field sampling and testing manualfrequency

FIELD SAMPLING AND TESTING MANUAL

SAMPLE AND TEST FREQUENCY TABLE

Revised 3-2000 F-1

North Dakota Department of Transportation

Frequency Guide of Sampling and Testing

March 1996 Spec Item No. Description

Acceptance Samples and Tests Field Lab Testing

Independent Assurance Samples and Tests

District Lab Testing Central Lab Testing 203 Excavation and

Embankment Compaction curve data is required for each major change in embankment material. Determine moisture-density relationships by the Proctor test or the one-point curve chart.

Conduct a minimum of one moisture and density test per one foot of compacted lift per 1500 feet per roadway.

Conduct a minimum of one moisture and density test, including a Proctor test, for each 3 miles of roadway or a minimum of one test per 200,000 cubic yards.

Take one random width measurement between the shoulder lines for each 3 miles.

Submit SFN 13889 to FHWA at completion of the project.

210 Structural Excavation, Structural Fill, and Foundation Preparation

Field or District Testing--Take one aggregate sample for gradation of select backfill or foundation fill for every source used.

See Field Lab Testing.

230 Reshaping Roadway and Subgrade Preparation

Conduct a minimum of one moisture and density test per 1,500 feet per roadway.

Conduct a minimum of one moisture and density test including a Proctor test per each 3 miles of roadway.

234 Stabilized Subgrade Perform moisture-density relationship tests for all soil types encountered on the project after complete mixing of the lime and/or fly ash with soil.

Perform moisture-density relationship tests (Proctor) and all the related density tests on the same day.

Conduct a minimum of one moisture and density test every 1,500 feet, or fraction thereof.

Perform a minimum of one moisture and density test including a Proctor test for each 3 miles of roadway. Stagger test locations on a four-lane facility. Complete the Proctor and density tests on the same day.

Perform one random width and depth check for each 2 miles of roadway or fraction thereof.

Submit SFN 13889 to FHWA at completion of the project.

Revised 3-2000 F-2






District Lab Testing Central Lab Testing 302 Aggregate Base or

Surface Course Refer to Section 302 of the manual.

Report results to District Materials Coordinator on SFN 10072. Submit SFN 14388 if there are failing test results.

Take one sample for every 30,000 tons for gradation and physical properties.

When plans call for specified density, perform one density test per 3 miles.

For aggregate base or surface course, perform one width and depth check per 2 miles.

Submit SFN 13889 to FHWA at the completion of the project.

One sample per project 6 miles or less in length and one sample for every additional 6 miles of length or fraction thereof.

304 Permeable Stabilized Base Course

Refer to Section 304 of the manual.

Report results to the District Materials Coordinator on SFN 10072. Submit SFN 14388 if there are failing test results.

Take one aggregate sample every 20,000 tons for gradation and physical properties.

One sample per project six miles or less in length and one sample for every additional six miles of length or fraction thereof.

401 Prime, Tack, or Fog Coat

Take one aggregate sample for gradation for every 5 miles or fraction thereof.

Report results to the District Materials Coordinator on SFN 10072.

Obtain two samples of bitumen from each load delivered to the project. If emulsified asphalt, submit both samples to the District Laboratory. For all other asphalts, submit one sample to the Central Laboratory and keep one in the field for a check sample.

Obtain one aggregate gradation sample for every 10 miles or fraction thereof.

If emulsified asphalt, obtain one sample and submit to the Materials and Research Division Central Lab.

See Field Lab Testing -District Labs test emulsified asphalts; Central Lab tests cutback asphalts.

Revised 3-2000 F-3






District Lab Testing Central Lab Testing 402

Cold Bituminous Pavement

Obtain one dry batch gradation sample for each 1,000 tons with a maximum of 3 samples per day.

Report results to the District Materials Coordinator on SFN 10072.

Obtain two samples of bitumen from each load delivered to the project. If emulsified asphalt, submit both samples to the District Laboratory. For all other asphalts, submit one sample to the Central Laboratory and keep one in the field for a check sample. Perform two moisture test on aggregate the first day and one thereafter, except more as required after a rain.

Obtain one dry batch gradation sample for each 10,000 tons.

Perform depth and width measurements at two random locations per mile.

If emulsified asphalt, obtain one sample and submit to the Materials and Research Central Lab. Submit SFN 13889 to the FHWA at the completion of the project.

One aggregate sample for each 10 miles in length or fraction thereof. See Field Lab Testing -District Labs test emulsified asphalts, Central Lab tests cutback asphalts.

403

Stockpiled Hot Bituminous Mix

Field or District Testing: Take two samples of bitumen from each load delivered to the project. If emulsified asphalt, submit both samples to the District Laboratory. For all other asphalts, submit one sample to the Central Laboratory and keep one in the field for a check sample. Obtain one aggregate sample for gradation and physical properties before production begins. Perform additional gradation tests on the aggregate for each 1000 tons of mix produced.

See Field Lab Testing

See Field Lab Testing -District Labs test emulsified asphalts, Central Lab tests cutback asphalts.

Revised 3-2000 F-4






District Lab Testing Central Lab Testing

407

Hot Recycled Bituminous Pavement

Refer to Section 818 for bitumen sampling frequency.

Perform two moisture tests on aggregate the first day and one per day, thereafter, except more as required after a rain.

Obtain one sample for every 500 tons of virgin aggregate for gradation testing with a maximum of 3 samples per day. Report results to District Materials Coordinator on SFN 10072.

Observe contractor perform Marshall density tests on 3 field Marshall plugs obtained by the contractor. Obtain one sample for each 1500 tons of mix. Report results on SFN 50289.

Observe contractor perform maximum theoretical density tests on loose mix obtained by the contractor. Obtain one sample for each 1500 tons of mix. Record results on SFN 50289.

Determine density on cores provided by the contractor and enter the results on SFN 19802.

Obtain one sample for gradation and physical properties for each 5,000 tons of virgin aggregate

Select random locations for contractor to obtain full depth cores for density testing and depth determination. The frequency is two cores per mile with one location in each lane. Perform width measurements at the same locations. Enter the results on SFN 19802.

Submit SFN 13889 to FHWA at completion of project.

One aggregate sample for each 10 miles in length or fraction thereof.

Revised 3-2000 F-5







408

Hot Bituminous Pavement

Refer to Section 818 for bitumen sampling frequency.

Perform two moisture tests on the aggregate the first day and one per day thereafter, except more as required after a rain.

The Contractor, under the observation of the Engineer, shall take aggregate samples to determine gradation, shale content, plasticity index, fractured faces, and L.A. Abrasion loss.

Obtain one aggregate sample for gradation for each 1500 ton of mix produced. Enter results on SFN 18552. Report results to District Materials Coordinator on SFN 10072.

Obtain 3 aggregate samples for each lot of 10,000 tons or fraction thereof to determine shale content and plastic index (Refer to Section 408.02 A of this manual).

Submit one composite aggregate sample obtained during beginning of aggregate stockpiling to Central Lab for L.A. Abrasion test.

Obtain 3 aggregate samples from each lot of 10,000 tons of bituminous mix produced to determine percentage of fractured faces (Refer to Section 408.02 A of the manual).

Obtain one aggregate sample for gradation and physical properties for each 10,000 tons.

Select random locations for contractor to obtain full depth cores for density testing and depth determination. The frequency is two cores per mile with one location in each lane. Perform width measurements at the same locations. Enter the results on SFN 19802.

Submit SFN 13889 to FHWA at completion of project.

One aggregate sample for each 10 miles in length or fraction thereof.

Revised 3-2000 F-6







Observe contractor perform Marshall density tests on 3 field Marshall plugs obtained by the contractor each time an aggregate sample is taken for gradation. Report results on SFN 50289.

Observe contractor perform maximum theoretical density tests on loose mix obtained by the contractor each time an aggregate sample is taken for gradation. Record results on SFN 50289.

Perform density tests on cores provided by the contractor and enter the results on SFN 19802.

Revised 3-2000 F-7






District Lab Testing Central Lab Testing 420

Bituminous Seal Coat

Refer to Section 420.03 of this Manual when no Field Laboratory is on the project.

Obtain three random samples from each lot of cover coat material for sieve analysis. See Section 420 of the manual for definition of a lot.

Obtain one sample for gradation for every 5 miles or fraction thereof for blotter sand.

Report results to District Materials Coordinator on SFN 10072.

The Contractor, under the observation of the engineer, shall obtain 2 samples of bitumen from each load delivered to the project and submit to the Central Lab. If emulsified, submit both samples to the District Laboratory. The District Laboratory will perform the sieve test and Saybolt viscosity test on these samples. In addition, the District Laboratory shall submit 2 one-gallon samples to the Central Lab during the first half of each project. Retain all samples from the first half of the project until results of tests performed by the Central Lab are reported. Submit an additional set of 2 one-gallon samples to the Central Lab during the second half of the project. Retain all samples from the second half of the project until test results are reported by the Central Lab. If the Central Lab reports failing test results for either half of the project, the remaining samples shall be submitted to the Central Lab for testing. For all other asphalts, submit one sample to the Materials and Research Division and keep one in the field for a check sample.

Obtain one aggregate sample of cover coat material for gradation for every 10 miles or fraction thereof.

One aggregate sample per project. See Field Lab Testing: The District Labs test the emulsified asphalts and the Central Lab tests cutback asphalts.

Revised 3-2000 F-8






District Lab Testing Central Lab Testing 550 Portland Cement

Concrete Pavement Obtain one aggregate sample (both coarse and fine) for gradation analysis per 2000 S.Y. of concrete pavement with a minimum of one test per day and a maximum of three tests per day.


Perform one slump and air test from the first load each day. Thereafter perform one slump, air, and yield test per 2,000 square yards with a minimum of one test per day and a maximum of 3 tests per day.

Perform one moisture test on both the coarse and fine aggregate daily.

Cast one flexure test beam per mile with a minimum of two per project for 28-day testing. Submit 28-day test results on SFN 19695 to Materials & Research upon project completion. Cast additional beams as required for determining opening to traffic.

Cast one set each of 7-day and two 28-day test cylinders per 2000 square yards of pavement or a maximum of three sets per day.

Submit one random sample of cement per project to the Materials and Research Division.

Refer to Section 550 of the manual for optional thickness determination.

Refer to Sec 550 of manual for CPR projects.

For Dowel Bar Retrofit projects cast one set of cylinders for each 4 hours of production. Test cylinders at 6 hours for compressive strength.

Obtain one sample for gradation and physical properties for each 20,000 S.Y. of concrete pavement.

Obtain one core for thickness and strength for every 4,000 square yards of pavement. Submit to Central Laboratory for testing.

Measure pavement width at all points where cores are taken.

Perform one slump, air, and yield test for every 3 miles on rural projects and every 8,000 square yards on urban projects. Record results on SFN 10069.

Cast one set of 28-day cylinders for every 3 miles on rural projects and every 8,000 square yards on urban projects.

One aggregate sample (both coarse and fine) per 5 miles with a minimum of two samples of each per project.

One sample of every water source used. Water known to be of potable quality may be used without testing.

One sample for each lot of hot applied joint sealant used.

Revised 3-2000 F-9






District Lab Testing Central Lab Testing 560 Recycled Portland

Cement Concrete Pavement

Obtain one aggregate sample each of virgin coarse, virgin fine, and salvage for gradation analysis per 500 tons with a minimum of one test per day and a maximum of three tests per day.


Perform one slump and air test from the first load each day. Thereafter perform one slump, air, and yield test per 2,000 square yards with a minimum of one test per day and a maximum of 3 tests per day.

Perform one moisture test on the virgin coarse, virgin fine, and salvage aggregate daily.

Cast one flexure test beam per mile with a minimum of two per project for 28-day testing. Submit 28-day test results on SFN 19695 to Materials & Research upon project completion. Cast additional beams as required for determining opening to traffic.

Cast one set each of 7-day and two 28-day test cylinders per 2000 square yards of pavement or a maximum of three sets per day.

Submit one random sample of cement per project to Materials and Research Division.

Refer to Section 560 of the manual for optional thickness determination.

Obtain one sample for gradation and physical properties for each 5,000 tons of virgin coarse aggregate and each 5,000 tons of virgin fine aggregate.

Obtain one sample for gradation for each 5,000 tons of salvaged coarse aggregate.

Obtain one core for thickness and strength for every 4,000 square yards of pavement. Submit to Materials & Research Laboratory for testing.

Measure pavement width at all points where cores are taken.

Perform one slump, air, and yield test for every 3 miles on rural projects and every 8,000 square yards on urban projects. Record results on SFN 10069.

Cast one set of 28-day cylinders for every 3 miles on rural projects and every 8,000 square yards on urban projects.

One aggregate sample per 5 miles of virgin sand, virgin coarse and salvage coarse with a minimum of two samples of each per project.

One sample of every water source used. Water known to be of potable quality may be used without testing.


Revised 3-2000 F-10







602

Concrete Structures

Perform one moisture test on the aggregate before the first pour each day.

Perform one slump and air test the first load each day. Thereafter perform air, slump, and yield tests each time a set of compression test cylinders are cast.

Cast compression test cylinders per Table 1 in Section 602 of the manual.


Refer to Section 602 of the manual for sieve analysis.

Refer to Section 602 of the manual for sieve analysis and physical properties of coarse and fine aggregate.

Perform one air, slump, and yield test for every 5 field tests with a minimum of one test per project. Cast one set of cylinders for each 250 C.Y. of concrete with a minimum of one set per project. Additionally perform a minimum of one set of tests per bridge deck. Record results on SFN 10069.

One sample of both coarse and fine aggregate per project.

One sample of water from every source of water used. If water is known to be of potable quality, it may be used without testing.

Revised 3-2000 F-11







650

Repair and Overlay of Portland Cement Concrete Bridge Decks with Low Slump Concrete or Latex-Modified Concrete

Perform one moisture test on the aggregate before the first pour each day.

Obtain one sample of each coarse and fine aggregate for gradation testing per 75 cubic yards of concrete.

Perform one air, slump, and yield test from the first load each day. After the initial load perform two air, slump, and yield tests per day.


Cast one set each of 7-day and two 28-day sets of compression test cylinders per lane or per 500 square yards of overlay, whichever is less. Cast the cylinders from concrete placed at approximately the 1/3 and the 2/3 points of the placement area.

Obtain one sample for gradation and physical properties of both coarse and fine aggregate for every 1,000 square yards of overlay.

Perform one air, slump, and yield test per deck overlay. Record results on SFN 10069.

One sample of both coarse and fine aggregate per project.

708 Erosion Control Refer to Section 708 of the manual. Refer to Section 708 of the Manual.

709 Geotextile Fabrics Refer to Section 709 of the manual.

714 Culverts, Storm Drains, and Underdrains


For Underdrain Granular Fill Material, obtain one sample for every 15,000 lineal feet placed for sieve analysis. Obtain a minimum of two samples per project.

For Underdrain Granular Fill Material, obtain one sample from each project for sieve analysis.

Revised 3-2000 F-12







720

Monuments and Right of Way Markers


722

Manholes, Catch Basins, and Inlets


724

Water Mains, Water Lines, and Sewer Lines


740

Dampproofing and Water Proofing


744 Insulation Board(Polystyrene)


Revised 3-2000 F-13







748

750

Curb Gutter

Sidewalks and Driveways

Perform sufficient gradation analysis of aggregates taken at an appropriate stage to ensure the continuing quality as specified. The type of mixing operation determines the sample timing, place, and frequency. This is at the discretion of the engineer/manager.

Report results on SFN 10072 and submit to the District Materials Coordinator.

Perform one moisture test on the aggregates per day.

For each pour, cast 1 set of compression test cylinders for every 50 C.Y. up to 100 C.Y. and 1 set for every 100 C.Y. thereafter. (See Section 802 of this manual for casting procedure).


At a minimum, perform one air. Slump, and yield test for each concrete sample from which cylinders are cast. (See Section 802 of this manual for procedure).

Obtain one sample of coarse and one sample of fine aggregate for each 150 cubic yards of concrete.

Cast one set (two cylinders) of compression test cylinders for each 200 cubic yards of concrete.

One sample for every source of water used. Water known to be of potable quality may be used without testing.


752

Fencing--Installation and Resetting


Revised 3-2000 F-14







754

Highway Signs

Obtain one sample for gradation of each size of aggregate for each 150 cubic yards of concrete.

Perform one air, slump, and yield test near the beginning of the operation and when approximately one-half of the plan quantity of concrete has been placed.

Submit one random sample of cement per project to Materials and Research Division.

Cast compression test cylinders per Table 1 in Section 602.4 of the manual.

Obtain one sample of both fine and coarse aggregate for gradation and physical properties for each 150 cubic yards of concrete.

One sample for every source of water used. Water known to be of potable quality may be used without testing.

762

Pavement Marking

Refer to Section 762.

Obtain two random samples of pavement marking paint for each lot and submit to Central Laboratory.

Obtain samples of glass beads at a ratio of one sample per 10,000 pounds shipped or fraction thereof. See Section 762.03 B. for sampling procedure.

Two samples of pavement marking paint for each lot.

One sample (100 lbs.) of glass beads per 10,000 pounds (see District Lab Testing).

764

Guardrail


770 Highway Lighting Refer to Section 770.

Revised 3-2000 F-15






District Lab Testing Central Lab Testing 772 Highway Traffic

Signals


820 Fly Ash


826 Joint Materials Refer to Section 826. One sample for each lot of hot applied joint sealant used.

834 Structural Steel and Related Materials


836 Reinforcing Steel Refer to Section 836.

Many items of material incorporated into a project are accepted with a certified analysis. The Engineer/Manager must have the approved certified analysis in his possession before the material is installed in the work (see Section 106.01 of the manual for exceptions.) Direct all questions on sampling and testing to the District Materials Coordinator.

Aggregate samples submitted to the District Laboratory must be obtained by the District Materials Coordinator or a designated representative. Aggregate samples submitted to the Central Laboratory may be a split of the field sample. Submit a copy of the field test results to the District Materials Coordinator. The District Materials Coordinator will immediately compare the District Laboratory's results with the field results. If there is a difference, document what action has been taken or will be taken and record on SFN 10072.

Revised 3-2000 F-16



March 1996

There are a number of situations where small amounts of concrete are required and there is no particular requirement covering the sampling and testing in these situations. Therefore, when small amounts of concrete are required for a specific item; for example, the apron of a pipe, all that will be required will be that the engineer/manager notify the District Laboratory that the materials used were approved materials that had been tested in other phases of work. In this way, there will be no need to sample and test the material that goes into the small items of work.

Projects tied into one contract or divided into east and west or north and south parts will be considered as one project unless each part is let to a different contractor. If each part is let to a different contractor, each part is considered a separate project.

Perform additional tests on any material bordering the specification limits to assure that the quality of all the material meets the requirements of the specifications.

The Department's representative will submit directly to the Division Engineer of the Federal Highway Administration all final measurements on SFN 13889. Submit additional copies to the Central Laboratory, Project Engineer/Manager and the District Office.

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