construction control manual (cespk pam 416-1-2) sampling & testing construction materials (us...

CESPK PAM 415-1-215 Jun 89

TABLE OF CONTENTS

PARAGRAPH PAGECHAPTER 1 CONSTRUCTION CONTROL MANUAL

General . . . . . . . . . . . . . . . . .Definitions . . . . . . . . . . . . . . .Purpose . . . . . . . . . . . . . . . . .Responsibility, Compilation, &Submittal of Test Results . . . . . . .

Contractor's Quality Control . . . . . .Government Quality Assurance . . . . . .Laboratory Facilities . . . . . . . . . .Quality Control Plan . . . . . . . . . .Special Test Requirements . . . . . . . .

CHAPTER 2 SOILS AND PROCESSED AGGREGATESS c o p e . . . . . . . . . . . . . . . . . .T e s t s . . . . . . . . . . . . . . . . . .Sampling and Testing of Fill, Backfill,

Embankment, Drainage, Subgrade,Subbase, & Base Course Materials . . .

Compilation of Test Data for Submittalof Test Results . . . . . . . . . . . .

1 - 1l - 2l - 3

1 - 4l - 5l - 6l-71 - 81 - 9

2 - l2 - 2

2 - 3

2 - 4

CHAPTER 3 AIRFIELD AND HELIPORT PAVEMENT, CONSTRUCTIONSUBGRADE AND PROCESSED AGGREGATES

S c o p e . . . . . . . . . . . . . . . . . .Tests . . . . . . . . . . . . . . . . . .Sampling and Testing of Fill,

Embankment, Subgrade, Subbase, &Base Course Materials . . . . . . . . .

Production Control Testing of Subbase &Base Course Materials . . . . . . . . .

Compilation of Test Data for Submittalof Test Results . . . . . . _ . . . . .

CHAPTER 4 BITUMINOUS MATERIAL ANDBITUMINOUS-AGGREGATE MIXTURES

S c o p e . . . . . . . . . . . . . . . . . .T e s t s . . . . . . . . . . . . . . . . . .Mix Design Submittals . . . . . . . . . .Minimum Test Requirements . . . . . . . .Sample Transmittal . . . . . . . . . . .Compilation of Test Data for Submittal

of Test Results . . . . . . . . . . . .

3 - 13~- 2

3 - 13 - l

3 - 3

3 - 4

3 - 5

3 - 3

3 - 4

3 - 4

4 - l 4 - l4 - 2 4 - l4 - 3 4 - l4 - 4 4 - l4 - 5 4 - 6

4 - 6 4 - 6

l - ll - ll - l

l - ll - 3l - 41 - 4l - 4l - 5

2 - 12 - 1

2 - 3

2 - 7


TABLE OF CONTENTS - Cont.

CHAPTER 5 CONCRETEs c o p e . . . . . . . . . . . . . . . . . .Mix Designs . . . . . . . . . . _ . . . .Excepted Features . . . . . . . . . . . .Minimum Test Requirements . . . . . . . .Admixtures . . . . . . . . . . . . . . .Methods of Curing . . . . . . . . . . . .Procedures for Sampling & Testing . . _ .Compilation of Test Data for Submittal

of Test Results . . . . . . . _ . . . .

PARAGRAPH PAGE

5 - l 5 - 15.7 2 5 - 15 - 3 5 - l5 - 4 5 - 15 - 5 5 - 55 - 6 5 - 55 - 7 5 - 5

5 - 8 5 - a

CHAPTER 6 MASONRY CONSTRUCTIONS c o p e . . . . . . . . . . . . . . . : . . 6 - 1Test Requirements for Masonry Units . . . 6 - 2Test Requirements for Mortar and Grout . 6 - 3

APPENDIX A - Master Test Forms _ . . . . . . . . . . . . . . .

6 - 16 - l6 - 2

A-l - A-23

ii

FIGURE

2-l

FORM TITLE PAGE

SPD FORM 561 Ott 72

2-2

2-3

SPD FORM 312-R1May 81

UNNUMBERED

2-4 ENG FORM 3841Jun 65

2-5 ENG FORM 2087May 63

2-6

2-7

DD FORM 1209?Alg 57

ENG FORM 3840Jun 65

4-l SPD FORM 591 Mar 80

4-2 SPD FORM 55 EXTRACTION TEST HOT MIX ASPHALTIC1 Ott 72 CONCRETE

4-3

4-4

4-5

WES FORM 886Aug 55

WES FORM 1505Sep 65

DD FORM 1218Dee 65

4-6 UNNUMBERED

4-7 DD FORM 1217Dee 65


INDEX OF COMPLETED TEST FORMS

COMPACTION-MOISTURE DENSITYDETERMINATIONS

FIELD DENSITY

NUCLEAR FIELD DENSITY TESTWORKSHEET

SIEVE ANALYSIS

GRADATION CURVES

ATTERBERG LIMITS DETERMINATION

SPECIFIC GRAVITY TESTS

DAILY PLANT AND LABORATORYREPORT OF BITUMINOUS PAVEMENT

AGGREGATE GRADING CHART

SIEVE ANALYSIS

MARSHALL METHOD - COMPUTATION OFPROPERTIES OF ASPHALT MIXTURES

mxmm THEORETICAL SPECIFICGRAVITY OF ASPHALT CONCRETE

BITUMINOUS MIX DESIGN -AGGREGATE BLENDING

iii

2-8

2-9

2-10

2-11

2-12

2-13

2-14

4-8

4-9

4-10

4-11

4-12

4-13

4-14


INDEX OF COMPLETED TEST FORMS

FIGURE

5-l

FORM

SPD FORM 581 Ott 72

TITLE PAGE 5-2

CONCRETE FIELD CONTROL 5-9

5-2 SPD FORM 22110 act 74

CONCRETE CONTROL DATA 5-10

5-3 SPK FORM 2171 JUl 82

SAND TEST 5-11

5-4

6-1

6-2

SPD FORM 54 AGGREGATE GRADING 5-121 Ott 72

SPK FORM 421 COMPRESSIVE STRENGTH CONCRETE1 Aug 88 CYLINDERS 6-3

SPK FORM 181 TEST DATA ON ABSORPTION 6-41 Aug 88 AND MOISTURE CONDITION OF

MASONRY BLOCKS

iv

CESPX PAM 415-l-215 Jun 89

CHAPTER 1

CONSTRUCTION CONTROL MANUAL

l-l. General. This manual is applicable to contracts awarded on orafter the date which appears on the cover of this manual. The 10 June1983 manual applies to projects awarded before the above-referenceddate.

l-2. Definitions.

a. Qg&:ruction Control (CC) - Construction Control is asystem involving the concurrent but separate efforts of theContractor and the Government personnel to achieve the level ofquality established by the project's contract documents.

b. Contractor OUalitY Control (OC) - Contractor's QualityControl is that part of the system by which the Contractor regulates,tests, and inspects his procedures, equipment, materials, andpersonnel so that the completed product will comply with therequirements of the project's contract documents.

C. Government Oualitv Assurance (OA) - Government QualityAssurance is that part of the system by which the Government (owner)verifies (1) that the Contractor's Quality Control system isperforming properly and (2) that the final product complies with theproject's contract documents.

d. Processed Aosresates - Processed aggregates are anymaterials the Contractor must process by washing, sorting, screening,crushing, etc. to produce an aggregate meeting the contractrequirements.

l-3. Purnose. This manual prescribes procedures to be followed byContractor and Government personnel assigned the responsibility ofperforming the Construction Control compliance. Procedures outlinedin this manual are for testing materials including, but not limitedto, materials used in fills, embankments, subgrades, base courses,flexible and rigid pavements, structural concrete, and masonry.Unless otherwise noted, this manual shall be used for all projects.

l-4. Resnonsibilitv. Comnilation. and Submittal of Test Results.

a . The Contractor shall be responsible for full compliancewith these instructions in the performance of tests and thepreparation, submittal, and maintenance of tests included herein and

l-l

CESPK PAR 415-1-215 Jun 89

listed in the contract specifications. The test results from QC andQA testing shall be compiled separately as outlined in this manual.The Resident Contracting Officer shall have overall responsibility toassure compliance by the Contractor, however, the Contractor shall beresponsible for controlling quality and for compliance with contractrequirements. The test results from both control and assurance testsshall be compiled as outlined in this manual. Copies of each testresult shall be prepared with all necessary data recorded,documentation and computations completed. Distribution to the Corpsof Engineers shall be as follows:

4 conies total:

2 copies to Resident Contracting Officer, Corps ofEngineers

1 copy to District Engineer (through ResidentContracting Officer), Corps of Engineers

1 copy to Area Contracting Officer, Corps of Engineers

b. Distribution of the copies to the Resident ContractingOfficer shall be made within 48 hours after sampling or initiatingeach test, except when the test duration requirements exceed 4% hoursIn the latter case, distribution shall be within 24 hours aftercompletion of the test. Each test shall be started and completedwithout delay. Payment for materials placed, as well as for anysubsequent construction dependent upon contract compliance of thesematerials, will not be authorized until test reports have beenproperly distributed. The Government will furnish sufficient copiesof the test report forms, if blank master forms (to be reproduced asnecessary by the Contractor) are not found in this manual. Requestfor resupply of forms will be the responsibility of the Contractor.

C . All test forms shall be accurately completed, and a testlocation plan shall be submitted when directed by the ResidentContracting officer. All test forms not accurately completed will beimmediately returned to the Contractor for correction or completion,and no Quality Control tests will be accepted unless signed by theLaboratory Manager and Supervising Technician. The Materials TestLog (summarizing QC testing) shall be maintained at the Contractor'sproject office and will be divided into four parts for recordingsample numbers of tests on (S) soils and processed aggregates, (B)bituminous materials and mixes, (C) Portland Cement concrete, and (0)

l-2


other types of material such as masonry, roofing material, etc. Eachsample and test will be assigned a laboratory number at the time ofarrival of the sample at the laboratory or beginning of the test.This number shall contain the last four digits of the contractnumber, followed by a letter designating the construction use of thematerial using the letter "S" for soils and processed aggregate, llB81for bituminous material, "C" for Portland Cement concrete, and 1'0*'for other types of material and then followed bythe sample number.For soil, processed aggregates, as well as bituminous materials andmixes, a second letter will be included to differentiate a test on amaterial from a bulk sample from a material obtained from a fielddensity hole - use a letter "S" from bulk samples and a "D** fromdensities. Retests will be made for failed tests and assigned thesame number as the original tests with a final letter to identifythem as a retest. For example 0062-BD-132, 0062-BD-132A. Inaddition, a copy of the Materials Test Log shall be submitted witheach monthly progress report for determining the Contractor'sprogress payment for materials placement represented by these tests.

1-5. Contractor's Oualitv Control fOC). The QC program is based, inpart, on specific tests required for several items of work involved.The location and frequency of tests required depend on the manner inwhich the work is being performed and the uniformity and quality ofthe tests obtained. A minimum testing program for quality controltesting is outlined in this manual. Additional testing may berequired by the specifications for contracts when the minimum testingprogram is not considered to be adequate or applicable. Testsindicating noncompliance with the contract documents shall bereported immediately to the Resident Contracting Officer or theResident Contracting Officer's representative, however, theContractor's Quality Control representative will recommend steps tobe taken to alleviate areas of noncompliant conditions. The ResidentContracting Officer or his representative reserves the right todesignate the location and type of additional sampling and testing(to be performed at the Contractor's expense) to verify compliance ifquality is inconsistent or questionable. References to standard testmethods and testing procedures for sampling and testing of thematerial are given in each chapter of this manual, unless otherwisespecified, and additional types of tests may be required by otherareas of the contract documents. Periodic Quality Assurance testsshall be made by the Contracting Officer's representative to assurethe Contractor's compliance with contract requirements andspecifications.

l-3


1-6. Government Oualitv Assurance (OAl. Unless otherwise specified,the frequency of QA testing will be determined by the ContractingOfficer's representative. For all projects, the recommended minimumtesting frequency will be at least two tests done concurrently withthe first two QC tests and thereafter at a rate of one test for every10 tests made by the Contractor.

1-7. Laboratorv Facilities. The Contractor shall use only anestablished commercial laboratory approved by the ResidentContracting Officer. Laboratory facilities and personnel are to bein accordance with ASTM D 3740 (soils), ASTM C 1077 (concrete), andASTM D 3666 (asphalt) as applicable. The Government reserves theright to make inspections of the Contractor's designated laboratoryfacilities, including test equipment and procedures. This is toensure that all equipment is in proper working order, as well ascorrectly calibrated, and that specified test procedures are beingperformed by qualified personnel. The Government also reserves theright to conduct additional QA testing, using either its ownequipment and facilities or the Contractor's. This additional QAtesting shall be performed for all projects, as the ResidentContracting Officer deems necessary, to assure the Contractor'scompliance with the contract documents.

l-8. Qualitv Control Plan. As soon as possible after the contracthas been awarded and prior to commencement of any work, aConstruction Quality Control Meeting shall be held. The purposes ofthis meeting will be to discuss quality control inspectionrequirements as well as the Contractor's Quality Control Plandesigned to fulfill these requirements. To address the~materialstesting portion of the Quality Control Plan, the following shall beincluded with the Quality Control Plan using this manual forguidance:

a . The QC organization and its structure.

b. Proposed methods of performing inspections.

C . Established areas of responsibility.

d. Name and qualifications of each individual assigned a QCfunction. (Quality Control Representative, Laboratory Manager,Supervising Technician, and Technicians)

l-4


e . Description of how testing will be performed.

(1) Name of commercial laboratory (to be approved bythe Resident Contracting Officer).

(2) Technicians employed by the laboratory to performthe test(s).

(3) Test methods to be used.

(4) Location and availability of test equipment.

f. Schedule of tests that will be performed (MaterialsTest Summary).

A date when the laboratory facility can be inspected(basis'of laboratory approval).

No construction work shall commence until the Quality ControlPlan has been approved by the Resident Contracting Officer, andany changes in the Quality Control Plan shall be submitted inwriting for approval.

1-9. Snecial Test Reuuirements.

a. Soils and Processed Aaareaates. When more than 30%of the material is retained on a 3/4-inch sieve, laboratorymaximum density shall be determined in accordance with EM 1110-2-1906, Appendix VI A (Utilizes a 12-inch mold). Field tests shallbe determined in accordance with ASTM D 1556 using a 12-inchdiameter ring and sand cone.

b. Lime. Asuhalt, or Cement Stabilization. Shall be sampledand tested as stated in the contract documents.

C . Geotextiles. Shall be sampled and tested as stated in thecontract documents.

l-5


CHAPTER 2

SOILS AND PROCESSED AGGREGATES2-l. m.

a. This chapter prescribes methods and procedures for theContractor Quality Control (QC) testing of materials used in allfills (except large dam embankments and cofferdams), backfills,embankments, subgrades, subbases, and base courses, unless otherwisenoted hereinafter. Drainage materials are included in this scope andshall include all poorly-graded and well-graded processed aggregatesused to remove moisture (or prevent the entrance of moisture)detrimental to final construction.

b. The types and frequencies of QC tests for large damembankments and cofferdams are excluded from this manual and will beprovided in the contract specifications for the respective projects.

c. The types and frequencies of QC tests for airfield andheliport construction are covered separately in this manual underChapter 3: Airfield and Heliport Pavement - Soils and ProcessedAggregates, or in the contract specifications for such projects.

2-2. Tests Testing and reporting shall be performed in accordancewith theAmerican Society of Testing and Materials (ASTM) Standardsas indicated below or as shown in Chapter 1 of this manual (latesteditions at time of contract award, unless otherwise indicated).

a. Samolinq. ASTMD75 Sampling Aggregates.

b. Samule ASTM D 2217 Wet preparation of SoilPrenaration. Samples for Particle Size

Analysis and Determinationof Soil Constants (MethodB) -

C . Gradation. ASTM C 117 Materials Finer than No.200 Sieve in MineralAggregates by Washing.

ASTM C 136 Sieve or Screen Analysisof Fine and CoarseAggregates.

2-1

CESPK PAW 415-l-215 Jun 89

d. Unit Weiaht. ASTM C 29

e. SvecificGravity.

f . SvecificGravity.

9. AtterberqLimits.

h. MoistureContent.

1 . Moisture -DensityRelationshiu.

j. FieldDensitv.

ASTM D 422Apparatus B

ASTMEl.1

ASTM c 127

ASTM D 854

ASTM D 4318(Procedure B)

ASTM D 2216

ASTM D 1557

EM 1110-2-1906Appendix VI A(Utilizes a12-inch mold)

ASTM D 4253*

ASTM D 1556**

Particle-Size Analysis ofSoils. (Only used whenhydrometer analysis isspecified)

Wire-Cloth Sieves forTesting Purposes.

Unit Weight and Voids inAggregates.

Specific Gravity andAbsorption of CoarseAggregate.

Specific Gravity ofSoils.

Liquid Limit, PlasticLimit and Plasticity Indexof Soils.

Laboratory Determination ofMoisture Content of Soil.

Moisture-Density Relationsof Soil and Soils AggregateMixture using lo-lb Rammerand 18-inch Drop (MethodsB or D).

Moisture-Density Relationsof Soil (using a 12-inchdiameter mold).

Maximum Index Density ofSoils Using a VibratoryTable.

Density of Soil in Placeby the Sand-Cone Method.

2-2

ASTM D 2922***

ASTM D 3017***

k. Wear Test. ASTM C 131

1. Materials ASTM D 2487Classification.


Density of Soil and Soil-Aggregate in Place byNuclear Methods (ShallowDepth).

Moisture Content of Soil &Soil-Aggregate in place byNuclear~Methods.

Resistance to Abrasion ofSmall-Size CoarseAggregate by Use of theLos Angeles Machine.

Classification of Soilsfor Engineering Purposes.

*Vibratory table shall be used for cohesionless materials for which awell-defined moisture-density relationship cannot be obtained usingASTM D 1557.

**The field density test shall be performed in accordance with theStandard Method of Test for Density of Soil in Place by the Sand-ConeMethod, ASTM D 1556, except that in each test the weight of thedisturbed sample representing the full depth of layer shall be notless than 10 pounds for fine-grained or sandy materials and 12 poundsfor gravelly materials using a scale for weighing of sufficientcapacity sensitive to .Ol pounds. All field density samples shall beoven-dried in accordance with ASTM D 1556 and D 2216.

***The use of Nuclear Methods for determining field densities andmoisture contents shall be limited to drainage materials and basecourse materials as outlined by Table 2-1, paragraph C-l.

2-3. Samnlinu and Testina of Fill. Backfill. Embankment, Drainaae.Subarade. Subbase, and Base Course Materials. This sampling andtesting shall be in accordance with the standard procedures referredto in this manual. The minimum number of QC tests to be performedshall be as indicated in Table 2-l.

2-3

CESPK PAM 415-I-215 Jun 89

Table 2-l. Type of Tests and Frequency

A. BACKFILL AND EMBANKMENTTEST FREQUENCY

1. Field Density w/MoistureContent.

1 . Two per lift for eachincrement or fraction of2000 s.y. placed duringeach S-hour shift.

2. Gradation w/Atterberg Limits 2. One per 5 field(from Compacted Material)* densities.

3. Moisture-Density Relation-ships w/Gradation, AtterbergLimits, Specific Gravity, andClassification (from BulkSample).

3 . One per 5 fielddensities (with not lessthan one per type ofmaterial) for the first25 field density tests.Thereafter, one additionaltest for each change inmaterial.

B. SUBGRADE AND SUBBASETEST FREQUENCY

1. Field Density w/BoistureContent

1 . Two per lift for eachincrement or fraction of1000 s.y. placed duringeach S-hour shift.

2. Gradation w/Atterberg Limits(from Compacted Material)*

2. Two per five fielddensities.

3. Moisture-Density Relation-ship w/Gradation, AtterbergLimits, Specific Gravity andClassification (from Bulk Sample)

3. One per 5 fielddensities (with not lessthan one per type ofmaterial) for the first25 field density tests.Thereafter, one additionaltest for each change inmaterial.

2-4


C. BASE COURSE AND DRAINAGE MATERIALTEST FREQUENCY

1. Field Density w/Moisture.

2. Gradation and AtterbergLimits (From CompactedMaterial)*

1. Two per lift for eachincrement or fraction of1000 s-y. placed duringeach 8-hour shift. First5 testsduring initialconstruction of each basecourse or drainagematerial shall be determi-ned by ASTM D 1556 andby ASTM D 2992 forcorrelation of sand coneand nuclear methods.Thereafter, every 5thnuclear test method shallbe verified by sand conemethod. If verificationtesting does not showadequate correlation asdetermined by theContracting Officer, alltests shall be performedin accordance with ASTM D1556. However, theContractor may, at hisoption, perform all fielddensity tests in accordancewith ASTM D 1556.

2. Two per five fielddensity tests.

3. Moisture-Density Relationshipw/Gradation, Atterberg Limits,Specific Gravity, and Classifica-tion (from Bulk Sample).

3. One per 5 fielddensity tests (with notless than one per type ofmaterial) for the first25 field density tests.Thereafter, one additionaltest for each change inmater ia l .

2-5

CESPK PAM 415-l-215 Jun 89

4 . Crushed Faces, L-A. Abrasion,and Smoothness

Frequency to be inaccordance with contractspecifications.

D. BACKFILL FOR CULVERT TRENCHES, WALLS, CULVERTS, h BUILDINGPERIMETERS

TEST FREQUENCY

1. Field Density w/Moisture la. Culverts and UtilityTrenches: One per liftfor each increment orfraction of 500 linealfeet of backfill.

lb. Walls and BuildingPerimeters: One per liftfor each increment orfraction of 200 linealfeet of backfill.

2. Lab Moisture Density Relations 2. One per 5 fieldw/Atterberg Limits, Gradation, density tests (with notSpecific Gravity, and Classification less than one per type of(from bulk sample). material) for the first

25 field density tests.Thereafter, one additionaltest each time there is achange in material.

*Compacted material sample taken adjacent to field density testsite.

gg@: For subbase and base courses, measure thickness of liftconcurrently with field density test and record on test form.

In addition to the minimum testing program listed above,representative samples of subgrade, subbase, base, and all otherconstruction materials (including on-site materials) shall becollected (prior to compaction) by the Contractor and submitted tothe Government for testing. Samples shall be taken under thedirection of the Contractor's Quality Control representative. Bagsamples for this purpose shall be shipped within 24 hours by theContractor at the Contractor's expense to the Sacramento DistrictLaboratory, Corps of Engineers, 2021 Jefferson Boulevard, WestSacramento, California 95691. Weight of these samples shall be a

2-6


minimum of 100 pounds for material containing less than 10% plusNo. 4 material, 150 pounds for material containing more than 10% plusNO. 4 material, or 750 pounds for material containing more than 30%plus 3/4-inch material.

2-4. Comoilation of Test Data for Submittal of Test Results.The following six test results shall be submitted concurrently:

a. Moisture-Density Determinations, IFiuure 2-l). Thisform is for use in determinins the ootimum moisture and maximumunit weight (density of soils-and processed aggregates). Themoisture-density curve shall be plotted based on a minimum offour compaction test specimens. The zero-air-voids curve shallalso be plotted using the specific gravity test data from ASTM D854 and ASTM C 127. Classification of sample shall be inaccordance with ASTM D 2487, with the classification group nameand group symbol clearly and accurately stated. The ResidentContracting Officer may require, at no additional cost to theGovernment, single-point checks of moisture-density relations(ASTM D 1557 dry of optimum moisture), if it is evident throughQuality Assurance testing that the Quality Control testing is notbeing adequately controlled with respect to the precisionrequirements of ASTM D 1557, paragraph 9.

ThisThisfill

test

b. Field Density Test (Sand Cone Method). (Fioure 2-2).test form is used to determine the degree of compaction.sheet can also be used for recording moisture content ofin borrow material or as placed.

C. Field Density Test (Nuclear Method). (Fioure 2-3). Thisform is used to determine the degree of compaction when

using the Nuclear Method.

d. Gradation Sheets, fFioures 2-4 and 2-5). These forms areused to record the results of gradation tests for all materials.Figure 2-4 shows a typical example in which gradation tests wereperformed in accordance with ASTM Standards C 136 and C 117.Results from these tests shall be tabulated as shown in Figure 2-4and plotted as shown in Figure 2-5.

e. Atterbera Limits Determination, (Figure 2-6). This formis used to compute liquid limit, plastic limit, and plasticity index.

f. Specific Gravitv Tests, (Fiuure 2-7). This form is usedto compute specific gravity of soils, aggregate, and stone.

2-7

CESPK PAW 415-1-215 Jun 89

CHAPTER 3

AIRFIELD AND HELIPORT PAVEMENT CONSTRUCTION,SUBGRADE, AND PROCESSED AGGREGATES

3-l. a. This chapter prescribes methods and procedures for theContractor Quality Control testing of materialsused in the backfill,embankment, subgrade, subbase, and base courses, etc. for rigid andflexible airfield and heliport pavement construction. Refer toChapter 2 for testing of other earthwork features such as buildingfills and trench backfill.

3-2. Tests. Testing and reporting shall be performed in accordancewith the American Society for Testing and Materials (ASTM) Standardsas listed below as specified in Chapters 1 and 2 of this manual.

a. Samnlinq. ASTM D 75

b. Samole ASTM D 2217Preoaration.

C . Gradation. ASTM c 117

ASTM C 136

ASTM D 422Apparatus B

ASTM E 11

d. Unit Weisht. ASTM c 29

Sampling Aggregates.

Wet Preparation of SoilSamples for Particle-SizeAnalysis and Determinationof Soil Constants (Method B).

Materials Finer than No.200 Sieve in MineralAggregates by Washing.

Sieve or Screen Analysisof Fine and CoarseAggregates.

Particle-SizeAnalysis of Soils. (Onlyused when hydrometer

Wire Cloth Sieves forTesting Purposes.

Unit Weight and Voids inAggregate.

3-1


e. Soecific ASTM C 127Gravity.

ASTM D 854

f. Atterberq ASTM D 4318Limits.(Procedure B)

c?. Moisture ASTM D 2216Content.

h. Moisture- ASTM D 1557DensityRelationshia.

EM 1110-2-1906Appendix VI A

ASTM D 4253*

1. Field ASTM D 1556**Densitv .

j- Wear Test. ASTM C 131

k. Materials ASTM D 2487Classification.

Specific Gravity andAbsorption of CoarseAggregate.

Specific Gravity of Soils.

Liquid Limit,~ PlasticLimit, and PlasticityIndex of Soils.

Laboratory Determinationof Moisture Content of Soil.

Moisture-Density Relationsof Soils and Soil-AggregateMixture Using lo-lbRammer and 18-in Drop(Methods B, or D).

Moisture-Density Relationsof Soil Using a 12-inchDiameter Mold.

Maximum Index Density ofSoils using a VibratoryTable.

Density of Soil~in Placeby the Sand-Cone Method.

Resistance to Degradationof Small-Size CoarseAggregate by Abrasion andimpact in the Los AngelesMachine.

Classification of Soilsfor Engineering Purposes.

*Vibratory table shall be used for cohesionless materials for which awell-defined moisture-density relationship cannot be obtained usingASTM D 1557.

3-2


**The field density test shall be performed in accordance with theStandard Method of Test for Density of Soil in Place, by the Sand-Cone Method, ASTM D 1556, except that in each test the weight of thedisturbed sample representing the full depth of layer shall be notless than 10 pounds for fine-grained or sandy materials and 12 poundsfor gravelly materials using a scale for weighing of sufficientcapacity sensitive to 0.01 pounds. All field density samples shallbe oven-dried in accordance with ASTM D 1556. ~~

3-3 Samolina and Testina of Fill, Embankment. Subarade. Subbase, andBase Course Materials, etc. The sampling and testing shall be inaccordance with the standard procedures referred to in this manual.The minimum number of tests required is shown in Table 3-l.

Table 3-1. Type of Tests and Frequency.

A. SURFACE PREPARATION AND FILLTEST FREQUENCY

1. Field Density w/Moisture 1. Two per lift for eachContent. increment or fraction of

2,500 s.y. placed duringeach 8-hour shift.

2. Gradation w/Atterberg Limits 2. One per 5 field density(from Compacted Material)* tests.

3. Lab Moisture-DensityRelationship w/Gradation,At'cerberg Limits, SpecificGravity, and Classification(from Bulk Sample)

3. One per 5 fielddensity tests (with notless than one per type ofmaterial) for the first25 field density tests.Thereafter, one additionaltest for each change inmaterials.

B . SUBGRADE, SUBBASE, AND BASE COURSES**TEST FREQUENCY

1. Field Densitv w/Moisture 1. Two ner lift for each-increment or fraction of1,500 s.y. placed duringeach a-hour shift.

2. Gradation w/Atterberg Limits(From Compacted Material)*

2. Two per five fielddensity tests.

3-3


3. Lab Moisture-DensityRelationship w/Gradation,Atterberg Limits, SpecificGravity, and Classification(from Bulk Sample)

3 . One per 5 fielddensity tests (with notless than one per type ofmaterial) for the first25 field density tests.Thereafter, one additionaltest for each change inmaterial. .~

*Compacted Sample taken adjacent to field density test site.

**Includes other imported aggregates, such as select granularmaterial, filter, or drainage materials.

Note: Unless otherwise specified, refer to Chapter 2 regardingtesting requirements for backfill of culverts and utility trenches.

In addition to the minimum testing program above, representativesamples of subgrade, subbase, base, and all other earthwork materialsshall be sampled by the Contractor (prior to compaction) for thefirst two and every tenth field density tests and submitted to theGovernment for testing. Samples shall be taken under direction of theContractor's Quality Control representative. Bag samples for thispurpose shall be shipped within 24 hours by the Contractor at theContractor's expense to the Sacramento District Laboratory, Corps ofEngineers, 2021 Jefferson Boulevard, West Sacramento, California95691. Weight of these samples shall be minimum 100 pounds formaterial containing less than 10% plus No. 4 material, 150 pounds formaterial containing more than 10% plus No. 4 material, or 750 poundsfor material containing more than 30% plus 3/4 inch material.

3-4. Production Control Testino of Subbase and Base CourseMaterials. Samples of the material shall be tested as specified, andtest reports submitted at least 30 days prior to starting placementoperations. These samples shall be representative and obtained atthe source, from trucks, stockpiles, belts, hoppers, or otherdesignated locations. The minimum number of tests required duringproduction shall be two gradation tests daily. Other specified testsshall be made whenever a change of materials occurs.

3-5. Comoilation of Test Data for Submittal of Test Results. Thefollowing test results shall be submitted concurrently:

3-4


a . Moisture-Density Determinations, fFioure 2-l). This formis for use in determining the optimum moisture and maximum unitweight (density of soils and processed aggregate). The curve shallbe plotted based on a minimum of four compaction test specimens. Inadditions, the zero-air-voids curve shall be plotted using specificgravity data obtained. Classification of sample shall be inaccordance with ASTM D 2487. The Resident Contracting Officer mayrequire, at no additional cost to the Governments, single-point checksof moisture-density relations (ASTM D 1557, dry of optimum moisture),if it is evident through Quality Assurance testing that the QualityControl testing is not being adequately controlled with respect tothe precision requirements of ASTM D 1557, paragraph 9.

b. Field Density Test (Sand Cone), (Figure 2-2L- This testform is used to determine the degree of compaction. This sheet canalso be used for recording moisture content of fill in borrowmaterial or as placed.

c. Field Densitv Test (Nuclear Method), (Fioure 2-3). Thistest form is used to determine the degree of compaction when usingthe Nuclear Method.

d. Gradation Sheets, (Figures 2-4 and 2-51. These forms areused to record the results of gradation tests of all materials.Figure 2-4 shows a typical example in which gradation tests wereperformed in accordance with ASTM Standards C 136 and C 117. Resultsfrom these tests shall be tabulated as shown in Figure 2-4.

e. Atterbers Limits Determination, (Fioure 2-6). This form isused to compute liquid limit, plastic limit, and plasticity index.

fcompute

. Snecific Gravitv Tests. IFioure Z-7). This formspecific gravity of soils, aggregate, and stone.

is used to

3-5


CHAPTER 4

BITUMINOUS MATERIAL AND BITUMINOUS-AGGREGATE MIKTURES

4-l. m. This chapter prescribes methods and procedures forthe Contractor Quality Control testing of bituminous mixturesused for the construction of streets, roads, parking areapavements, and unless otherwise specified, for the constructionof airfield and heliport pavements.

4-2. Tests Testing and reporting shall be performed inaccordG;ith American Society for Testing Materials (ASTM)Standards as listed herein.

4-3. Mix Desian Submittals. Certain features on projects whichinvolve comparatively small quantities of bituminous mixture(less #an 6 tons) may be excluded from testing requirementslisted hereinafter, provided the material is delivered from aplant with a history of consistently producing bituminousmixtures which conform to contract requirements. The ContractingOfficer's representative reserves the right to request certifiedtest data to ensure that materials produced from the plant willconform to the contract requirements. On projects requiring morethan 6 tons the Contractor shall submit the minimum items in Table4-1, A.l. at least 30 days prior to bituminous material placement.

4-4. Minimum Test Recruirements. For placement, the minimumnumber of each type of production test and each type of controltest are listed below. These frequencies of testing may beincreased by the Contracting Officer to maintain adequate controlof the bituminous mix, plant production, and placementoperations.

Table 4-1. Contractor's Materials Submittal & QualityControl Testing.

A. SUBMITTALS AND TEST SAMPLE SUBMITTALSITEM REQUIREMENT

1. Mix Design*(prior to placement)

1 . Test results andmaterial sources 30 days(minimum) in advance ofpaving. These data shallbe presented with respect

4-l



1. Cont.

2 . Hot Mix Sample(during placement)

to asphalt cement contentin tabulated form, as wellas in graphical form, andshall include curves forunit weight, percent voidsof total mix, percent voidsfilled, and stability; theoptimum oil content shall beindicated, unless otherwisespecified.

2 . Two 70-pound (minimum)samples shall be obtainedfrom the belt or transporttruck. One shall beobtained at the beginningof each 8-hour shift andone at mid-shift. Each70-pound sample shall besplit in half. The twohalf-samples (frombeginning and mid-shift)shall be labeled packedseparately and thensubmitted for QA testingto the Sacramento DistrictLaboratory within 24 hoursof sampling. Retainremaining two half-samplesfor QC testing.

3. Aggregate Sample**(during placement)

3 . Two 50-pound (minimum)samples shall be obtainedfrom the hot bins. Oneshall be collected at thebeginning of each 8-hourshift and one at mid-shift. Each 50-poundsample shall be split in

4-2



3. Cont. half. The two half-samples(from the beginning andmid-shift) shall be packedseparately and submitted tothe Sacramento DistrictLaboratory within 24 hoursof obtaining. Retainremaining two half-samplesfor QC testing.

4 . Bituminous MaterialSample (during placement)

5. Core Specimens(4" diameter min.)(after each day's placement)

4. Obtain one quart ofbituminous material andrefinery certification ofcompliance and submit toSacramento DistrictLaboratory with first hotmix sample. Repeatanytime bituminousmaterial source changes.

5. Obtain 1 set of 5cores per each hot mixsample obtained (ifpossible, 2 cores fromcenterline of joints).Number cores and notelocations obtained on as-built drawings. From eachset, 2 cores shall be sub-mitted Sacramento Districtto the Laboratory,(Preferably 1 core fromjoint). Retain remainingcores for QC testing.

4-3


B. QUALITY CONTROL TESTINGITEM REQUIREMENTS

1. Bituminous Material. 1. None.

2 . Aggregate. 2 . On each of the splitsamples of aggregatesretained by the Contrac-tor, a sieve analysis andspecific gravity testshall be performed.

3. Hot Mix Sample*

4. Core Specimens

5. Smoothness Testing.

3. On each of the splitsamples retained by theContractor, the Contractorshall determine thebitumen content and per-form a complete MarshallMethod test, (includingstability, flow, unit-weight, percent voids oftotal mix and percentvoids filled with bitumen).On every 10th sample theContractor shall perform aretained-stability test.

4. For each core specimenretained by the Contractorthe relative compactionand bitumen content shallbe determined. The thick-ness of the cores shall bemeasured and recorded.

5. Shall be performed bythe Contractor as requiredby the contract documents.

4-4


Table 4-2. Reference Test Procedures

REFERENCE TEST PROCEDURE

ASTM D 1559 Test for Resistance to Plastic flow ofBituminous Mixtures using MarshallApparatus (mechanical agitators in thehot water baths, in addition to the otherequipment, shall be required). mreouired by contract specifications, para3.5 of ASTM D 1559 shall be changed toouire 75 blows (high density

g&ements). Mechanical hammer may beused when properly calibrated againststandard manual hammer.

ASTM D 2726

ASTM D 2172

ASTM C 131

ASTM C 136

ASTM C 2041

ASTM C 183

ASTM C 188

ASTMC88

ASTMD75

ASTM D 140

ASTM D 946

Standard Test Method for Bulk SpecificGravity of Compacted Bituminous Mixtures.

Standard Test Method for QuantitativeExtraction of Bitumen from BituminousPaving Mixtures, Method A or B.

Resistance to Degradation of Small-SizeCoarse Aggregate by Abrasion and Impactin the Los Angeles Machine.

Standard Test Method for Sieve or ScreenAnalysis of Fine and Coarse.Aggregates.

Theoretical Maximum Specific Gravity ofBituminous Paving Mixtures.

Density of Hydraulic Cement.

Sampling and Acceptance of HydraulicCement.

Soundness of Aggregates by Use of SodiumSulfate or Magnesium Sulfate.

Sampling Aggregates, Practice.

Sampling Bituminous Materials.

Penetration-Graded Asphalt Cement for Usein Pavement Construction.

4-5

CESPX PAM 415-1-215 Jun 89

4-5. Samole Transmittal. Samples of asphalt, aggregates, cores, andhot mixes (noted in Table 4-l) shall be delivered to the SacramentoDistrict Laboratory, Corps of Engineers, 2021 Jefferson Boulevard,West Sacramento, California 95691. These samples shall be takenunder the direction of the Contractor's Quality Control representa-tive and shall be shipped prepaid in suitable containers by theContractor at the Contractor's expense. Testing of these samples inthe Sacramento District Laboratory will be performed by theGovernment at no cost to the Contractor.

4-6. Comnilation of Test Data for Submittal of Test Results.

a. Daily Plant and Laboratorv Reoort - Bituminous Pavement(Ficure 4-1). This form is used to record the data from the testsperformed on asphaltic concrete mix samples taken prior to placementon grade and from cored samples taken from the compacted pavement.All data shall be recorded in appropriate spaces and columnsaccording to the examples given.

b. Extraction Test - Hot Mix AsDhaltiC Concrete, (Ficure 4-2).The test data for asphalt extraction shall be recorded on this form.

Ausreaate Gradins Chart, IFicure 4-3) The aggregategradin:; of hot bin samples and the extraction tests and specificlimits shall be recorded on this form.

d. Sieve Analvsis, (Ficrure 4-4). The grading data from thehot bin samples shall be recorded on this form.

e. Marshall Method - Comvutation of ProDerties of AsDhaltMixture, fFicure 4-5). This work sheet form is used in recordingMarshall test data and for recording field density data.

f. Theoretical Maximum Soecific Gravitv. (Ficrure 4-6). Thisform shall be used to record test data for theoretical maximumspecific gravity.

g- Bituminous Mix Desiqn - Assreoate Blendinu, (Fiuure 4-71.This form is to be used for computations for combined gradings ofaggregate for bituminous mix design.

4-6


*The theoretical maximum specific gravity of paving mixtures shall bedetermined in accordance with ASTM D 2041 (standard procedure). Whendetermining Marshall properties on hot mix samples, measure themaximum specific gravity in triplicate and average. When determiningMarshall properties for mix design purposes, measure the maximumspecific gravity in triplicate for each design curve point andaverage z determine the maximum specific gravity in triplicate onthe projected optimum and calculate the specific gravity of theremaining points in accordance with the Asphalt Institute Manual MS-2, Chapter VI paragraph 6.07 (May 1984, or most recent edition).

**For batch plants not utilizing hot bins, individual bin samplesshall be obtained from the cold feed bins. If it is determined bythe Contracting Officer's representative that representative samplescannot be readily obtained from the individual cold feed bins,representative samples shall be obtained from the combined cold feedconveyor.

4-7


CHAPTER 5

CONCRETE

5-l. ScOpe. This chapter prescribes methods and procedures forthe Contractor Quality Control testing of concrete materials usedin the construction of buildings and other facilities and will beprescribed in the contract documents for the respective projects.

5-2. Mix Desians. For projects involving 1,200 cubic yards ormore of concrete, a job mix design shall be made for each classof concrete, unless otherwise specified. For projects involvingless than 1,200 cubic yards, an established plant mix design maybe used, for each class of concrete, provided it meets allspecified requirements.

5-3. Exceuted Features. Certain features which involve smallquantities of concrete (10 cubic yards or less) may be excluded fromthe testing requirements shown in Table 5-1, provided the materialdelivered is from a plant consistently producing concrete whichconforms to the requirements of the contract documents. TheContracting Officer's representative reserves the right to requestsupporting test data reports in evidence of plant and materialsconformance with the aforementioned documents. Some typical exceptedproject features are nonstructural concrete curbs and gutters,sidewalks, duct backfill, thrust and anchor blocks, pole anchorage,lean concrete backfills, and manhole works. Project features such asisolated, continuous, and strip footings for the wall and columns,piles and pile caps, exterior vehicular slabs, interior on-gradefloor slabs, and similar structurally related building features arenot to be considered excluded items regardless of the quantities ofconcrete required.

5-4. Minimum Test Reouirements. A minimum number of productionand control tests are listed below. The frequency of testing maybe increased or decreased as directed by the Contracting Officerto maintain adequate control of the concrete mix, plantproductions, and placement operations.

5-l

CESPK PAM 43.5-1-215 Jun 89

Table 5-1. Test Requirements.

ITEM REQUIREMENT

1. Concrete Mix Design 1. Mix design for each classof concrete shall includeall of the following data:

(a) Weights andvolumes of all materials.

(b) Water-cementratio by weight.

(c) 7 and 28-daycompressive strengths.

(d) Air Content.

(e) Slump.

(f) Unit weight (also28-day air-dry unit weightfor lightweight concrete).

(g) For class Pconcrete, flexural beamstrength tests for 7, 28,and 90 days, as specified.

(h) Certified testreports of aggregatecompliance with ASTM C 33(ASTM C 330 for lightweightaggregate) or otherspecified standards.

(i) Certification ofadmixture compliance withthe requirements as statedin the contract documents.

5-2


ITEM

1. Cont.

REQUIREMENT

(j) Certified testreports for cement andpozzolan, accompanied byMill Test Reports from aplant with a record ofhigh quality production forthe past 3 years.

2. Slump, Entrained Air,Unit Weight (LightweightConcrete Only), Temperatureof Mix

3. Test Cylinders

2. Three per day per 8-hrshift as minimum andwhenever there is achange in consistency ofconcrete. Samples shallbe taken at the point ofdischarge as stated byASTM C 172, unless other-wise specified. Samplesshall be taken at thebeginning, midpoint, andend of each daily place-ment of each concrete used.

3. One set of threecylinders shall be madefor each increment orfraction oft 150 c.y.placed during each g-hourshift. For lightweightconcrete, a minimum of oneset of four cylindersshall be taken. Onecylinder shall be used todetermine 28-day air-dryunit weight. If theconsistency of theconcrete (as measured bythe slump test) exceedsthe maximum slump obtainedin the design mix or bythe contract requirements,then one additional set of

5-3


ITEM REQUIREMENT

3. Cont. represent any deficientconcrete already deliveredto the forms. Anyremaining concrete at thesite exceeding the slumpstated above.shall beremoved from the site atno additional cost tothe Government. Allsubsequent batches shallbe tested for slump untilthe necessary adjustmentshave been made to ensurethat concrete delivered tothe forms does not exceedthe maximum slump.

4. Test Beams

5. Plant and MixingEquipment Compliance Testsand Materials Tests at Plant

4. For flexural concrete,one set of four beams shallbe made for each incrementor fraction of 300 c.y.placed during each 8-hourshift. Additional sets maybe required when concreteslump or mix proportionsare adjusted. Additionalsets will be required whenthe concrete slump isexcessive as stated inItem 3 above, or when mixproportions are adjusted.

5. Contractor compliancewith ASTM C 94 "StandardSpecifications for ReadyMix Concrete", withdocumentation, reports,or certification ofcompliance upon requestby the Contracting Officer.

*Where pumping is approved samples for slump test shall be obtainedprior to entering the pump.

5-4


5-5. Admixtures. Except where authorized by the specifications,admixture other than an air-entraining agent is not to be used in

any

concrete without prior approval of the Contracting Officer. Theadmixture type proposed for use will be thoroughly investigated inlaboratory tests of concrete made with the cement and aggregateproposed for use on the project. Minimum test requirements willinclude the effect of the admixture on strength of concrete at an ageof 28 days and may include strength test of up to 90 days, as well ason such other properties as may be necessary to demonstrate thatthere will be no adverse effect on the concrete. Continued use ofany approved admixture other than entrained air will be based onsatisfactory control of the concrete under all conditions in thefield.

5-6. Methods of Curinq.are suitable,

Several different methods of curingand the Contractor is given the option of selecting a

preferred method in accordance with AC1 requirements, unlessotherwise specified. However, any curing method that has provedunsatisfactory in a particular geographic area will not be permittedfor projects in that area. All materials and equipment necessary forcuring and protecting the concrete must be available on the jobbefore concrete placement is started,curing will be tolerated.

and no delays in starting theCuring procedures will include provisions

for attaining proper moisture and temperature conditions in theconcrete. Experience has indicated that evaporation shrinkagecracking can be controlled by moist curing of the concrete under wetcovers for a minimum of 24 hours after placement.excessive heat loss and promote hydration,

To preventit is important that the

covers extend over the forms as well as the concrete surface. Fog-spraying equipment should direct a very fine mist of water onto theconcrete surface until curing under wet covers can be started.During cold weather, other approved methods of curing providingadequate protection against rapid heat loss from the concrete shallbe used during the early hardening period. Precautions shall also betaken at the end of the curing period to avoid rapid cooling of theconcrete and the resulting development of undesired stresses.

5-7. Procedures for Samolina and Testinq.

a. Testing and reporting shall be performed in accordance withthe American Society for Testing and Materials (ASTM) Standards asfollows: Sampling Fresh Concrete', ASTM C 172; Slump of PortlandCement Concrete, ASTM C 143; Air Content of Freshly- Mixed Concreteby Pressure Method, ASTM C 231 (for lightweight concrete use

5-5


volumetric method, ASTM C 173); and Unit Weight, Yield, and AirContent (Gravimetric) of Concrete, ASTM C 138, with the exceptionthat a 0.25 cubic-foot container, such as the lower part of an airmeter, may be used in place of the 0.50 cubic-foot capacity specifiedfor concrete with coarse aggregates up to l-1/2 inch maximum size.

b. The minimum number of cylinder specimens shall be three perset (one for 7-day and two for 28-day compressive strength tests).For lightweight concrete, one additional cylinder specimen shall betaken to test for 28-day air-dry unit weight. Additional specimenshall be made if required to establish strengths for form strippingor other purposes. Concrete samples shall be secured in conformancewith Standard Method of Sampling Fresh Concrete, ASTM C 172, and testspecimens fabricated and cured in accordance with Standard Method ofMaking and Curing Concrete Compression Test Specimens in the Field,ASTM c 31. Cylinders shall be tested in accordance with StandardTest Method for Compressive Strength of Molded Concrete Cylinders,ASTM C 39. Unit weight shall be tested in accordance with StandardTest Method for unit weight for Structural Lightweight Concrete, ASTMC 567.

C . Use of plastic molds, in lieu of other approved molds, willbe based upon the following:

(1) Prior approval as to type, dimensions, and otherproperties shall be required.

(2) Plastic molds will not be reused.

d. Field adjustment of approved water-cement ratios.

(1) Addition of water to the plastic concrete at the jobsite will not be permitted, except when directed by the Contractor'sQuality Control representative with the approval of the ContractingOfficer's representative.

(2) Adjustment of the concrete mix at the job sitewill be cause for rejection in the absence of compliance with theabove provision.

(3) Adjustments, if required, will be made by the supplierat the point of mixing and the water-cement ratio of the concretedelivered to the project shall not exceed that ratio which has beenpreviously submitted and approved.

5-6

CESPK PAW 415-1-215 Jun 89

Unless otherwise specified, the minimum number of beamsshall bee four per set and shall be tested for flexural strengthin pairs at 7 and 28 days. Additional beams shall be made, ifrequired, to establish strengths after changes in mix proportionsare made. Concrete samples shall be secured in conformance withStandard Method of Sampling Fresh Concrete, ASTM C 172 and testspecimens shall be fabricated and cured in accordance withStandard Method for Making and Curing Concrete Test Specimens inthe Field, ASTM C 31. Beams shall be tested in accordance withStandard Method of Test for Flexural Strength of Concrete, ASTM C78.

f . The coarse and fine aggregates shall be tested weekly atthe plant for gradation and the amount of surface moisture of thefine and coarse aggregate shall be determined prior to batching.Additional gradation and moisture testing may be required by theContracting Officer at no additional cost to the Government, if it isevident that there is excessive variation in the consistency of theconcrete delivered to the project site. The procedure outlined inStandard Method of Testing for Sieve or Screen Analysis of Fine andCoarse Aggregates, ASTM C 136, and Standard Method of Test forMaterials Finer Than No. 200 Sieve in Mineral Aggregates by Washing,ASTM C 117 shall be followed for gradation test. Moisture tests areto be performed in accordance with the Standard Method of Test forTotal Hoisture Content of Aggregate, ASTM : C 566. Other methodssuch as the use of a graduated volumetric flask may be used, providedaccurate moisture contents based on saturated-surface-dry conditionsare obtained.

. Evaluation of the Contractor's mixers and concretehandlinz equipment shall be made periodically throughout theconstruction period to ensure that no concrete of marginal qualitydue to segregation is being placed in any structure. The compliancetests which provides the test data for this evaluation is describedin the specification for Ready Mixed Concrete, ASTM C 94.

h. In addition to the minimum testing program above, forlarge projects only (greater than 1200 c-y.), samples consistingof 15 pounds of fine aggregate, 25 pounds of 3/4" x #4 coarseaggregate, and 35 pounds of l-l/2" x 3/4" coarse aggregate usedin concrete mix shall be delivered onlv uoon reouest toSacramento District Laboratory, Corps of Engineer, 2021 JeffersonBoulevard, West Sacramento, California 95691. These samples

5-7


shall be taken under the direction of the Contractor's QualityControl representative and shall be shipped prepaid in suitablecontainers by the Contractor at the Contractor's expense.Testing of these samples will be performed by the Government atno cost to the Contractor.

5-8. Comoilation of Test Data for Submittal of Test Results.

a. Concrete Field Control, (Fiuure 5-l). This form is tobe used for reporting results of concrete tests performed onconcrete during the placement.

b. Concrete Test Soecimens. fFioure 5-21. This form shallbe used when submitting compressive and flexural test results.It shall be completed showing the required information includingthe batch weights of cement, water, and the fine and coarseaggregate as corrected for surface moisture and the mix designweights per cubic yards in addition to other pertinent testsnoted in Table 5-1. The result of each strength test shall besubmitted for each age interval.

c. Sand Test (Fioure 5-31. and Acrcfreoate Gradina, fFiuure

5-41. The results shall be computed and plotted on theappropriate form.

5-8

CESPX PAM 415-1-215 Jun 89

CHAPTER 6

MASONRY CONSTRUCTION

6-l. ScoDe . This chapter prescribes methods and procedures forQuality Control testing of concrete masonry units, and mortar andgrout used in the construction of buildings Andy other facilities.Sampling and testing shall be performed by the Contractor inaccordance with the standard procedures referred to in thismanual, unless otherwise specified.

6-2. Test Reouirements for Masonrv Unite. The following testsshall be made by the Contractor on concrete masonry units, atintervals noted below:

a. Drvins Shrinkace. A sample of three units shall beselected at random from units proposed for use and tested forlinear shrinkage potential in accordance with ASTM C 426.Sampling and testing of the units shall be done not more than 6months nor less than 14 days before delivery of materials to thejobsite. A minimum of one such set of drying shrinkage testsshall be made for every 10,000 or less masonry units. Additionaltests shall be performed when changes are made either in themanufacturing processes or in materials used in the production ofthe masonry units.

b. Absorntion. Moisture Content. Comnressive Strenoth. andUnit Weioht. Upon delivery of units to the jobsite and weeklythereafter, a sample of three units shall be selected at randomfrom stockpiles and tested for compliance with ASTM C-90. Whentests indicate that the masonry units do not meet therequirements of ASTM C-90, those units represented by the randomsampling shall be removed from the project site at no expense tothe Government.

C. Waiver of Tests. For small projects requiring lessthan 1,000 masonry units, tests may be waived at the discretionof the Contracting Officer, and acceptance shall be based onmanufacturer's certified test report.

d. Reoortins Test Results. Results of these tests, exceptfor the compressive strength test, for which Figure 6-l isprovided, shall be reported as shown in Figure 6-2.

6-l

CESPK PAM 415-I-215 Jun 89

6-3. Test Reauirements for Mortar and Grout. At specifiedintervals shown below, the following tests shall be made of themortar and grout during masonry construction:

a. Gradation. At weekly intervals, gradation test of theaggregates used in the mortar and grout shall be performed inaccordance with ASTM C 136. The results of tests shall becompiled as shown in Figure 5-3.

b. Comnressive Strenoth. At weekly intervals, compressivestrengths of grout and mortar shall be tested in accordance withASTM C 1019 and ASTM C 780 respectively. Three grout samples (3112" x 3 l/2" x 7" high specimen) and three mortar samples (2" x4" high cylinder, or 2-inch cube), shall be prepared asspecified. One shall be tested at 7 days and two at 28 days.The minimum strength shall be so specified in the contractdocuments, and the results of tests shall be reported as shown inFigure 6-l.

6-2


APPENDIX A

MASTER TEST FORMS

MAXIMTJM THEORETICAL SPECIFICASPHALT CONTENT

ASTM D 2041METHOD C

CESPK PAM 415-1-2APP A

15 Jun 89GRAVITY

CONTRACT NUMBER:

DATE

DATE

PROJECT:

SAMPLED:

TESTED:

ADES

Dry Weight of Sample (g)Weight of Pycnometer + Water (77OF) (g)Weight of Pycnometer + Sample + Water (g)SSD Weight of Sample (g) - Substitute for in Denominator

Equation if Dry Back Method is Used'A' of

OIL CONTENTA =D =SG =

AS G = A + D - E



OIL CONTENTA =n=i-G =

Water Temp (OF)E =s =*SG (Corr for Temp) =




A-15

construction control manual (cespk pam 416-1-2) sampling & testing construction materials (us...

Documents

sand test

spk form

dd form

eng form

compilation of test

wes form

submittalof test results1

submittalof test results3