1 VIRGINIA DEPARTMENT OF TRANSPORTATION MATERIALS DIVISION MEMORANDUM GENERAL SUBJECT: System Based Independent Assurance Testing for Hydraulic Cement Concrete on Design Bid Build and Design Build projects NUMBER: MD 414-18 SPECIFIC SUBJECT: Revision of Section 410.05 Testing Frequencies in Chapter IV of Manual of Instructions on Hydraulic Cement Concrete and addition of Appendix G System-based Independent Assurance Test Evaluation Form DATE: May 1, 2018 SUPERSEDES: APPROVED: Charles A. Babish, PE State Materials Engineer Approved: EFFECTIVE DATE This memorandum is effective May 1, 2018. PURPOSE To revise Chapter IV of the Materials Manual of Instructions on Hydraulic Cement Concrete (HCC) Testing frequencies to establish a system based Independent Assurance (IA) testing protocol on design build and design bid build projects. The system based independent assurance testing will be more efficient, reduce repetitive IA testing on projects and provide a better assessment of VDOT’s certified concrete testing technician testing proficiency statewide. Remove Verification Sampling and Testing Frequencies in Tables IV-1, IV-2 and IV-3 in Chapter IV of the Materials Manual of Instructions on Hydraulic Cement Concrete. The Verification Sampling and Testing Frequencies are defined in the Minimum Requirements for Quality Assurance and Quality Control for Design Build and Public Private Transportation Act Projects and the Local Assistance Project Manual Chapter 13. Changes are Shaded PROCEDURES
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VIRGINIA DEPARTMENT OF TRANSPORTATION …€¦ · ASTM C31 and ASTM C39 One per day of production, or every 0.1 mile of paving, whichever is greater Permeability* (One set of two
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VIRGINIA DEPARTMENT OF TRANSPORTATION
MATERIALS DIVISION
MEMORANDUM
GENERAL SUBJECT: System Based Independent Assurance Testing for Hydraulic Cement Concrete on Design Bid Build and Design Build projects
NUMBER: MD 414-18
SPECIFIC SUBJECT: Revision of Section 410.05 Testing Frequencies in Chapter IV of Manual of Instructions on Hydraulic Cement Concrete and addition of Appendix G System-based Independent Assurance Test Evaluation Form
DATE: May 1, 2018
SUPERSEDES:
APPROVED:
Charles A. Babish, PE State Materials Engineer Approved:
EFFECTIVE DATE
This memorandum is effective May 1, 2018. PURPOSE
To revise Chapter IV of the Materials Manual of Instructions on Hydraulic Cement Concrete (HCC) Testing frequencies to establish a system based Independent Assurance (IA) testing protocol on design build and design bid build projects.
The system based independent assurance testing will be more efficient, reduce repetitive IA testing on projects and provide a better assessment of VDOT’s certified concrete testing technician testing proficiency statewide.
Remove Verification Sampling and Testing Frequencies in Tables IV-1, IV-2 and IV-3 in Chapter IV of the Materials Manual of Instructions on Hydraulic Cement Concrete. The Verification Sampling and Testing Frequencies are defined in the Minimum Requirements for Quality Assurance and Quality Control for Design Build and Public Private Transportation Act Projects and the Local Assistance Project Manual Chapter 13.
Changes are Shaded PROCEDURES
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Replace Chapter IV Section 410.05 Testing Frequencies of the Materials Manual of Instructions on
Hydraulic Cement Concrete (HCC) with the following:
Sec. 410.05 Testing Frequencies and Independent Assurance
HCC testing frequencies are defined in Tables IV-1, IV-2 and IV-3 for Design-Bid-Build projects,
Increasing or Decreasing Testing frequencies:
Testing frequencies may only be adjusted at the discretion of the District Materials Engineer
if questions arise regarding HCC quality.
When consistency is observed in testing fresh HCC properties (air content, density, slump and
temperature), the responsible charge Engineer may reduce testing frequencies. However,
when testing demonstrates out-of-compliance HCC, testing frequencies return to at least the
minimum(s) specified in Tables IV-1, IV-2 and IV-3.
Independent Assurance (IA) testing for Hydraulic Cement Concrete will be performed systematically
on a yearly basis for Design Bid Build and Design Build projects.
In early January, the District Materials Engineer will contact the District Construction
Engineer and the District staff responsible for Design Build projects to obtain the names of all
VDOT certified concrete technicians anticipated to be performing acceptance testing on
VDOT projects.
By the end of March a final list of VDOT certified Technicians will be obtained from the
District Construction Engineer and the District staff responsible for Design Build projects.
Technicians not evaluated on the list that become inactive during the year will be excluded
from the evaluation list.
As soon as the finalized list is made available to the District Materials Engineer, the District
Concrete Technician for Design Bid Build or District staff responsible for Owner IA on
Design Build projects will begin evaluating the technicians on the list in accordance with the
guidance provided in this section, appendix IV-G and the specific ASTM test method used for
acceptance.
The District Materials Quality Assurance Manager (QAM) will monitor the progress of the
District Concrete Technician for Design Bid Build or District staff on Design Build Projects
assigned to perform IA testing on a periodic basis to evaluate the progress made.
The District QAM will ensure that during each calendar year a System-based Independent
Assurance Evaluation Form will be completed on at least 80% of the technicians on the final
list obtained in March from the district construction staff.
At the end of the year, an assessment will be made on the final March list to determine the
number of technicians that were actually performing acceptance tests and an IA evaluation
form was filled out on them. Those technicians not evaluated during the current calendar year
will be designated (given priority) for IA evaluation the following year.
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The net goal for VDOT will to be to evaluate all active concrete testing technicians every 2
years. VDOT understands that it is a goal to evaluate as close to 100% as practical yearly.
A summary report on technicians examined in each district will be reported to the State
Materials Engineer for inclusion in the annual system based IA report to FHWA.
o The report should include number of technicians an IA evaluation was performed on.
o The number of active technicians performing HCC testing in the district.
o Deficiencies noticed during the examination.
o Recommended corrective actions.
o Any observed trends.
Conducting an IA test evaluation on 80% of active concrete testing technicians will fulfill the
Independent Assurance testing requirements for hydraulic cement concrete on VDOT
projects.
The independent assurance test evaluation will be conducted on a split sample test taken from
the same sample location where the hydraulic cement concrete was sampled for the
acceptance test.
The acceptance test will be performed either by the VDOT Inspector, VDOT Consultant
Inspector, the Design Builder’s Quality Control technician responsible for quality control, or
the Design Builder’s Quality Assurance Technician operating under the Quality Assurance
Manager responsible for Quality Assurance on Design Build projects.
The IA test will be performed at the same time as the acceptance test by the VDOT
designated materials representative on Design Bid Build projects and by QC and VST testing
on Design Build projects.
Ensure the technician performing the IA test does not use the same equipment (slump cone,
air meter, scale and thermometer) that was used by the technician performing the acceptance
test. The results of the slump, air and temperature will be compared between the Acceptance
test and IA test and recorded on the evaluation form (Appendix IV- G).The results of the
slump, air and temperature will be compared between the Acceptance test and IA test using
the tolerances established in the contract documents and reported to the District Materials and
District Construction Engineer or their representative for a particular project. If the tolerances
are not established in the contract documents, the tolerances in Appendix IV-G will be used.
Independent Assurance Testing for Hydraulic Cement Concrete will be performed on a project basis
on Local Assistance projects at required frequency in accordance with the LAP Manual.
Verification Sampling and Testing (VST) for Hydraulic Cement Concrete will be performed on
Design Build and P3 projects according to the specific Design Build Contract documents.
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Tables IV-1, IV-2 and IV-3 will change to the following:
Table IV-1. Testing Frequencies for Structural HCC
Test Reference Acceptance
Testing
Temperature ASTM C1064 Every Load
Slump (Consistency) ASTM C143 Every Load
Unit Weight
(Density)*
ASTM C138 Every Load
Air Content ASTM C231
or
ASTM C173
Every Load
Strength
(One set of three
4” x 8” cylinders or
one set of two 6” x
12” cylinders )
ASTM C31 and
ASTM C39
One set per 100
cubic yards
(minimum one set
per day)
Permeability *
(One set of two
4” x 8” cylinders)
ASTM C31 and
VTM-112
One set per 100
cubic yards
(minimum one set
per day)
* If specified.
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Table IV-2. Testing Frequencies for Miscellaneous HCC
Test Reference Acceptance
Testing**
Temperature ASTM C1064 One per day
Slump (Consistency) ASTM C143 Two per day
Unit Weight
(Density)*
ASTM C138 One per day
Air Content ASTM C231
or
ASTM C173
One per day
Strength
(One set of three
4” x 8” cylinders or
one set of two 6” x
12” cylinders )
ASTM C31
and
ASTM C39
One per 250 cubic
yards
Permeability*
(One set of two
4” x 8” cylinders)
ASTM C31
and
VTM-112
One per 250 cubic
yards (minimum
one set per project)
* If specified.
**Minimum one test/set per project.
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Table IV-3. Testing Frequencies for Pavement HCC
Test Reference Acceptance
Testing**
Temperature ASTM C1064 One per hour
Slump (Consistency) ASTM C143 One per hour
Unit Weight
(Density)*
ASTM C138 One per hour
Air Content ASTM C231
or
ASTM C173
One per hour
Strength
(One set of three
4” x 8” cylinders or
one set of two 6” x
12” cylinders)
ASTM C31 and
ASTM C39
One per day of
production, or
every 0.1 mile of
paving, whichever
is greater
Permeability*
(One set of two
4” x 8” cylinders)
VTM-112 One per day of
production, or
every 0.1 mile of
paving, whichever
is greater
Pavement Thickness VTM-26 One per 0.1 mile
Flexural Strength
(used for opening to
traffic and not an
acceptance test)
ASTM C78 As deemed
necessary to
determine opening
to traffic
* If specified.
**Minimum one test/set per project.
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The System-based IA evaluation form would be added to Chapter IV as Appendix G:
System-based Independent Assurance Evaluation Form
District Administrators Virginia Ready Mix Association District Location & Design Engineers Precast Concrete Association of Virginia
District Construction Engineers Virginia Transportation Construction Alliance District Maintenance Engineers Virginia Asphalt Association
District Bridge Engineers American Concrete Paving Association Mid-Atlantic Chapter District Traffic Engineers Old Dominion Highway Contractors Association