane penetrating sealant, with 40 percent solids and active 

materials dispersed in water, conforming to Table 725-5. 

Table 725-5 

Penetrating Sealant Requirements

Property Test Method Requirement

VOC content EPA Method 24 675 lb/yd3 maximum

Water absorption NCHRP Report 244 Series II 85% reduction minimum

Chloride absorption NCHRP Report 244 Series II 85% reduction minimum

Chloride absorption NCHRP Report 244 Series IV 

Weathering Test 95% reduction minimum

Resistance to chloride ion 

penetration AASHTO T 259 & T 260 0.55 lb/yd3 at 0.5 inch depth maximum
Section 725

877

INDEX

Abbreviations .............................................................................................................................................. 2 

Acceptance

of work ................................................................................................................................................... 29 

partial and final ...................................................................................................................................... 39 

Accidents (report) ..................................................................................................................................... 43 

Acquisition regulations ............................................................................................................................. 12 

Acronyms .................................................................................................................................................... 2 

Anchor bases (lighting material) ............................................................................................................. 860 

Anchor bolt covers (lighting material) .................................................................................................... 860 

Archeological ............................................................................................................................................ 40 

As-built drawings ...................................................................................................................................... 20 

Backer rod ............................................................................................................................................... 818 

Balled and burlapped plants .................................................................................................................... 824 

Bars

dowel ................................................................................................................................................... 810 

fabricated deformed steel ..................................................................................................................... 811 

low alloy steel deformed...................................................................................................................... 811 

Bid

guarantee ................................................................................................................................................ 12 

opening of .............................................................................................................................................. 13 

preparation ............................................................................................................................................. 12 

rejection of ............................................................................................................................................. 12 

Blended hydraulic cement ....................................................................................................................... 781 

Bolts, nuts, and washers (lighting material) ............................................................................................ 860 

Bonds (performance and payment) ........................................................................................................... 13 

Bulletin board............................................................................................................................................ 41 

Certificates of insurance ........................................................................................................................... 42 

Certification

commercial ............................................................................................................................................ 30 

production .............................................................................................................................................. 31 

Channel preservation .............................................................................................................................. 127 

Chromium alloy steel castings ................................................................................................................ 841 

Circuit breakers and panels (electrical material) .................................................................................... 858 

Claims ....................................................................................................................................................... 42 

release .................................................................................................................................................... 59 

Clean Water Act ............................................................................................. See Environmental protection

Clearances

contractor-selected, noncommercial ...................................................................................................... 44 

Clevis connector (MSE wall material) .................................................................................................... 855 

Coating .................................................................................................................................................... 550 

steel ...................................................................................................................................................... 500 

Cofferdams .............................................................................................................................................. 128 

Coir rolls ................................................................................................................................................. 827 

Cold-drawn steel wire ............................................................................................................................. 811 

Commercial weighing systems ................................................................................................................. 52 
Section 725

Compaction ............................................................................................................................. 105, 236, 317 

Compost socks ........................................................................................................................................ 827 

Concrete 

curing ................................................................................................................................................... 480 

finishes ................................................................................................................................................. 481 

Concrete-lined corrugated steel pipe ...................................................................................................... 806 

Conduit (electrical material) ................................................................................................................... 857 

Conformance 

measured or tested ................................................................................................................................. 31 

Conformity with contract requirements .................................................................................................... 29 

Contactors and control transformers (electrical material) ...................................................................... 858 

Contract 

conformity with requirements ............................................................................................................... 29 

determination and extension of time ..................................................................................................... 45 

intent of .................................................................................................................................................. 14 

Contract quantity ....................................................................................................................................... 49 

Contracting Officer ............................................................................................................................... 7, 16 

Contracting Officer’s Representative ....................................................................................................... 16 

Contractor records ..................................................................................................................................... 14 

Contractor-located sources .......................................................................................... See Material Sources

Control strip ............................................................................................................................................ 337 

Coordination of contract documents ......................................................................................................... 24 

Crack fillers ............................................................................................................................................. 817 

Curing concrete ....................................................................................................................................... 480 

Definitions

measurement units ............................................................................................................................. 6, 49 

Subsection 101.04 .................................................................................................................................... 6 

Deformed steel wire ................................................................................................................................ 810 

Direct & indirect payment ........................................................................................................ See Payment

Direct payment .......................................................................................................................... See Payment

Disposal

excess material ..................................................................................................................................... 107 

unsuitable material ............................................................................................................................... 107 

Disputes..................................................................................................................................................... 14 

Dowel bars .............................................................................................................................................. 810 

Drawings ................................................................................................................................................... 17 

Elastomeric bearings (plain or laminated) .............................................................................................. 842 

Electronic Documentation ........................................................................................................................ 16 

Embankment 

construction ......................................................................................................................................... 104 

Environmental protection.......................................................................................................................... 43 

Epoxy mortar .......................................................................................................................................... 873 

Epoxy-coated reinforcing bars ................................................................................................................ 810 

Excavation 

borrow .................................................................................................................................................. 103 

roadway ............................................................................................................................................... 103 

subexcavation ...................................................................................................................................... 103 

Excelsior fiber rolls ................................................................................................................................. 827 

Fabricated deformed steel bar or rod mats .............................................................................................. 811 
Section 725

879

Fasteners (MSE wall material) ................................................................................................................ 855 

Fillers

crack..................................................................................................................................................... 817 

preformed expansion joint ................................................................................................................... 817 

Final acceptance ................................................................................................................... See Acceptance

Final payment............................................................................................................................................ 59 

Fly ash (pozzolan material) ..................................................................................................................... 781 

FP (definition) .............................................................................................................................................. i 

Geotextile (silt fence) .............................................................................................................................. 827 

Government-furnished

material stockpile ..................................................................................................... See Material Sources

sources ..................................................................................................................... See Material Sources

Grading standards (nursery stock) .......................................................................................................... 824 

Grounding and bonding equipment (electrical material) ........................................................................ 858 

Grouted riprap ......................................................................................................................................... 147 

Handling and storing material ................................................................................................................... 27 

Hardware cloth (MSE wall material) ...................................................................................................... 855 

Health ........................................................................................................................................................ 42 

High load rotational spherical bearings .................................................................................................. 842 

High-strength low-alloy structural (HSLA) steel ................................................................................... 840 

High-strength quenched and tempered (QT) steel .................................................................................. 840 

Hook bolts ............................................................................................................................................... 810 

Indirect payment ....................................................................................................................... See Payment

Industry standards ..................................................................................................................................... 31 

Inspection 

Government’s rights .............................................................................................................................. 29 

visual ...................................................................................................................................................... 30 

Inspection and Quarantine (nursery stock) ............................................................................................. 824 

Inspectors .................................................................................................................................................. 16 

OSHA & others ..................................................................................................................................... 43 

Insurance 

automobile liability ................................................................................................................................ 42 

certificates of ......................................................................................................................................... 42 

comprehensive/general .......................................................................................................................... 42 

worker’s compensation .......................................................................................................................... 42 

Invoices (weighing) .................................................................................................................................. 52 

Joint 

sealants................................................................................................................................................. 817 

Keyed riprap ............................................................................................................................................ 147 

Laws .......................................................................................................................................................... 40 

Liquidated damages .................................................................................................................................. 47 

Load restrictions ........................................................................................................................ 24, 484, 643 

Luminaries (lighting material) ................................................................................................................ 861 

Maintaining roadways 

during non-work periods ....................................................................................................................... 84 

Material

handling and storing .............................................................................................................................. 27 

salvaging ................................................................................................................................................ 98 

source management ............................................................................................................................... 27 
Section 725

source restoration ................................................................................................................................... 28 

sources ................................................................................................................................................... 26 

Material found in work ............................................................................................................................. 27 

Meaning of terms ........................................................................................................................................ 2 

Measurement record format ...................................................................................................................... 48 

Meter cabinet (electrical material) .......................................................................................................... 858 

Mineral filler ........................................................................................................................................... 872 

Mineral slurry (drilling fluids) ................................................................................................................ 873 

Mulch ...................................................................................................................................................... 740 

bonded fiber matric hydromulch ......................................................................................................... 823 

grass straw cellulose fiber .................................................................................................................... 822 

mature compost.................................................................................................................................... 822 

peat moss ............................................................................................................................................. 822 

recycled pulp fiber ............................................................................................................................... 823 

straw..................................................................................................................................................... 821 

straw for hydroseeding ........................................................................................................................ 823 

wood chips ........................................................................................................................................... 824 

wood fiber ............................................................................................................................................ 821 

Neat hydraulic cement grout ................................................................................................................... 781 

Non-native plants ...................................................................................................................................... 44 

Notice to Proceed ........................................................................................................................................ 9 

Operations 

limitations on ......................................................................................................................................... 85 

nighttime ................................................................................................................................................ 85 

Painting ...................................................................................................................................... See Coating

Paleontological .......................................................................................................................................... 40 

Partnering .................................................................................................................................................. 14 

Pavement markers (temporary pavement markings) .............................................................................. 851 

Pay factor

concrete ................................................................................................................................................ 183 

Payment 

final ........................................................................................................................................................ 59 

scope of .................................................................................................................................................. 53 

Placed riprap ........................................................................................................................................... 147 

Plank floors ............................................................................................................................................. 529 

Plant names ............................................................................................................................................. 824 

Planting material (antidesiccant)............................................................................................................. 825 

Planting material (braces and anchors) ................................................................................................... 825 

Planting material (hose) .......................................................................................................................... 825 

Planting material (tree wound dressing) ................................................................................................. 825 

Planting material (twine)......................................................................................................................... 825 

Planting material (wire) .......................................................................................................................... 825 

Planting material (wrapping material) .................................................................................................... 825 

Pole arms (lighting material) .................................................................................................................. 860 

Poles (lighting material) .......................................................................................................................... 859 

Portland cement ...................................................................................................................................... 781 

Posts (silt fence) ...................................................................................................................................... 827 

Preformed

expansion joint fillers .......................................................................................................................... 817 
Section 725

881

joint seals ............................................................................................................................................. 818 

Preformed polychloroprene elastomeric joint seal for bridges ............................................................... 819 

Preformed retroreflective tape (temporary pavement markings) ............................................................ 851 

Prework meeting ..................................................................................................................................... 427 

Project weighing systems .......................................................................................................................... 52 

Protection

archeological .......................................................................................................................................... 40 

environmental ............................................................................................. See Environmental protection

forests, parks, and public lands .............................................................................................................. 44 

paleontological....................................................................................................................................... 40 

property .................................................................................................................................................. 40 

railroad ................................................................................................................................................... 41 

utilities ................................................................................................................................................... 40 

workers .................................................................................................................................................. 41 

Pull boxes, frames, and covers (electrical material) ............................................................................... 857 

Quality of plant material ......................................................................................................................... 824 

Railroad ..................................................................................................................................................... 41 

Receiving procedures ................................................................................................................................ 53 

Regulations 

blasting................................................................................................................................................. 113 

FAR .......................................................................................................................................................... i 

TAR .......................................................................................................................................................... i 

Reinforcing bars ...................................................................................................................................... 810 

Reinforcing strips (MSE wall material) .................................................................................................. 855 

Restoration

material source ....................................................................................................................................... 28 

Right-of-Way

furnishing ............................................................................................................................................... 42 

Roadways 

maintaining during non-work periods ............................................................ See Maintaining roadways

Safety ........................................................................................................................................................ 42 

audible alarms ........................................................................................................................................ 43 

traffic and safety supervisor .................................................................................................................. 86 

Safety disconnect switches (electrical material) ..................................................................................... 858 

Salvaging 

material .................................................................................................................................................. 98 

Sample

labeling .................................................................................................................................................. 73 

Sand

bags (material) ..................................................................................................................................... 827 

Sanitation .................................................................................................................................................. 42 

Scales ...................................................................................................................................... See Weighing

Schedules .................................................................................................................................................. 75 

Scope of payment ...................................................................................................................................... 53 

Secondary lightning arrester (electrical material) ................................................................................... 858 

Service pole (electrical material) ............................................................................................................ 858 

Sieve (AASHTO M 92.............................................................................................................................. 10 

Silica fume (pozzolan material) .............................................................................................................. 782 

Silt fence reinforcement .......................................................................................................................... 828 
Section 725

Slag cement (pozzolan material) ............................................................................................................. 781 

Slope notation ............................................................................................................................................. 6 

Source 

of supply ................................................................................................................................................ 26 

quality requirements .............................................................................................................................. 26 

Specifications ............................................................................................................................................ 17 

format....................................................................................................................................................... 2 

more strict .............................................................................................................................................. 29 

Spill prevention, control, and countermeasure (SPCC) plan .................................................................... 43 

Steel castings ........................................................................................................................................... 841 

Straightedge measurement ...................................................................................................................... 350 

Straw fiber rolls....................................................................................................................................... 827 

Structural carbon steel ............................................................................................................................. 840 

Structural steel (bolts and nuts) ............................................................................................................... 840 

Structural steel (high-strength bolts, nuts, and washers) ........................................................................ 840 

Surety ........................................................................................................................................................ 12 

Survey and staking

tolerances ............................................................................................................................................... 67 

Tackifier (plant based) ............................................................................................................................ 826 

Tackifier (polmer stabilized fiber matrix) ............................................................................................... 826 

Tackifier (polymeric emulsion blend) .................................................................................................... 826 

Tie bars.................................................................................................................................................... 810 

Tie strips (MSE wall material) ................................................................................................................ 855 

Time extensions ........................................................................................................................................ 46 

Tolerances

manufacturing ........................................................................................................................................ 29 

Topsoil 

conserved ............................................................................................................................................. 103 

Traffic and Safety Supervisor ................................................................................................................... 86 

Traffic paint (temporary pavement markings) ........................................................................................ 851 

Trusses .................................................................................................................................................... 530 

Value Engineering .................................................................................................................................... 14 

Visual Inspection ................................................................................................................... See Inspection

Weigh ticket format .................................................................................................................................. 52 

Weighing ................................................................................................................................................... 51 

Welded fabric

deformed steel wire ............................................................................................................................. 811 

steel wire .............................................................................................................................................. 810 

Welding ................................................................................................................................................... 524 

Wire

cold-drawn steel ................................................................................................................................... 811 

deformed steel...................................................................................................................................... 810 

Wire and cable (electrical material) ........................................................................................................ 857 

Work

acceptance .............................................................................................................................................. 29 

Commencement, Prosecution, and Completion .................................................................................... 45 

contractor’s responsibility ..................................................................................................................... 42 

eliminated .............................................................................................................................................. 56 

Government's responsibility .................................................................................................................. 42 
Section 725

883

limitations .............................................................................................................................................. 85 

measurement of...................................................................................................................................... 48 

statistical evaluation .............................................................................................................................. 31 
Section 725

Publication No. FHWA-FLH-24-001