MICHIGAN DEPARTMENT OF TRANSPORTATION · destructive examinations, paint, etc. In some cases the...

STRUCTURAL FABRICATION UNIT

V112917

TABLE OF CONTENTS

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MICHIGAN DEPARTMENT OF TRANSPORTATION

Table of Contents

1. Quality Assurance

# Structural Fabrication Inspection Flowchart 1

# Structural Fabrication Inspection Web Links 2

# Structural Fabrication Quality Assurance Guidance Document 3

# Materials Quality Assurance Procedures Manual Section 4.04 12

# Materials Quality Assurance Procedures Manual Section 4.11 24

2. Request for Information

# Structural Fabrication Request for Information Process 33

3. Nonconformance Program

# Structural Fabrication Nonconformance Policy 37

# Structural Fabrication Nonconformance Process 42

# Structural Precast Concrete Repair Guidance Document 50

4. Buy America

# Structural Fabrication Buy America Guidance Document 69

# Buy America Sample Letters 74

5. Material Sampling

# Metals Laboratory Sampling Guidance Document 77

# Sample Identification (Form 1923) 83

# Sample Identification (Form 1923) – Example 84

6. Miscellaneous

# Structural Fabrication E-construction Process 85

# Structural Fabrication Bookmarking Template 87

# Industry Letters 88

# Commentary for Project Folder Checklist 103

7. Forms

# Project Folder Checklist (Form 2001) 111

# Fabrication Inspection Report (Form 5617) 114

# Strand Tensioning Report (Form 0513) 115

# Bar Reinforcement Report (Form 1985) 118

# Pre and Post Pour Inspection Checklist (Form 5616) 119

# Field and Lab Test Report (Form 0590) 121

# Repair Observation Report (Form 1981) 122

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V012418

STRUCTURAL FABRICATION INSPECTION WEB LINKS

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Structural Fabrication Inspection Web Links

DescriptionThis document contains several important links to resources related to structural fabrication inspection for

the Michigan Department of Transportation. Click on the title of each section for the link.

" 2012 Standard Specifications for Construction This link will take you to a printable/downloadable copy of the MDOT 2012 Standard Specifications for Construction as well as the Supplemental Specifications for Errata to these Specifications. These specifications detail all of MDOT’s policies on construction. There are subsections that are related specifically to structural precast concrete and Structural Steel inspection.

" Materials Quality Assurance Procedures Manual This document provides guidance on MDOT’s requirements for performing QA inspections.

" Materials Source Guide This document describes the acceptance criteria for materials, and should be looked at prior to the materials being incorporated into a project.

" Forms All of the inspection forms are stored on this site which can be searched by the form number.

" Bridge Field Services

This site serves as a statewide resource for structures, and contains reference materials for bridge personnel.

1. Field Manual for Concrete Anchoring

2. Field Manual for Structural Welding

3. Field Manual for Structural Bolting

" Structure Technical SectionThis site contains all of the contact information for the Structural Fabrication Unit for which the inspector is working for. You can also find the current QAI Fabrication Portfolios.

1. MDOT Shop Drawing Review Process

2. 2018 MDOT Structural Steel QAI Manual

3. 2018 MDOT Structural Precast Concrete QAI Manual

" MDOT Buy America Compliance Listing This site contains a listing of Approved Manufacturers, QPL’s and Tested Stock Suppliers that are either fully compliant, partially compliant, or do not have any steel/iron in their product as noted next to each company name. For our use we only need to look at the BA+ or BA- listings.

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QA GUIDANCE DOCUMENT

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Structural Fabrication Quality Assurance Guidance Document

Description The purpose of this document is to provide the Michigan Department of Transportationj` (MDOT)

Structural Fabrication Unit guidance to supplement C;EJj` CNaR_VNY` GbNYVaf 7``urance Procedures

(MQAP) Manual. This guidance document will be used to ensure statewide consistency in performing

quality assurance (QA) verification inspection at fabrication facilities. The Structural Fabrication Unit is

_R`]\[`VOYR S\_ VZ]YRZR[aV[T aUR ;R]N_aZR[aj` ^bNYVaf N``b_N[PR ]_\T_NZ S\_ `a_bPab_NY RYRZR[a`

_R^bV_RQ a\ OR NPPR]aRQ ON`RQ \[ h=NO_VPNaV\[ @[`]RPaV\[i ]R_ C;EJj` CG7F Canual and utilizes

vendors to provide the shop inspection. It is imperative for the quality assurance inspector (QAI) to

completely understand their role and responsibilities when performing QA verification inspection on

MDOT projects to ensure a successful QA program. It is important to note that this document is not

contractual and all project related decisions should be based on the project specifications. This

document is broken down into the following sections:

1. Definitions

2. Contact Information

3. Responsibilities

4. QAI Roles and Responsibilities

5. QAI Frequent Questions and Answers

1. DefinitionsBelow is a list of terms that are significant to this guidance document:

1.1 Contractor The Contractor is responsible for proper completion of all tasks required by the contract.

Subcontractors, including fabricators, erectors, and field painters, may be used by the Contractor,

but the Contractor retains responsibility for all material, operations, and the final product. The

Contractor should permit direct subcontractor interaction with MDOT to expedite the project, but

subcontractors must inform the Contractor of any proposed modifications to contract requirements.

1.2 Design Project Manager (PM) The Design PM can be the Engineer of Record or could be managing a consultant contract where

the consultant is the Engineer of Record.

1.3 Engineer The Engineer can be the Director of the Department of Transportation or the MDOT Construction

Engineer designated by the Director, acting directly or through authorized representatives, who is

responsible for engineering supervision of the construction. The Engineer has the authority to allow

exceptions to contract document requirements.

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1.4 Engineer of Record (EOR) JU\`R ]_R]N_V[T aUR P\[a_NPa Q\PbZR[a`& V[PYbQV[T aU\`R _R`]\[`VOYR S\_ aUR à_bPab_Rjs adequate

design. The Engineer of Record seals and signs the contract plans.

1.5 Fabricator The facility performing such shop activities as cutting, welding, drilling, punching, tying rebar,

tensioning strand, pouring concrete, cleaning and painting of structural steel, etc. The Fabricator also

includes any agents of the Fabricator, such as those who prepare shop detail drawings, perform non-

destructive examinations, paint, etc. In some cases the Fabricator may also be the Contractor, but

the Fabricator is typically a subcontractor.

1.6 Fabrication Inspection The examination by MDOT or the Fabricator of processes and products to verify general

conformance with contract requirements.

1.7 Fabrication Inspection Acceptance JUR SV_à àR] V[ C;EJj` ad\ ]N_a NPPR]aN[PR ]_\PR`` S\_ à_bPab_NY RYRZR[a` _R^bV_RQ a\ OR NPPR]aRQ

ON`RQ \[ h=NO_VPNaV\[ @[`]RPaV\[i ]R_ C;EJj` CG7F Manual.

1.8 Field Inspection Acceptance The second àR] V[ C;EJj` ad\ ]N_a NPPR]aN[PR ]_\PR`` S\_ à_bPab_NY RYRZR[a` _R^bV_RQ a\ OR

NPPR]aRQ ON`RQ \[ h=NO_VPNaV\[ @[`]RPaV\[i ]R_ C;EJj` CG7F Manual.

1.9 Materials Quality Assurance Procedures Manual (MQAP) The formal written document prepared by MDOT that describes the policies and procedures used to

accept materials for incorporation into MDOT projects. The document contains inspection

procedures for fabricated structural precast (prestressed and non-prestressed) concrete, structural

steel, and other structural elements.

1.10 Michigan Department of Transportation (MDOT) The entity (owner) paying the Contractor to fulfill the terms of the contract. MDOT also encompasses

the Engineer who is authorized and responsible for engineering supervision of the construction. The

Engineer is an employee of MDOT; however, MDOT may contract with a professional firm to oversee

the day to day supervision with all critical decisions coming through the Engineer.

1.11 Nonconformance Report (NCR) An alteration in the work or a fabrication error that results in the element not meeting project

specifications. The fabricator generates a NCR submittal after fabrication has begun and their quality

control inspector (QCI) has noted a nonconformance to the project specifications.

Nonconformances are generally defined to be material or workmanship in nature and are further

classified by MDOT to be minor or major. Minor nonconformances can be repaired by the fabricator

without approval of a NCR, whereas major nonconformances require approval of a NCR.

1.12 Precast Concrete Precast concrete is a construction product produced by casting concrete in a reusable form, which is

then cured in a somewhat controlled environment, transported to the construction site, and lifted into

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place. Precast concrete can be either prestressed or non-prestressed. In contrast, cast-in-place (CIP)

concrete is poured into site-specific forms and cured on site.

1.13 Procedure Qualification Record (PQR) A production welding procedure specification (WPS) qualification is based on a procedure

qualification test record (PQR) produced by the Contractor in conformance with required heat input

qualifications and other code requirements. The test is designed to provide assurance that the weld

metal produced by welding in conformance with the provisions of the code must produce weld

metal strength, ductility, and toughness conforming to the code.

1.14 Quality Assurance (QA) Quality assurance (QA) encompasses the activities undertaken by the Owner to verify that the final

product satisfies contract requirements, including verifying that quality control is performed

effectively.

1.15 Quality Assurance Inspector (QAI) C;EJj` representative that is responsible for duties specified in the MDOT MQAP, with the authority to

accept work that meets contract requirements.

1.16 Quality Control (QC) The activities undertaken by the Contractor/Fabricator to ensure a product is provided that meets

contract requirements.

1.17 Quality Control Inspector (QCI) 7 ^bNYVSVRQ RZ]Y\fRR \S aUR =NO_VPNa\_ dU\ ]R_S\_Z` V[`]RPaV\[ N` QRSV[RQ Of aUR =NO_VPNa\_j`

Quality Control Plan.

1.18 Quality Control Plan (QCP) The formal written document prepared by the Fabricator and reviewed by a certification agency

(AISC, NPCA, PCI, etc.) that describes the policies and procedures used to verify that fabricated

structural precast (prestressed and non-prestressed) concrete, structural steel, and other structural

elements will satisfy the contract requirements.

1.19 Request for Information (RFI) Requests by the Fabricator seeking additional information or proposing alternate material, fabrication

method, or inspection method for the structural element.

1.20 Spot Inspection JUR _N[Q\Z ReNZV[NaV\[ \S aUR =NO_VPNa\_js processes or products for verification of conformance

with contract requirements.

1.21 Structural Fabrication Unit C;EJj` `]RPVNYVgRQ QA unit that is _R`]\[`VOYR S\_ VZ]YRZR[aV[T aUR ;R]N_aZR[aj` G7 ]_\T_NZ S\_ NYY

structural elements required to be accepted ON`RQ \[ h=NO_VPNaV\[ @[`]RPaV\[i ]R_ C;EJj` CG7F(

1.22 Welding Procedure Specification (WPS) Is a formal written document describing welding procedures, which provides direction to the welder

or welding operators for making sound and quality production welds as per the code requirements.

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The purpose of the document is to guide welders to the accepted procedures so that repeatable

and trusted welding techniques are used.

2. Contact InformationThe Structural Fabrication Unit can be contacted by phone or email. G7@j` N_R _R^bV_RQ a\ O_V[T b_TR[a

matters to the appropriate contact person by phone and then immediately follow up by email for record

and attach all applicable supporting documentation to the email. All other matters are required to be

submitted via email and then a call, if needed, can be setup. JUR Ia_bPab_NY =NO_VPNaV\[ K[Vaj` RZNVY

resource is shown below:

[email protected]

3. Responsibilities

3.1 Team Effort

3.1.1 The Contractor, Fabricator, and MDOT will approach quality control and quality assurance

as a team effort to facilitate accurate and timely construction.

3.1.2 All parties will cooperate and maintain open lines of communication so that problems can

be quickly addressed and resolved.

3.1.3 JUR G7@j` cR_VSVPNaV\[ Q\es not relieve the Fabricator from the responsibility to perform the

required testing and inspection and produce a product satisfying the contract.

3.2 Fabricator

3.2.1 Provide quality control to ensure that the finished product meets or exceeds contract

requirements.

3.2.2 Develop and implement a QCP that reflects a commitment to quality and describes the

quality control activities that will be employed on each project.

3.2.3 Provide MDOT with a copy of the QCP.

3.2.4 Submit shop drawings to MDOT for review with weld procedure specification (WPS) and

supporting procedure qualification record (PQR), as applicable.

3.2.5 Provide structural precast concrete Material Source List (MSL) prior to the prefabrication

meeting.

3.2.6 Provide qualified QCIs who report to personnel responsible for quality control as defined by

the QCP.

3.2.7 Provide MDOT with an accurate notification before beginning work in the shop and all

production scheduling as required by the contract requirements.

3.2.8 F_R`R[a NYY ZNaR_VNY S\_ aUR G7@j` NPPR]aN[PR V[ N ZN[[R_ aUNa dVYY NYY\d N thorough

inspection of components and assemblies.

3.2.9 Provide the QAI full access to shop facilities where the work is being stored, fabricated, or

assembled.

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3.2.10 Provide the QAI with all approved shop drawings, NCRs, RFIs, MDOT Welder Qualification

test reports, WPSs, QC reports, material certifications/test reports, NDE reports,

personnel/plant certifications, equipment calibration reports, and all other applicable

documents in a timely manner as required by the contract requirements.

3.2.11 Keep the QAI informed prior to performing in-process repairs, NCRs (if applicable), QC

inspection activities, and pending nondestructive examination (if applicable).

3.3 MDOT

3.3.1 M\[Va\_ aUR =NO_VPNa\_j` P\[a_\Y \S aUR \]R_NaV\[` N[Q cR_VSf P\[S\_ZVaf \S aUR d\_X with the

contract requirements.

3.3.2 KRR] aUR =NO_VPNa\_js QCP confidential.

3.3.3 Observe fabrication (either on a schedule or at random) and perform testing of materials

N[Q SNO_VPNaRQ RYRZR[a` N` [RPR``N_f a\ P\[SV_Z aUR RSSRPaVcR[R`` \S aUR =NO_VPNa\_j` G9F(

3.3.4 MDOT has the right to observe all phases of the work, from initial receipt and preparation of

raw materials through prestressing, tying steel, fresh concrete testing, placing concrete,

testing cylinders, repairs, burning and cutting, welding, nondestructive testing, cleaning,

coating, shipping, and any other activities deemed appropriate by MDOT.

3.3.5 The frequency and nature of QA inspection will vary with the type of structure, experience

\S aUR =NO_VPNa\_& `a_R[TaU \S aUR =NO_VPNa\_j` G9 \_TN[VgNaV\[& N[Q \aUR_ `VZVYN_ SNPa\_`

that affect the quality of work.

3.3.6 Verify that production quality and fabrication processes generally satisfy contract

requirements, including the QCP.

3.3.7 Accept materials and fabricated elements that satisfy the contract requirements.

3.3.8 Notify MDOT when fabricator ships elements for projects, and specify if the shipment is the

final shipment for the project.

3.3.9 Submit project file to MDOT within one week of final shipment of elements.

3.3.10 MDOT will not waive items that are contractual obligations of the Fabricator and will not

accept material that does not conform to the contract requirements. However, based on

experience and knowledge of the specific situation, the Engineer may accept materials

and elements that are not in conformance with the contract and may allow material

substitutions. See the following two documents for more information:

' MDOT Structural Fabrication RFI Process

' MDOT Structural Fabrication Nonconformance Policy

3.3.11 MDOT dVYY [\a QV_RPa aUR =NO_VPNa\_j` d\_X( ?\dRcR_& MDOT should advise the Fabricator to

discontinue any operation that would result in noncompliance with the contract.

3.3.12 MDOT dVYY QV_RPa NYY \SSVPVNY P\ZZb[VPNaV\[` a\ aUR =NO_VPNa\_j` ^bNYVaf P\[a_\Y \_

management as determined in the prefabrication meeting.

3.3.13 MDOT will not convey directives or personal judgements about overall shop quality or

concerns about employee competence to production personnel.

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3.3.14 MDOT will not publish, copy, or distribute any proprietary information, documents, or forms

received from the Fabricator for any purpose other than the contractual needs of MDOT.

3.4 Prefabrication Meetings Prefabrication meetings facilitate effective quality control and quality assurance and are conducted

Of C;EJj` Ia_bPab_NY =NO_VPNaV\[ K[Va ]_ior to the start of fabrication and preferably after shop

drawings have been approved. The Structural Fabrication Unit, QAI, Fabricator, and QCI must be

present, whereas the Engineer and Contractor should be present to ensure a team effort to facilitate

accurate and timely construction. Quality assurance and quality control contact information will be

shared during this meeting to ensure effective and timely communication.

4. QAI Roles and Responsibilities

4.1 Qualifications of the QAIQualification requirements of the QAI is covered in the MDOT MQAP Manual for the type of inspection

required.

4.2 Equipment Requirements of the QAIEquipment requirements of the QAI is covered in the MDOT MQAP Manual for the type of inspection

required.

4.3 SchedulingThe scheduling of inspection and other QA functions can have a significant impact on the project.

The QAI must follow these guidelines:

4.3.1 Coordinate with the QCI for anticipated production scheduling to anticipate timing and

staffing needs. Discuss the progress of the work with appropriate fabrication personnel

designated during the prefabrication meeting.

4.3.2 Schedule inspections in a timely manner to facilitate fabrication progress, especially if

multiple shifts are used.

4.3.3 Discuss with the Structural Fabrication Unit whether additional presence in the shop is

required.

4.3.4 Document problems with scheduling inspection, including inaccurate information from

fabrication personnel and production delays.

4.4 Role of the QAI

4.4.1 Perform verification tests, measurements, inspection, or observations to ensure that

fabricated elements conform to the contract requirements. Although the QAI does not

perform the QC work, some QA activities may duplicate a portion of the QC activity for

verification purposes.

4.4.2 If there are questions about a requirement or level of quality, contact the Structural

Fabrication Unit and, if appropriate, alert the Fabricator.

4.4.3 Conduct consistent inspections based on the contract requirements and obtain assistance

from the Structural Fabrication Unit as needed.

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4.4.4 Be familiar with the QCP to better understand the QC operations of the shop.

4.5 Responsibilities of the QAI See subsection 3.3 above for a list of QAI responsibilities.

4.6 Interaction with the Fabricator QCI

4.6.1 LR_VSf aUR RSSRPaVcR[R`` \S aUR G9@j` RcNYbNaV\[ \S aUR d\_X(

4.6.2 Perform verification inspection after the QCI has completed their inspection and testing in

accordance with the =NO_VPNa\_j` QCP. However, serious problems noted at any time or

stage of fabrication must be immediately pointed out to the QCI.

4.6.3 Though QA inspection may include all aspects of fabrication, the QAI must not supersede

QC, which is the responsibility of the Fabricator. If QC is not accomplishing its role then the

Structural Fabrication Unit, Engineer, Contractor, and Fabricator must determine the

necessary corrections.

4.7 Interaction with Fabricator @S aUR =NO_VPNa\_j` V[^bV_VR` V[c\YcR QR`VT[ ^bR`aV\[`& ZNaR_VNY `bO`aVabaV\[`& NYaR_[NaR SNO_VPNaV\[

methods, or items that are beyond the authority of the QAI, refer them to (%*/EA .B@C3BC@19

Fabrication Request for Information Process. If thR =NO_VPNa\_j` V[^bV_VR` V[c\YcR SNO_VPNaV\[ \_ ZNaR_VNY

nonconformance questions, refer them to (%*/EA .B@C3BC@19 &12@831B8=< )=<3=<6=@;1<35 -5>=@B8<7

Process. Do not direct the fabricator.

4.8 Interpretation of the Contract Review contract requirements and seek guidance from the Structural Fabrication Unit if the QAI has

questions. Do not direct the Fabricator.

4.9 Fabrication Observation

4.9.1 Establish a pattern of regular and frequent observations during the progress of work to

verify satisfactory workmanship without delaying production or missing critical operations.

4.9.2 Coordinate verifications with the QCI and accomplish them with minimal additional

material handling by the Fabricator and with as little interference with the work in process

as possible.

4.9.3 Though there are not designated points during fabrication when the suitability of materials

must be checked, problems should be discovered and addressed as early as possible.

4.9.4 Provide narrative record keeping in accordance with applicable sections of the MQAP

manual.

4.10 Nonconforming Materials and Workmanship See (%*/EA .B@C3BC@19 &12@831B8=< )=<3=<6=@;1<35 +=983D and (%*/EA .B@C3BC@19 &12@831B8=<

Nonconformance Reporting Process for more information.

4.11 Final Acceptance of the Work Acceptance of structural elements must be in accordance with (%*/EA (,$+ (1<C19.

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5. QAI Frequent Questions and Answers The purpose of this section is to provide answers to frequently asked questions to ensure consistency and

alignment.

5.1 Fabricating without Approved Shop Drawings The QAI must notify the Structural Fabrication Unit immediately if the Fabricator is working without

MDOT approved shop drawings. Approved shop drawings are required prior to stamping elements

approved for shipping.

5.2 Inspecting Approved Repair Plans QAI must have the approved repair plan in hand prior to performing QA verification inspection of the

repair. Verification inspection also includes confirming that production and QCI have the approved

repair plan. If production and QCI do not have the approved plan then the QAI must notify them

that they are required to have the approved plan in hand during all aspects of the repair. If the

Fabricator begins working on the repair without the approved plan then the QAI must notify the

Fabricator of their observation in writing immediately and carbon copy the Structural Fabrication. The

Structural Fabrication Unit will notify the Engineer and Fabricator that the repair is recommend to be

rejected.

5.3 Stamping Elements Approved for Use QAI must have approved shop drawings prior to stamping any element approved for use. Elements

proposed to be shipped by the Fabricator that are not in general conformance with the approved

shop drawings must not be stamped. The only exception is if a nonconformance report (NCR) has

been approved by MDOT. Approved NCRs are to be used in conjunction with approved shop

drawings for acceptance. If elements are not in conformance with the approved shop drawings

then they are not to be stamped approved for use by the QAI. If requests for information (RFI) have

been approved by MDOT for the project then they must be incorporated into the shop drawings, if

applicable, prior to shipping.

5.4 Welder Qualification Testing See (%*/EA 05945@ ,C1986831B8=< +@=7@1; for all welding information.

5.5 As-Built Shop Drawings The Fabricator is required to submit as-built shop drawings to MDOT for historical purposes. All

approved RFIs that are incorporated into the project must be added to the shop drawings and

submitted to MDOT for review and approval. Very minor changes toward the end of fabrication must

be documented and submitted as as-built shop drawings to the QAI prior to shipping. The Structural

Fabrication Unit can provide more guidance on a project by project basis as to what constitutes a

shop drawing revision and what is considered an as-built.

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HOH ..1 H_Y^_]Wd O[ij H[jêZ \eh HWa_d] >edYh[j[ Nf[Y_c[di \eh Ah[[p[*O^Wm O[ij_d] e\ >edYh[j[ >eWhi[ <]]h[]Wj[

HOH ..2 H_Y^_]Wd O[ij H[jêZ \eh O[ij_d] >edYh[j[ \eh ?khWX_b_jo Xo MWf_Z

12

1+-1

Ah[[p_d] _d <_h WdZ O^Wm_d] _d RWj[h

HOH /-3 H_Y^_]Wd O[ij H[jêZ \eh Pi[ e\ PdXedZ[Z >Wfi _d ?[j[hc_dWj_ed e\ >ecfh[ii_l[ Njh[d]j^ e\ CWhZ[d[Z >edYh[j[ >ob_dZ[hi

2+ <<NCOJ NjWdZWhZi

O // >ecfh[ii_l[ Njh[d]j^ e\ >ob_dZh_YWb >edYh[j[ Nf[Y_c[di

O /0 HWa_d] WdZ >kh_d] >edYh[j[ O[ij Nf[Y_c[di _d j^[ A_[bZ

O /0. >Wff_d] >ob_dZh_YWb >edYh[j[ Nf[Y_c[di

3+ <NOH NjWdZWhZi

< .52 NjWdZWhZ Nf[Y_\_YWj_ed \eh Nj[[b R[bZ[Z R_h[ AWXh_Y) KbW_d) \eh >edYh[j[ M[_d\ehY[c[dj

< 1.3 NjWdZWhZ Nf[Y_\_YWj_ed \eh Gem*M[bWnWj_ed) N[l[d*R_h[ Nj[[b NjhWdZ \eh Kh[ijh[ii[Z >edYh[j[

< 164 NjWdZWhZ Nf[Y_\_YWj_ed \eh Nj[[b R[bZ[Z R_h[ AWXh_Y) ?[\ehc[Z) \eh >edYh[j[ M[_d\ehY[c[dj

> 0. NjWdZWhZ KhWYj_Y[ \eh HWa_d] WdZ >kh_d] >edYh[j[ O[ij Nf[Y_c[di _d j^[ A_[bZ

> 06 NjWdZWhZ O[ij H[jêZ \eh >ecfh[ii_l[ Njh[d]j^ e\ >ob_dZh_YWb >edYh[j[ Nf[Y_c[di

> 61 NjWdZWhZ Nf[Y_\_YWj_ed \eh M[WZo*H_n[Z >edYh[j[

> .03 NjWdZWhZ O[ij H[jêZ \eh N_[l[ <dWboi_i e\ A_d[ WdZ >eWhi[ <]]h[]Wj[i

> .05 O[ij H[jêZ \eh ?[di_jo &Pd_j R[_]^j') T_[bZ WdZ <_h >edj[dj &BhWl_c[jh_Y' e\ >edYh[j[

> .10 NjWdZWhZ O[ij H[jêZ \eh Nbkcf e\ CoZhWkb_Y >[c[dj >edYh[j[

> .4/ NjWdZWhZ KhWYj_Y[ \eh NWcfb_d] Ah[i^bo H_n[Z >edYh[j[

> .40 NjWdZWhZ O[ij H[jêZ \eh <_h >edj[dj e\ Ah[i^bo H_n[Z >edYh[j[ Xo j^[ Qebkc[jh_Y H[jêZ

> /0. NjWdZWhZ O[ij H[jêZ \eh <_h >edj[dj e\ Ah[i^bo H_n[Z >edYh[j[ Xo j^[ Kh[iikh[ H[jêZ

> 262 NjWdZWhZ Nf[Y_\_YWj_ed \eh =b[dZ[Z CoZhWkb_Y >[c[dji

> 3.4 NjWdZWhZ KhWYj_Y[ \eh >Wff_d] >ob_dZh_YWb >edYh[j[ Nf[Y_c[di

> ./0. NjWdZWhZ KhWYj_Y[ \eh Pi[ e\ PdXedZ[Z >Wfi _d Z[j[hc_dWj_ed e\ >ecfh[ii_l[ Njh[d]j^ e\ CWhZ[d[Z >edYh[j[ >ob_dZ[hi

> ./3- NjWdZWhZ O[ij H[jêZ \eh Kej[dj_Wb <baWb_ M[WYj_l_jo e\ <]]h[]Wj[i &HehjWh =Wh H[jêZ'

> .234 NjWdZWhZ O[ij H[jêZ \eh ?[j[hc_d_d] j^[ Kej[dj_Wb <baWb_*N_b_YW M[WYj_l_jo e\ >ecX_dWj_edi e\ >[c[dj_j_eki HWj[h_Wbi WdZ <]]h[]Wj[ &<YY[b[hWj[Z HehjWh =Wh H[jêZ'

4+ K>D NW\[jo WdZ Geii Kh[l[dj_ed HWdkWb NGK*.--

5+ H?JO <YY_Z[dj Kh[l[dj_ed KbWd

13

1+-1

1+-1+-0+ LkWb_\_YWj_edi) M[ifedi_X_b_j_[i) ?kj_[i) WdZ @gk_fc[dj

<+ LkWb_\_YWj_edi e\ j^[ L<D s L<D f[h\ehc_d] j^[ \WXh_YWj_ed _dif[Yj_ed ckij feii[ii j^[ \ebbem_d] gkWb_\_YWj_edi7

.+ H_Y^_]Wd Khe\[ii_edWb @d]_d[[h &K@' b_Y[di[ eh Kh[YWij,Kh[ijh[ii[Z >edYh[j[Ddij_jkj[ &K>D' O[Y^d_Y_Wd G[l[b DD8

/+ H_Y^_]Wd >edYh[j[ <iieY_Wj_ed &H><' G[l[b D A_[bZ O[ij_d] O[Y^d_Y_Wd Y[hj_\_YWj_edeh <c[h_YWd >edYh[j[ Ddij_jkj[ &<>D' >edYh[j[ A_[bZ O[ij_d] O[Y^d_Y_Wd s BhWZ[ D&[nY[fj f[h_eZ e\ [\\[Yj_l[d[ii m_bb X[ h[ZkY[Z \hec 2 o[Whi je 0 o[Whi je cWjY^ H><'8WdZ

0+ H_Y^_]Wd >[hj_\_[Z <]]h[]Wj[ O[Y^d_Y_Wd &H><O' G[l[b D &edbo h[gk_h[Z \eh W]]h[]Wj[iWcfb_d]'+

=+ M[ifedi_X_b_j_[i e\ j^[ L<D s L<D f[h\ehc_d] j^[ \WXh_YWj_ed _dif[Yj_ed _i dej f[hc_jj[Z je cWa[ Y^Wd][i je j^[ YedjhWYj WdZ ^Wi j^[ \ebbem_d] h[ifedi_X_b_j_[i7

O^[ >edjhWYjeh) AWXh_YWjeh) WdZ H?JO m_bb WffheWY^ gkWb_jo Yedjheb WdZ gkWb_jo WiikhWdY[ Wi W j[Wc [\\ehj je \WY_b_jWj[ WYYkhWj[ WdZ j_c[bo YedijhkYj_ed+ L<Dvi l[h_\_YWj_ed Ze[i dej h[b_[l[ j^[ AWXh_YWjeh \hec j^[ h[ifedi_X_b_jo je f[h\ehc j^[ h[gk_h[Z j[ij_d] WdZ _dif[Yj_ed je fheZkY[ W fheZkYj iWj_i\o_d] j^[ YedjhWYj+ Oêk]^ L< _dif[Yj_ed cWo _dYbkZ[ Wbb Wif[Yji e\ \WXh_YWj_ed) j^[ L<D ckij dej ikf[hi[Z[ L>) m^_Y^ _i j^[ h[ifedi_X_b_jo e\ j^[ AWXh_YWjeh+ D\ L> _i dej WYYecfb_i^_d] _ji heb[ j^[d j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j) @d]_d[[h) >edjhWYjeh) WdZ AWXh_YWjeh ckij Z[j[hc_d[ j^[ d[Y[iiWho Yehh[Yj_edi+

L<D _i j^[ h[ifedi_Xb[ fWhjo) h[fh[i[dj_d] j^[ @d]_d[[h) mê f[h\ehci gkWb_jo WiikhWdY[ l[h_\_YWj_ed _dif[Yj_ed ed j^[ [b[c[dj W\j[h gkWb_jo Yedjheb &L>' _dif[Yji WdZ Wffhel[i j^[ _j[c e\ meha+ O^[ L<D ckij X[ Wj j^[ \WXh_YWj_ed \WY_b_jo Wj Wbb j_c[i Zkh_d] \WXh_YWj_ed Wi h[gk_h[Z Xo j^[ _dif[Yj_ed fheY[Zkh[ ijWj[Z X[bem+ D\ _iik[i Wh_i[) _j m_bb X[ Wj j^[ @d]_d[[hvi Z_iYh[j_ed m^[j^[h je _dYh[Wi[ j^[ b[l[b e\ L< _dif[Yj_ed+

Dj _i j^[ @d]_d[[hvi h[ifedi_X_b_jo je [d]W][ j^[ @d]_d[[h e\ M[YehZ &@JM' m^[d cWa_d] ijhkYjkhWb Z[Y_i_edi+ O^[ @d]_d[[h _i Wbie h[ifedi_Xb[ \eh \ebbem_d] _dj[hdWb H?JO fheY[Zkh[i \eh h[l_[m WdZ WffhelWb e\ iêf ZhWm_d]i) \WXh_YWj_ed fheY[Zkh[i) h[gk[ij \eh _d\ehcWj_ed &MAD') dedYed\ehcWdY[ h[fehji &I>M') WdZ \eh fhe\[ii_edWb Z[Y_i_ed cWa_d] ed \WXh_YWj_ed fheXb[ci j^Wj Wh_i[+ O^[ @d]_d[[h h[b_[i ed j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j je cWdW][ WdZ Wii_ij m^[d Wffhefh_Wj[+ O^[ @d]_d[[h ^Wi j^[ fh[he]Wj_l[ \eh êbZ_d] W fh[\WXh_YWj_ed c[[j_d] m_j^ j^[ AWXh_YWjeh je Z_iYkii WdZ YbWh_\o j^[ YedjhWYj fbWdi WdZ if[Y_\_YWj_edi+ O^[ @d]_d[[h _i j^[ h[ifedi_Xb[ fWhjo mê [dikh[i H?JOvi \WXh_YWj_ed L< fhe]hWc _i \ebbem[Z \eh _dif[Yj_ed WdZ WYY[fjWdY[ e\ j^[ [b[c[dj+

AWXh_YWj_ed iêkbZ fheY[[Z edbo m_j^ Wffhel[Z iêf ZhWm_d]i+ Cem[l[h) _\ j^[ AWXh_YWjeh ckij fheY[[Z fh_eh je h[Y[_fj e\ Wffhel[Z iêf ZhWm_d]i &f[h\ehc_d] meha Wj j^[_h emd h_ia') [dikh[ j^Wj j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j _i WmWh[ e\ j^_i WYj_l_jo WdZ WmW_j _dijhkYj_ed ed êm je fheY[[Z+ D\ j^[ @d]_d[[h f[hc_ji j^[ meha je fheY[[Z m_jêkj Wffhel[Z iêf ZhWm_d]i) fheY[[Z m_j^ XWi_Y L< \kdYj_edi ki_d] j^[ ded*Wffhel[Z iêf ZhWm_d]i+ GWj[h) l[h_\o dej[i W]W_dij Wffhel[Z ZhWm_d]i+ Iej_\o j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j _cc[Z_Wj[bo _\ \WXh_YWj_ed _i dej _d Yed\ehcWdY[ m_j^ j^[ Wffhel[Z iêf ZhWm_d]i+

>+ ?kj_[i e\ j^[ L<D s L<D f[h\ehc_d] j^[ \WXh_YWj_ed _dif[Yj_ed ^Wi j^[ \ebbem_d] Zkj_[i7

.+ L<D ckij jêhek]^bo kdZ[hijWdZ j^[ YedjhWYj+

14

1+-1

/+ L<D ckij l[h_\o ij[[b cWj[h_Wb Y[hj_\_YWj_edi iêm Yecfb_WdY[ m_j^ =ko <c[h_YWYedjhWYj h[gk_h[c[dji+

0+ L<D ckij X[ fhe\_Y_[dj _d f[h\ehc_d] \h[i^ YedYh[j[ j[iji) iWcfb_d] W]]h[]Wj[ WdZej^[h cWj[h_Wbi) l[h_\o_d] cWj[h_Wb jhWY[WX_b_jo) WdZ _dif[Yj_d] YedYh[j[ fekhi+

1+ L<D ckij X[ fhe\_Y_[dj _d mh_j_d] h[fehji WdZ ki_d] Yecfkj[hi+

2+ L<D ckij dej_\o j^[ @d]_d[[h _\ fheZkYj_ed X[]_di X[\eh[ Wffhel[Z iêf ZhWm_d]i Wh[ed j^[ iêf \beeh WdZ fhel_Z[Z je j^[ L<D+

3+ L<D ckij Yecckd_YWj[ Wbb YedY[hdi j^hek]^ L>D eh mêc[l[h j^[ AWXh_YWjeh Z_h[YjiZkh_d] j^[ fh[\WXh_YWj_ed c[[j_d]+

4+ L<D ckij Yecckd_YWj[ m_j^ L>D je eXjW_d j^[ meha iY^[Zkb[+

5+ L<D ckij \ebbem MDOT’s Structural Fabrication E-Construction Process \eh Ybei_d]ekj \WXh_YWj_ed _dif[Yj_ed \_b[+

?+ ?[\_Y_[dY_[i ed GeYWb <][dYo Khe`[Yji s H?JOvi L<D ckij dej_\o j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j _\ j^[o eXi[hl[ \WXh_YWj_ed eh _dif[Yj_ed Z[\_Y_[dY_[i ed beYWb W][dYo fhe]hWc &G<K' fhe`[Yji+ O^[ NjhkYjkhWb AWXh_YWj_ed @d]_d[[h m_bb h[fehj j^[ Z[\_Y_[dY_[i l_W [cW_b je j^[ @d]_d[[h j^Wj _i h[ifedi_Xb[ \eh YedijhkYj_ed el[hi_]^j e\ j^[ beYWb W][dYo fhe`[Yj WdZ YWhXed Yefo j^[ Wffb_YWXb[ >AN WdZ ?[i_]d ?_l_i_ed G<K @d]_d[[hi+

@+ Ddif[Yj_ed AWY_b_j_[i WdZ <YY[ii s AWY_b_j_[i \eh j^[ L<D ckij X[ fhel_Z[Z Xo j^[ AWXh_YWjeh f[h YedjhWYj+ L<D ckij ^Wl[ WYY[ii je Wbb fWhji e\ j^[ meha Wj Wbb j_c[i+ O^[ Wkjêh_jo WdZ ][d[hWb Zkj_[i e\ j^[ L<D Wh[ if[Y_\_[Z _d N[Yj_ed .-1+-.+? WdZ @ e\ j^[ H?JO NN>+

A+ Ddif[Yj_ed @gk_fc[dj s L<D m_bb X[ \khd_i^[Z m_j^ j^[ \ebbem_d] _j[ci Xo j^[ @d]_d[[h7

.+ >edjhWYj &H?JO NN>) if[Y_Wb fhel_i_edi) ijWdZWhZ fbWdi) if[Y_Wb Z[jW_bi) fbWdi^[[ji) [jY+'

/+ <ffhel[Z iêf ZhWm_d]i &fhel_Z[Z Xo AWXh_YWjeh'

0+ <YY[ii je H?JOvi AWXh_YWj_ed Ddif[Yj_ed $ >edijhkYj_ed Noij[c &AD>N'

1+ H?JO iêf WffhelWb ijWcf

L<D ckij fhel_Z[ j^[ \ebbem_d] _dif[Yj_ed [gk_fc[dj7

.+ >ecfkj[h m_j^ ^_]^ if[[Z _dj[hd[j WYY[ii

/+ >[bb fêd[ m_j^ YWc[hW

0+ AbWi^b_]^j

1+ O[cf[hWjkh[ c[Wikh_d] Z[l_Y[i YWfWXb[ e\ Yel[h_d] j^[ hWd][ \hec -qA je /--qA

2+ Ah[i^ YedYh[j[ j[ij_d] [gk_fc[dj &j^[hcec[j[h) ibkcf Yed[ a_j) WdZ W_h*c[j[h'

3+ H[Wikh_d] Z[l_Y[i &/-- \eej WdZ /- \eej ij[[b jWf[ WdZ YWb_f[hi'

4+ NjhW_]^j[Z][ WdZ b[l[bi

5+ NW\[jo [gk_fc[dj

6+ Jj^[h Wi d[[Z[Z \eh j^[ fhe`[Yj

15

1+-1

1+-1+-1+ Ddif[Yj_ed KheY[Zkh[

<+ Kh[\WXh_YWj_ed H[[j_d] s Kh[\WXh_YWj_ed c[[j_d]i \WY_b_jWj[ [\\[Yj_l[ gkWb_jo Yedjheb WdZ gkWb_jo WiikhWdY[ ed j^[ fhe`[Yj WdZ Wh[ YedZkYj[Z Xo H?JOvi NjhkYjkhWb AWXh_YWj_ed Pd_j fh_eh je j^[ ijWhj e\ \WXh_YWj_ed WdZ fh[\[hWXbo W\j[h iêf ZhWm_d]i ^Wl[ X[[d Wffhel[Z+ O^[ NjhkYjkhWb AWXh_YWj_ed Pd_j) L<D) AWXh_YWjeh) WdZ L>D ckij X[ fh[i[dj) m^[h[Wi j^[ @d]_d[[h WdZ >edjhWYjeh iêkbZ X[ fh[i[dj je [dikh[ W j[Wc [\\ehj je \WY_b_jWj[ WYYkhWj[ WdZ j_c[bo YedijhkYj_ed+ LkWb_jo WiikhWdY[ WdZ gkWb_jo Yedjheb YedjWYj _d\ehcWj_ed m_bb X[ i^Wh[Z Zkh_d] j^_i c[[j_d] je [dikh[ [\\[Yj_l[ Yecckd_YWj_ed+

=+ AWXh_YWj_ed Ddif[Yj_ed s Kh[ijh[ii[Z YedYh[j[ ckij X[ \WXh_YWj[Z _d WYYehZWdY[ m_j^ j^[ H?JO NN> WdZ YedjhWYj+ L<D WdZ L>D ckij fWii WddkWb H?JO _dZ[f[dZ[dj WiikhWdY[ j[ij_d] &D<O' fh_eh je f[h\ehc_d] \h[i^ YedYh[j[ j[ij_d]+ AWXh_YWj_ed _dif[Yj_ed ckij X[ f[h\ehc[Z Wi iêmd X[bem7

.+ Kh[ijh[ii[Z YedYh[j[ \WXh_YWj_ed _dif[Yj_ed Yedi_iji e\ l[h_\o_d] Yecfb_WdY[ m_j^ j^[Wffhel[Z iêf ZhWm_d]i) YedjhWYj) WdZ Wffhel[Z I>Mi+ MADi ckij X[ _dYehfehWj[Z_dje j^[ Wffhel[Z iêf ZhWm_d]i \eh j^[ L<D je _dif[Yj je+

/+ <d Wffhel[Z HWj[h_Wbi NekhY[ G_ij &HNG' _i fhel_Z[Z je j^[ L<D Xo j^[ @d]_d[[h iej^Wj j^[ L<D ademi m^Wj cWj[h_Wbi Wh[ X[_d] _dYehfehWj[Z _dje j^[ fhe`[Yj WdZ m^Wjj^[ XWi_i e\ WYY[fjWdY[ _i+ O^[ HNG _i ki[Z je jhWYa cWj[h_Wb iWcfb_d] Xo j^[ L<DWdZ je \eij[h Yecckd_YWj_ed m_j^ L>D je [dikh[ Wbb h[gk_h[Z iWcfb_d] WdZ j[ij_d]eYYkhi _d W j_c[bo cWdd[h je fh[l[dj _cfWYji je j^[ fhe`[Yj iY^[Zkb[+ Dj _i j^[AWXh_YWjehvi h[ifedi_X_b_jo je dej_\o j^[ L<D m^[d cWj[h_Wbi Wh[ WlW_bWXb[ \eh iWcfb_d]+

0+ L<D X[]_di Xo _dif[Yj_d] cWj[h_Wbi j^Wj m_bb X[ ki[Z _d j^[ \WXh_YWj_ed fheY[ii WdZ[dikh[i j^[o Wh[ X[_d] ijeh[Z Yehh[Yjbo) jW]][Z \eh jhWY[WX_b_jo fkhfei[i) WdZ Wh[ _dYed\ehcWdY[ m_j^ j^[ YedjhWYj+ I[nj) j^[ L<D _dif[Yji j^[ AWXh_YWjehvi ef[hWj_edi je[dikh[ j^[ YedZ_j_ed e\ j^[ [gk_fc[dj WdZ meha Wh[W \eh Yed\ehcWdY[ je j^[ YedjhWYj+

1+ H?JOvi <YY_Z[dj Kh[l[dj_ed KbWd ijWj[i) tH?JO [cfbeo[[i i^Wbb dej [d]W][ _d WdoWYj m^_Y^ mekbZ [dZWd][h Wdej^[h [cfbeo[[ eh j^[ci[bl[iu+ L<D ckij dej_\o j^[@d]_d[[h _cc[Z_Wj[bo _\ meha YedZ_j_edi [n_ij j^Wj Wh[ dej iW\[+ D\ j^[ b[l[b e\_dif[Yj_ed Z_c_d_i^[i X[bem m^Wj _i if[Y_\_[Z _d j^_i L< fheY[Zkh[) Zk[ je iW\[joYedY[hdi) j^[d j^[ [b[c[dj m_bb dej X[ Wffhel[Z \eh ki[+

>+ NjhWdZ O[di_ed_d]

.+ General Information s R^_b[ j^[ ijhWdZ _i ij_bb l_i_Xb[) j^[ L<D ckij _dif[Yj j^[ ijhWdZije Wiikh[ j^Wj j^[o Wh[ \h[[ e\ e_b eh ej^[h \eh[_]d cWj[h_Wb+ NjhWdZi dej \h[[ e\ e_b eh\eh[_]d cWj[h_Wb) eh j^Wj YedjW_d a_dai) X[dZi) d_Yai) eh ej^[h Z[\[Yji &_dYbkZ_d] iYWb[eh [nY[ii_l[ hkij' m_bb X[ Xhek]^j je L>i Wjj[dj_ed j^Wj _dYehfehWj_ed e\ j^[i[dedYed\ehc_d] ijhWdZi m_bb h[dZ[h j^[ [b[c[dj kdWYY[fjWXb[ WdZ j^[ [b[c[dj m_bb dejX[ Wffhel[Z \eh ki[+

W+ NjhWdZi Wh[ fei_j_ed[Z je Zkfb_YWj[ j^[ ijhWdZ fWjj[hd iêmd ed j^[ Wffhel[Ziêf ZhWm_d]i+ >^Wd]_d] j^[ l[hj_YWb fei_j_ed e\ j^[ ijhWdZi ckij ^Wl[ j^[WffhelWb e\ j^[ @d]_d[[h+ >^Wd]_d] j^[ êh_pedjWb fei_j_ed e\ j^[ ijhWdZi jei_cfb_\o \WXh_YWj_ed eh je WYYecceZWj[ jme ijhWdZ fWjj[hdi ed W X[Z _if[hc_jj[Z fhel_Z[Z j^[ \ebbem_d] _i ij_bb WY^_[l[Z7

_+ Nf[Y_\_[Z YedYh[j[ Yel[h8

__+ >[dj[h je Y[dj[h Z_ijWdY[ e\ ijhWdZi _i Wj b[Wij / _dY^[i8

___+ IkcX[h e\ ijhWdZi f[h hem _i cW_djW_d[Z8 WdZ

16

1+-1

_l+ M[ikbj_d] ijhWdZ fWjj[hd _i iocc[jh_YWb WXekj j^[ l[hj_YWbY[dj[hb_d[ e\ j^[ [b[c[dj+

X+ Ome ijhWdZ fWjj[hdi _i f[hc_jj[Z je X[ YecX_d[Z ed W YWij_d] X[Z fhel_Z[Zj^[ \ebbem_d] YedZ_j_edi Wh[ c[j WdZ Wffhel[Z Xo j^[ @d]_d[[h7

_+ =edZ Xh[Wa[h ckij X[ fbWY[Z ed [WY^ e\ j^[ kdh[gk_h[Z ijhWdZi\eh j^[ \kbb b[d]j^ e\ [WY^ [b[c[dj+ =edZ Xh[Wa[h &h_]_Z) el[hi_p[Z)WdZ cedeb_j^_Y' cWj[h_Wb h[gk_h[i j^[ WffhelWb e\ j^[ @d]_d[[h+

__+ HWn_ckc e\ jme \kbb b[d]j^ Z[XedZ[Z ijhWdZi f[h [b[c[dj+

Y+ <bb ikffehji ki[Z je fei_j_ed j^[ ijhWdZ hemi ckij X[ e\ WZ[gkWj[ j^_Yad[iije êbZ j^[ jhk[ fei_j_ed e\ j^[ ijhWdZi+

Z+ Ddif[Yj_ed e\ j^[ j[di_ed_d] ef[hWj_ed Yedi_iji e\ l[h_\o_d] j^[ `WYa _iYWb_XhWj[Z WdZ eXi[hl_d] j^[ WYYkhWj[ _djheZkYj_ed e\ j^[ _d_j_Wb beWZ _d [WY^ e\j^[ ijhWdZi+ A_dWb ijh[ii_d] e\ j^[ ijhWdZi _i f[h\ehc[Z Xo Wffb_YWj_ed e\ beWZ_dje [WY^ ijhWdZ eh Wbb j^[ ijhWdZi Wj edY[ je fheZkY[ Wd [bed]Wj_ed [gkWb_d]W net elongation &]heii [bed]Wj_ed c_dki b_l[ [dZ i[Wj_d]'+ O^[ L<D ckijl[h_\o j^[ WbbemWXb[ ijh[ii _d [WY^ ijhWdZ Xo c[Wikh_d] j^[ net elongation e\j^[ _dZ_l_ZkWb ijhWdZi W\j[h j^[ \_dWb ijh[ii_d]+ O^[ cWn_ckc beWZ Wffb_[Z je[WY^ ijhWdZ) Wi _dZ_YWj[Z Xo j^[ fh[iikh[ ]Wk][ e\ j^[ j[di_ed_d] Z[l_Y[) _iWbie h[YehZ[Z \eh XWYa Y^[Ya_d]+

[+ L<D ckij Yecfb[j[ _dZ[f[dZ[dj ijhWdZ j[di_ed_d] YWbYkbWj_edi \eh l[h_\_YWj_edfkhfei[i m_j^ L>+

/+ O^[ L<D ckij l[h_\o j^[ beWZ &c[Wikh[Z _d fekdZi' WdZ [bed]Wj_ed &c[Wikh[Z _d_dY^[i' Wffb_[Z je [WY^ ijhWdZ ki_d] j^[ \ebbem_d] fheY[Zkh[i7

W+ Initial Load * <\j[h Wbb ijhWdZi Wh[ fei_j_ed[Z ed j^[ YWij_d] X[Z [WY^ ijhWdZ _ii[Ykh[Z Xo W ijhWdZ*l_i[ Wj j^[ Z[WZ [dZ WdYêh_d] Xkba^[WZ e\ j^[ YWij_d]X[Z+ @WY^ ijhWdZ _i _dZ_l_ZkWbbo \_jj[Z Wj j^[ b_l[ [dZ WdYêh_d] Xkba^[WZ&j[di_ed_d] [dZ' e\ j^[ YWij_d] X[Z WdZ Wd initial load _i Wffb_[Z [_j^[h ed[ijhWdZ Wj W j_c[ eh Wbb Wj edY[+ O^[ initial load ckij X[ Z[i_]dWj[Z Xo j^[AWXh_YWjeh WdZ ckij dej [nY[[Z 2--- fekdZi+

R^[d j^[ initial load _i h[WY^[Z) W h[\[h[dY[ cWha _i cWZ[ ed j^[ ijhWdZ edj^[ ekji_Z[ e\ j^[ b_l[ [dZ WdYêh_d] Xkba^[WZ ikY^ j^Wj c[Wikh[c[dj e\Yedj_dk[Z [bed]Wj_ed YWd X[ eXi[hl[Z+ O^[ fkhfei[ e\ Wffbo_d] Wd initialload je [WY^ ijhWdZ _i je [ijWXb_i^ W YedijWdj ijWhj_d] fe_dj \eh c[Wikh_d] j^[net elongation c[Wikh[c[dji Xo [b_c_dWj_d] ibWYa _d j^[ ioij[c+ <j j^_i j_c[)j^[ ijhWdZ fWjj[hd _i Y^[Ya[Z Wj [WY^ Xkba^[WZ je cWa[ Y[hjW_d Wbb ijhWdZi Wh[_d j^[_h Yehh[Yj fei_j_ed WdZ ded[ e\ j^[ ijhWdZi Wh[ Yheii[Z+

Final Load s Di j^[ \ehY[ h[gk_h[Z X[oedZ initial load.

X+ Net Elongation s Pi_d] j^[ ijhWdZ cWha \hec j^[ fh[l_eki ij[f &W\j[h _d_j_WbbeWZ' j^[ \_dWb beWZ _i Wffb_[Z je j^[ ijhWdZ+ O^[ Z_ijWdY[ X[jm[[d j^[ ijhWdZcWha WdZ j^[ h[\[h[dY[ fe_dj ckij X[ c[Wikh[Z je j^[ d[Wh[ij -+-3/2 _dY^[ije Z[j[hc_d[ m^[d j^[ net elongation is reached+ D\ j^[ c[Wikh[Z [bed]Wj_ed_i [gkWb je eh ib_]^jbo ]h[Wj[h j^Wd &2 f[hY[dj eh b[ii' j^[ Yecfkj[Z [bed]Wj_ed)j^[ j[di_ed_d] ef[hWj_ed _i Yecfb[j[+ H_deh WZ`kijc[dji _d j^[ `WYa_d]ef[hWj_ed Wh[ cWZ[ je Xh_d] j^[ h[\[h[dY[ cWha je j^[ Z[i_h[Z c[Wikh[c[dj+R^[d j^[ j[di_ed_d] ef[hWj_ed \eh [WY^ ijhWdZ _i Yecfb[j[ WdZ X[\eh[ j^[j[di_ed _i h[b[Wi[Z \hec j^[ `WYa) W i[YedZ h[\[h[dY[ cWha ckij X[ cWZ[ ed

17

1+-1

j^[ ijhWdZ Wj j^[ _di_Z[ e\ j^[ WdYêh_d] fbWj[ WdZ j^[ ijhWdZ*l_i[ ckij j^[d X[ jWff[Z _dje fei_j_ed W]W_dij j^[ ekji_Z[ \WY[ e\ j^[ WdYêh_d] fbWj[+ R^[d j^[ j[di_ed ^Wi X[[d h[b[Wi[Z \hec j^[ ̀ WYa j^[ L<D ckij Y^[Ya j^[ h[\[h[dY[ cWhai ed j^[ ijhWdZ Wj j^[ _di_Z[ e\ j^[ WdYêh_d] fbWj[ je Z[j[hc_d[ j^Wj de ib_ffW][ e\ j^[ ijhWdZ*l_i[ &b_l[ [dZ i[Wj_d] beii' ̂ Wi eYYkhh[Z+ D\ ib_ffW][ ̂ Wi eYYkhh[Z j^[d _j ckij X[ YecfWh[Z je j^[ Wiikc[Z b_l[ [dZ i[Wj_d] beii ki[Z _d j^[ ijhWdZ j[di_ed_d] YWbYkbWj_edi+ <do Z_\\[h[dY[i ckij X[ dej[Z WdZ Yecckd_YWj[Z je L>+

Y+ Strand Elongation * O^[ j[di_ed_d] ef[hWj_ed ckij X[ ijeff[Z _cc[Z_Wj[bom^[d[l[h j^[ ijhWdZ _i [bed]Wj_d] m_jêkj W Yehh[ifedZ_d] _dYh[Wi[ _d j^[beWZ) eh j^[ beWZ _dYh[Wi[i m_jêkj W Yedj_dk_d] _dYh[Wi[ _d ijhWdZ [bed]Wj_ed+Dd j^[i[ eYYkhh[dY[i) j^[ \ebbem_d] ij[fi ckij X[ jWa[d7

_+ NjhWdZ [bed]Wj_ed YecfkjWj_ed _i Y^[Ya[Z8

__+ >Wij_d] X[Z b[d]j^ _i l[h_\_[Z8

___+ HeZkbki e\ [bWij_Y_jo e\ j^[ ijhWdZ _i l[h_\_[Z8 WdZ

_l+ AWYjehi h[ijh_Yj_d] j^[ \h[[ cel[c[dj e\ j^[ ijhWdZ Wh[ h[l_[m[Z+

O[cf[hWjkh[ Y^Wd][i cWo W\\[Yj j^[ ôZhWkb_Y ioij[c e\ j^[ j[di_ed_d] WffWhWjki h[ikbj_d] _d lWh_Wj_edi _d beWZ h[WZ_d]i+

Z+ Tensioning Draped Strands * L<D ckij X[ Wb[hj je j^[ ijhWdZ [bed]Wj_ed WdZj[di_ed_d] ef[hWj_ed Z_iYkii[Z WXel[+ Dd iec[ YWi[i) j^[ dkcX[h WdZ[\\_Y_[dYo e\ êbZ*Zemd,êbZ*kf ^WhZmWh[ cWo h[ijh_Yj j^[ \h[[ cel[c[dj e\ WijhWdZ el[h j^[ [dj_h[ X[Z b[d]j^ h[ikbj_d] _d W Yedj_dk_d] [bed]Wj_ed e\ ijhWdZm_jêkj W Yehh[ifedZ_d] _dYh[Wi[ _d j^[ beWZ+ R^[d j^_i i_jkWj_ed eYYkhi) j^[j[di_ed_d] ef[hWj_ed _i ijeff[Z WdZ j^[ h[cW_d_d] [bed]Wj_ed Z[l[bef[Z _dj^[ ijhWdZ jWa[d Xo j[di_ed_d] j^[ ijhWdZ \hec j^[ effei_j[ [dZ e\ j^[ YWij_d]X[Z+

[+ Confirming Uniform Elongation of Draped Strands * O^_i YWd X[ WYYecfb_i^[ZXo cWha_d]*e\\ W .- \eej &eh ceh[ _\ WlW_bWXb[' b[d]j^ e\ ZhWf[Z ijhWdZ Wj j^[effei_j[ [dZ e\ j^[ X[Z W\j[h j^[ _d_j_Wb beWZ ef[hWj_ed ^Wi X[[d Yecfb[j[Z+ <jj^[ Yecfb[j_ed e\ j^[ \_dWb c[Wikh[Z [bed]Wj_ed ef[hWj_ed) j^[ c[Wikh[ZZ_ijWdY[ X[jm[[d j^[ cWhai iêkbZ ^Wl[ _dYh[Wi[Z je j^[ net elongationYecfkjWj_ed \eh W .- \eej ijhWdZ b[d]j^ &eh m^Wj[l[h mWi _d_j_Wbbo cWha[Z e\\'+

\+ Wire Failure in Strand * N[[ K>D HIG ..3 \eh WYY[fjWdY[ e\ \W_bkh[ e\_dZ_l_ZkWb m_h[i _d W fh[j[di_ed_d] ijhWdZ+

?+ Forming and Casting

.+ General Information * L<D ckij Yed\_hc j^[ Z_c[di_edWb h[gk_h[c[dji e\ j^[Xkba^[WZi) i_Z[ \ehci) X[Wh_d] fbWj[i) ij[[b h[_d\ehY[c[dj) le_Z Xen[i) _di[hji) WdZWdo ej^[h Z[l_Y[i f[h j^[ Wffhel[Z iêf ZhWm_d]i Wi fWhj e\ j^[_h feij*fekh_dif[Yj_ed+ O^[ edbo [nY[fj_ed _i j^Wj Wdoj^_d] j^Wj YWddej X[ _dif[Yj[Z feij*fekh)ckij X[ _dif[Yj[Z Zkh_d] fh[*fekh+ Dj _i _cfehjWdj je [cf^Wi_p[ j^Wj L< ckij dejikf[hi[Z[ L> ie j^[ L<Dvi _dif[Yj_ed ckij Yec[ W\j[h L> ^Wi Yecfb[j[Z j^[_h_dif[Yj_ed WdZ Wffhel[i j^[ [b[c[dj+ L<D j^[d ki[i j^[ L> _dif[Yj_ed h[fehji &_\WlW_bWXb[' Zkh_d] j^[_h l[h_\_YWj_ed _dif[Yj_ed+

/+ Concrete Forms * >edYh[j[ \ehci ckij X[ cW_djW_d[Z WdZ h[cW_d jhk[ je j^[ i^Wf[iWdZ Z_c[di_edi Wi iêmd ed j^[ Wffhel[Z ZhWm_d]i+

18

1+-1

W+ H[jWb \ehci ckij X[ ki[Z i_dY[ j^[o Wh[ Z[i_]d[Z WdZ Wb_]d[Z je dej h[ijh_Yjj^[ bed]_jkZ_dWb cel[c[dj e\ j^[ YWij_d] m^[d j^[ fh[ijh[ii_d] \ehY[ _ijhWdi\[hh[Z+ Aehci ckij X[ m[bb XhWY[Z WdZ ij_\\[d[Z W]W_dij kdZ[i_hWXb[Z[\ehcWj_edi kdZ[h fh[iikh[ e\ \h[i^ YedYh[j[ WdZ ckij ^Wl[ iceej^ è_djiWdZ _di_Z[ ikh\WY[i WYY[ii_Xb[ \eh WZ[gkWj[ Yb[Wd_d] W\j[h [WY^ ki[+

X+ Ee_dji X[jm[[d fWd[b \ehci ckij X[ cWZ[ WdZ cW_djW_d[Z iceej^ WdZj_]^j+ Pdb[ii ej^[hm_i[ iêmd ed Wffhel[Z iêf ZhWm_d]i) Wbb Yehd[hi eh_dj[hi[Yj_edi e\ ikh\WY[i [nfei[Z _d j^[ Yecfb[j[Z ijhkYjkh[ ckij X[Y^Wc\[h[Z m_j^ W c_d_ckc Z_c[di_ed e\ -+2- _dY^[i WdZ Wbb h[*[djhWdj Wd]b[ickij X[ hekdZ[Z m_j^ W c_d_ckc hWZ_ki e\ -+42 _dY^[i+

Y+ Aehci j^Wj Wh[ mWhf[Z) Z_ijehj[Z) ZWcW][Z) eh _cfhef[hbo Yb[Wd[Z ckij dejX[ ki[Z+ ReeZ \ehci cWo X[ ki[Z \eh Xkba^[WZi+ O^[ _di_Z[ \WY[i e\ Wbb\ehci ckij X[ YeWj[Z m_j^ Wd Wffhel[Z Y^[c_YWb h[b[Wi[ W][dj+

0+ Reinforcing Steel s L<D ckij Yed\_hc j^Wj j^[ h[_d\ehY_d] ij[[b _i e\ j^[ Yehh[Yj i_p[)\h[[ \hec Z[\[Yji) WdZ fhef[hbo fei_j_ed[Z+ O^[ h[_d\ehY_d] ij[[b ckij X[ \h[[ e\ e_b)bkXh_YWdji) \eh[_]d cWj[h_Wb) WdZ [nY[ii_l[ hkij+ D\ [feno YeWj[Z XWhi Wh[ je X[ ki[Zj^[d d_Yai _d j^[ YeWj_d] Wh[ dej f[hc_jj[Z+

L<D ckij ifej Y^[Ya j^Wj j^[ h[_d\ehY_d] ij[[b ^Wi X[[d fhef[hbo fei_j_ed[Z WdZi[Ykh[Z _d WYYehZWdY[ m_j^ j^[ Wffhel[Z iêf ZhWm_d]i WdZ cWa[ Y[hjW_d j^Wj _di[hji^Wl[ X[[d fbWY[Z m^[h[ h[gk_h[Z+

1+ Qe_Z =en[i * Qe_Z Xen[i ckij X[ e\ j^[ Z_c[di_edi WdZ fei_j_ed[Z _d j^[ \ehc _dWYYehZWdY[ m_j^ j^[ Wffhel[Z iêf ZhWm_d]i+

<\j[h j^[ XWh h[_d\ehY[c[dj Wii[cXbo ^Wi X[[d fei_j_ed[Z _d j^[ \ehcmeha) j^[ L<Dckij Yed\_hc j^Wj j^[ le_Z Xen[i Wh[ i[Ykh[bo YbWcf[Z je j^[ \ehcmeha ie j^[o YWddejcel[ ekj e\ fei_j_ed Zkh_d] Yedieb_ZWj_ed WYj_l_j_[i+ <\j[h j^[ kd_j ^Wi X[[d YWij) WdZ_cc[Z_Wj[bo W\j[h j^[ jef ^Wi X[[d ijhkYa*e\\) j^[ jef ibWX j^_Yad[ii ckij X[Yed\_hc[Z Xo j^[ L<D je Wiikh[ j^Wj j^[h[ ^Wi X[[d de kfmWhZ cel[c[dj e\ j^[ le_ZXen WdZ j^Wj j^[ jef ibWX j^_Yad[ii _i m_j^_d j^[ WYY[fjWXb[ if[Y_\_YWj_ed b_c_ji+ O^[Z[fj^ e\ YedYh[j[ el[h j^[ le_Z Xen[i m_bb X[ ifej Y^[Ya[Z WdZ Wdo YedY[hdi dej[ZWdZ _cc[Z_Wj[bo i^Wh[Z m_j^ L>+

2+ Tests on Fresh Concrete s L<D ckij f[h\ehc j[ij_d] Wi h[gk_h[Z _d j^[ YedjhWYj WdZZeYkc[dj j^[ h[ikbji _d H?JO Aehc -26-+ O^[ AWXh_YWjeh ckij Yebb[Yj WZZ_j_edWb\h[i^ YedYh[j[ \eh L<D je f[h\ehc j^[_h j[iji Wi d[[Z[Z+

3+ Placing of Concrete s O^[ YedYh[j[ ckij X[ fhecfjbo fbWY[Z m_j^ c_d_ckc ^WdZb_d]je Wle_Z i[]h[]Wj_ed e\ j^[ cWj[h_Wbi WdZ j^[ Z_ifbWY[c[dj e\ j^[ h[_d*\ehY[c[dj+ @WY^ [b[c[dj ckij X[ YWij _d W Yedj_dkeki ef[hWj_ed m_j^ c_d_cWb_dj[hhkfj_ed X[jm[[d j^[ fbWY_d] e\ WZ`WY[dj fehj_edi e\ YedYh[j[ WdZ [WY^ bWo[h ckijX[ fbWY[Z WdZ Yedieb_ZWj[Z X[\eh[ j^[ fh[Y[Z_d] bWo[h ^Wi jWa[d _d_j_Wb i[j+

4+ Consolidation of Concrete s < c_d_ckc Wcekdj e\ l_XhWj_ed d[Y[iiWho je jêhek]^boYedieb_ZWj[ j^[ YedYh[j[ ckij X[ ki[Z+ L<D ckij l[h_\o W hkXX[h YeWj[Z l_XhWjeh^[WZ _i ki[Z m^[d [feno*YeWj[Z eh ej^[h YeWj[Z h[_d\ehY[c[dj _i ki[Z+

@+ Transfer of Prestress s O^[ j[di_ed _d j^[ ijhWdZi ckij dej X[ jhWdi\[hh[Z je j^[ YedYh[j[ _d j^[ [b[c[dj kdj_b j^[ YedYh[j[ ^Wi WjjW_d[Z j^[ h[gk_h[Z Yecfh[ii_l[ ijh[d]j^ Wi

19

1+-1

_dZ_YWj[Z Xo j[ij h[ikbji e\ L> Yecfh[ii_l[ ijh[d]j^ j[ij Yob_dZ[hi m^_Y^ ^Wl[ X[[d YWij WdZ cWjY^ Ykh[Z f[h j^[ YedjhWYj+ L<D ckij m_jd[ii j^_i j[ij_d]+

.+ Aehci Wh[ h[cel[Z WdZ j^[ ijhWdZi Wh[ h[b[Wi[Z Xo i_ckbjWd[ekibo Ykjj_d] Xej^ [dZie\ j^[ iWc[ ijhWdZ ki_d] W jehY^ eh ej^[h c[jêZ Wffhel[Z Xo j^[ @d]_d[[h+ O^[AWXh_YWjeh ckij h[b[Wi[ ijhWdZi _d W iocc[jh_YWb fWjj[hd WXekj j^[ l[hj_YWb Y[dj[hb_d[+@njh[c[ YWh[ ckij X[ [n[hY_i[Z Xo j^[ AWXh_YWjeh je Wle_Z ZWcW]_d] j^[ YedYh[j[ Xoikf[h^[Wj_d] _j m_j^ j^[ jehY^+

/+ @b[c[dji Wh[ cel[Z \hec j^[ YWij_d] X[Z je j^[ oWhZ kfed Yecfb[j_ed e\ j^[ jhWdi\[he\ fh[ijh[ii+ <\j[h h[celWb \hec j^[ X[Z) j^[ L<D ckij _cc[Z_Wj[bo _dif[Yj j^[[b[c[dj \eh Wdo Z[\[Yji Yh[Wj[Z Zkh_d] YWij_d] WdZ f[h\ehc feij*fekh _dif[Yj_ediW\j[h L> ^Wi Yecfb[j[Z j^[_h _dif[Yj_ed WdZ Wffhel[i j^[ [b[c[dj+ L<D ckij dej[Wdo Z[\_Y_[dY_[i ed Aehc -26- WdZ _cc[Z_Wj[bo dej_\o j^[ AWXh_YWjeh WdZ @d]_d[[h+O^[ @d]_d[[h cWo h[gk[ij j^[ L<D je Yecfb[j[ W LM WdZ WhhWd][ W c[[j_d]m_j^ L> je Z_iYkii mô j^[ Z[\_Y_[dYo mWidvj YWk]^j Xo L>+

A+ Curing Requirements * >kh_d] h[gk_h[c[dji \eh fh[ijh[ii[Z YedYh[j[ ckij X[ Wi if[Y_\_[Z _d ikXi[Yj_ed 4-5+-0 e\ j^[ H?JO NN> Wi ceZ_\_[Z Xo j^[ YedjhWYj+ R^[d ij[Wc eh hWZ_Wdj ^[Wj Ykh_d] _i ki[Z) h[YehZ_d] j^[hcec[j[hi ckij X[ fhel_Z[Z Xo j^[ AWXh_YWjeh j^Wj ced_jehi j^[ j_c[,j[cf[hWjkh[ h[bWj_edi^_f j^hek]^ j^[ Ykh_d] f[h_eZ m^_b[ Whj_\_Y_Wb ^[Wj _i ki[Z+ O^[ L<D ckij l[h_\o j^Wj j^[ h[YehZ_d] j^[hcec[j[hi Wh[ fbWY[Z _d Yh_j_YWb beYWj_edi \eh ced_jeh_d] j^[ j_c[,j[cf[hWjkh[ h[bWj_edi^_f Zkh_d] j^[ Ykh_d] f[h_eZ+ Q[h_\o L> ^Wi j^[ h[gk_h[Z dkcX[h e\ h[YehZ_d] j^[hcec[j[hi f[h j^[ YedjhWYj WdZ j^[o Wh[ fbWY[Z Wj beYWj_edi m^[h[ j^[ Wdj_Y_fWj[Z ̂ [Wj ][d[hWj[Z Xo j^[ YedYh[j[ _i j^[ bem[ij WdZ ^_]^[ij `kij W\j[h _d_j_Wb YedYh[j[ i[j+ ?eYkc[djWj_ed \hec j^[ AWXh_YWjeh%i h[YehZ_d] j^[hcec[j[h ckij X[ ]_l[d je j^[ L<D \eh j^[_h h[l_[m+ O[cf[hWjkh[ h[gk_h[c[dji Zkh_d] j^[ Ykh_d] ef[hWj_ed ckij X[ _d WYYehZWdY[ m_j^ j^[ YedjhWYj if[Y_\_YWj_edi+

B+ Material Requirements s HWj[h_Wbi ckij c[[j j^[ h[gk_h[c[dji e\ j^[ YedjhWYj kdb[ii W MAD h[gk[ij_d] Wbj[hdWj[ cWj[h_Wbi ^Wi X[[d Wffhel[Z Xo j^[ @d]_d[[h+

C+ Shipping Requirements s @b[c[dji ckij WjjW_d j^[ h[gk_h[Z Yecfh[ii_l[ ijh[d]j^ Wi _dZ_YWj[Z Xo j[ij h[ikbji e\ L> Yecfh[ii_l[ ijh[d]j^ j[ij Yob_dZ[hi) m^_Y^ ^Wl[ X[[d YWij WdZ cWjY^ Ykh[Z \eh j^_i fkhfei[ Wi Z[iYh_X[Z f[h j^[ YedjhWYj+ O^[i[ Yob_dZ[hi ckij X[ YWij m_j^ c[jWb H?JO jW]i WdZ j^[ Yecfh[ii_ed j[ij_d] ckij X[ m_jd[ii[Z Xo j^[ L<D+

1+-1+-2+ M[fehji

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=+ L<D ckij Yecfb[j[ Wd WYYkhWj[ WdZ Z[jW_b[Z WYYekdj e\ \WXh_YWj_ed \eh j^[ fhe`[Yj+ O^[ h[fehj ckij _dYbkZ[ W Z_iYkii_ed e\ \WXh_YWj_ed fhe]h[ii \eh Wbb Wif[Yji e\ j^[ meha+ Dj _i _dj[dZ[Z je X[ W Z[jW_b[Z h[YehZ e\ j^[ ijWjki e\ \WXh_YWj_ed WdZ iêkbZ _dYbkZ[ dkcX[h e\ [b[c[dji \WXh_YWj[Z) ZeYkc[djWj_ed e\ if[Y_\_YWj_ed WdZ fheY[Zkh[ Yecfb_WdY[ Wi m[bb Wi ZeYkc[djWj_ed e\ Yed\b_Yji) h[fW_hi) WdZ ej^[h fheXb[ci eh Z_iYkii_ed m^_Y^ YekbZ W\\[Yj j^[ fhe`[Yj _d WdomWo+ D\ \ehY[ WYYekdj meha _i jWa_d] fbWY[) ZeYkc[dj [WY^ ZWo j^Wj j^[ meha eYYkhi _d j^[ iêf WdZ m^_Y^ [b[c[dji Wh[ X[_d] meha[Z+

20

1+-1

>+ ?eYkc[djWj_ed _i dej W ikXij_jkj[ \eh Wffhefh_Wj[ Z_Wbe]k[ m_j^ j^[ AWXh_YWjeh) Xkj iêkbZ fhel_Z[ W h[YehZ e\ _cfehjWdj Z_iYkii_edi+ Dd iec[ YWi[i) j^[ L<D _i ceh[ \Wc_b_Wh m_j^ j^[ [l[dji eh _iik[i WdZ j^[h[\eh[ iêkbZ h[l_[m WdZ Yecc[dj ed ZhW\j Yef_[i e\ j^[ NjhkYjkhWb AWXh_YWj_ed Pd_jvi Yehh[ifedZ[dY[+

?+ M[fehji ckij X[ Wii[cXb[Z _dje ed[ \WXh_YWj_ed _dif[Yj_ed fehjWXb[ ZeYkc[dj \ehcWj &K?A' \_b[ WdZ ijeh[Z _d H?JOvi Khe`[YjR_i[ ZeYkc[dj ijehW][ fhe]hWc f[h MDOT’s Structural Fabrication Unit’s E-Construction Process+ O^[ @d]_d[[h m_bb h[Y[_l[ W \WXh_YWj_ed _dif[Yj_ed c[cehWdZkc \hec j^[ NjhkYjkhWb AWXh_YWj_ed @d]_d[[h W\j[h \WXh_YWj_ed _dif[Yj_ed _i Yecfb[j[+ O^[ c[cehWdZkc _i \eh _d\ehcWj_edWb fkhfei[i WdZ _i dej ki[Z \eh WYY[fjWdY[+

@+ =[bem _i W b_ij e\ lWh_eki H?JO h[fehji,\ehci WdZ W Xh_[\ Z[iYh_fj_ed e\ j^[_h fkhfei[ WdZ ki[ h[gk_h[c[dj+ N_c_bWh \ehci YWd X[ ki[Z _d fbWY[ e\ j^[ ijWdZWhZ H?JO \ehc _\ dej[Z X[bem+

.+ Project Folder Checklist (Form 2001) s O^_i \ehc ckij X[ Yecfb[j[Z Xo L<D \eh [WY^fhe`[Yj+ O^[ Y^[Yab_ij _i fbWY[Z ed jef e\ j^[ \WXh_YWj_ed _dif[Yj_ed \ebZ[h m^[d j^[fhe`[Yj _i Yecfb[j[+

/+ Shop Inspection Report (Form 5617) – O^_i \ehc ckij X[ Yecfb[j[Z Xo L<D ed Wm[[abo XWi_i \eh [WY^ fhe`[Yj WdZ iêkbZ YedjW_d W Xh_[\ dWhhWj_l[ e\ j^[ mehaf[h\ehc[Z el[h j^[ h[fehj_d] f[h_eZ+ O^[ h[fehj ckij YedjW_d j^[ \ebbem_d]_d\ehcWj_ed7 R[Wj^[h YedZ_j_edi) [b[c[dji meha[Z ed) cWj[h_Wbi _dYehfehWj[Z _dje[b[c[dji &ckij ZeYkc[dj l_ikWbbo _dif[Yj[Z WdZ WYY[fj[Z') meha WYj_l_jo)dedYed\ehcWdY[i) i^_ff_d]) \ehY[ WYYekdj meha &hWh[') WdZ Wdoj^_d] [bi[ Z[[c[Z_cfehjWdj Xo j^[ L<D+

0+ Sample Identification (Form 1923) s O^_i \ehc ckij X[ ikXc_jj[Z m^[d cWj[h_WbiWcfb_d] _i h[gk_h[Z ed W fhe`[Yj+ L<D ckij Yecfb[j[bo \_bb ekj j^[ \ehc WdZ a[[f WYefo _d j^[ \WXh_YWj_ed _dif[Yj_ed \ebZ[h+

1+ Strand Tensioning Report (Form 0513) s O^_i \ehc ckij X[ Yecfb[j[Z Xo L<D \eh[WY^ X[Z) m^_Y^ cWo YedjW_d i[l[hWb [b[c[dji+

2+ Bar Reinforcement Report (Form 1985) s O^_i \ehc _i edbo ki[Z _\ L<D f[h\ehci L<l[h_\_YWj_ed _dif[Yj_ed ed XWh h[_d\ehY[c[dj \eh fh[\WXh_YWj[Z Xh_Z][ [b[c[dj ioij[ci&K=@N' eh ej^[h [b[c[dji j^Wj YedjW_d Yecfb[n h[_d\ehY[c[dj Wi Z_h[Yj[Z Xo j^[@d]_d[[h+

6. Pre and Post Pour Inspection Checklist (Form 5616) s O^_i Y^[Yab_ij ckij X[Yecfb[j[Z Xo L<D \eh W c_d_ckc e\ ed[ [b[c[dj f[h fhe`[Yj+ O^[ Y^[Yab_ij _i fbWY[Z_d j^[ \WXh_YWj_ed _dif[Yj_ed \ebZ[h m^[d j^[ fhe`[Yj _i Yecfb[j[+

4+ Field and Lab Test Report (Form 0590) s O^_i \ehc ckij X[ Yecfb[j[Z Xo L<D \eh[WY^ fekh m^_Y^ cWo YedjW_d i[l[hWb [b[c[dji+

5+ Repair Observation Report (Form 1981) s O^_i \ehc _i edbo ki[Z _\ L<D f[h\ehci L<l[h_\_YWj_ed _dif[Yj_ed ed h[fW_hi j^Wj ^Wl[ X[[d Wffhel[Z Xo j^[ @d]_d[[h+

6+ Material Source List (Form 0501) s O^_i \ehc _i i[dj _d Xo j^[ \WXh_YWjeh) j^[ L<D m_bbl[h_\o j^Wj j^[ \WXh_YWjeh \_bb[Z ekj j^[ \ehc Yecfb[j[bo) WdZ ZeYkc[dj j^[ XWi_i e\WYY[fjWdY[ \eh Wbb cWj[h_Wbi+ D\ j^[h[ Wh[ Wdo cWj[h_Wbi j^Wj h[gk_h[ j[ij_d] j^[d j^[NjhkYjkhWb AWXh_YWj_ed Pd_j ckij X[ Yef_[Z ed j^[ Yecfb[j[Z HNG je YeehZ_dWj[ j^[WYY[fjWdY[ j[ij_d]+

1+-1+-3+ NjeYaf_b[ KWoc[dj

21

1+-1

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.+ Q[h_\o \WXh_YWj[Z cWj[h_Wb c[[ji Wffhel[Z iêf ZhWm_d]i &_\ Wffb_YWXb['8

/+ Q[h_\o ijeYaf_b[ gkWdj_jo WdZ _dYbkZ[ gkWdj_jo _d h[fehj8

0+ Q[h_\o cWj[h_Wb _i bWX[b[Z \eh H?JO ki[ edbo8

1+ Q[h_\o cWj[h_Wb _i Yehh[Yjbo ijeh[Z WdZ fhej[Yj[Z \hec j^[ [b[c[dji8 WdZ

2+ Khel_Z[ W h[fehj ikccWh_p_d] j^[ _dif[Yj_ed WdZ fhel_Z[ WZ[gkWj[ fêjei j^Wjh[fh[i[dj j^[ ][d[hWb YedZ_j_ed e\ j^[ [b[c[dji) êm j^[ovh[ X[_d] ijeh[Z) WdZ f_[Y[cWhai+

1+-1+-4+ <YY[fjWdY[

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.+ L<D

/+ @d]_d[[h

0+ AWXh_YWjeh

1+ >edjhWYjeh

2+ OhkYa_d] YecfWdo

O^[ =_bb e\ GWZ_d] _i h[gk_h[Z je YedjW_d) Wj W c_d_ckc) j^[ \ebbem_d] _d\ehcWj_ed7

.+ N^_ff_d] ZWj[

/+ ?[iYh_fj_ed e\ YWh]e &gkWdj_jo) [b[c[dj i_p[) m[_]^j) [jY+'

0+ @b[c[dj kd_gk[ f_[Y[ cWha

1+ H?JO fhe`[Yj beYWj_ed &hekj[) Yheii heWZ,h_l[h) WdZ Y_jo'

2+ H?JO fhe`[Yj _d\ehcWj_ed &ijhkYjkh[ dkcX[h) Yedjheb i[Yj_ed) WdZ èX dkcX[h'

3+ HWdk\WYjkh[hvi dWc[ WdZ WZZh[ii

=+ <YY[fjWdY[ Yedi_iji e\ j^[ \ebbem_d] jme*fWhj fheY[ii7

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22


1+-1

^WdZb_d]+ O^_i l_ikWb _dif[Yj_ed i^ekbZ X[ ZeYkc[dj[Z _d j^[ \_[bZ _dif[Yjehvi ZW_bo h[fehj+

23

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.+ >kbl[hji &_\ h[gk_h[Z Xo j^[ YedjhWYj eh Wi Z_h[Yj[Z Xo j^[ @d]_d[[h'

/+ Kh[\WXh_YWj[Z Xh_Z][ [b[c[dj ioij[ci

0+ H[Y^Wd_YWbbo ijWX_b_p[Z [Whj^ fWd[bi &_\ h[gk_h[Z Xo j^[ YedjhWYj eh Wi Z_h[Yj[Z Xo j^[ @d]_d[[h'

1+ NekdZ mWbb feiji WdZ fWd[bi &_\ h[gk_h[Z Xo j^[ YedjhWYj eh Wi Z_h[Yj[Z Xo j^[ @d]_d[[h'

1+..+-/+ M[\[h[dY[ ?eYkc[dji

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.+ O^[ \ebbem_d] i[Yj_edi e\ j^[ H?JO NjWdZWhZ Nf[Y_\_YWj_edi \eh >edijhkYj_ed &H?JO NN>' Wi ceZ_\_[Z Xo ikffb[c[djWb if[Y_\_YWj_ed ./NN*--.< s @hhWjW) Wi Wffb_YWXb[7

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/+ O^[ \ebbem_d] if[Y_Wb fhel_i_edi) Wi Wffb_YWXb[7

./NK*.-2< NekhY[ e\ Nj[[b WdZ Dhed &=ko <c[h_YW'

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0+ H?JO NjhkYjkhWb Kh[YWij >edYh[j[ L<D HWdkWb

1+ >edijhkYj_ed A_[bZ N[hl_Y[i ?_l_i_ed &>AN' HWj[h_Wbi NekhY[ Bk_Z[ &HNB'

2+ H?JO NjhkYjkhWb AWXh_YWj_ed Pd_j @*>edijhkYj_ed KheY[ii

3+ H?JO NjhkYjkhWb AWXh_YWj_ed LkWb_jo <iikhWdY[ Bk_ZWdY[ ?eYkc[dj

4+ Kh[\WXh_YWj_ed c[[j_d] c_dkj[i &_\ WlW_bWXb['

=+ L<D ckij X[ \Wc_b_Wh m_j^ j^[ \ebbem_d] h[\[h[dY[i7

.+ H?JO NjhkYjkhWb AWXh_YWj_ed M[gk[ij \eh Dd\ehcWj_ed KheY[ii

/+ H?JO Nêf ?hWm_d] M[l_[m KheY[ii

0+ H?JO NjhkYjkhWb AWXh_YWj_ed IedYed\ehcWdY[ KheY[ii

1+ H_Y^_]Wd O[ij H[jêZi

HOH .-/ H_Y^_]Wd O[ij H[jêZ \eh <XhWi_ed M[i_ijWdY[ e\ <]]h[]Wj[ Xo j^[ Gei <d][b[i HWY^_d[

HOH .-5 H_Y^_]Wd O[ij H[jêZ \eh HWj[h_Wbi A_d[h j^Wd Ie+ 42 N_[l[ _d H_d[hWb

24

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HOH ..1 H_Y^_]Wd O[ij H[jêZ \eh HWa_d] >edYh[j[ Nf[Y_c[di \eh Ah[[p[*O^Wm O[ij_d] e\ >edYh[j[ >eWhi[ <]]h[]Wj[

HOH ..2 H_Y^_]Wd O[ij H[jêZ \eh O[ij_d] >edYh[j[ \eh ?khWX_b_jo Xo MWf_Z Ah[[p_d] _d <_h WdZ O^Wm_d] _d RWj[h

HOH /-3 H_Y^_]Wd O[ij H[jêZ \eh Pi[ e\ PdXedZ[Z >Wfi _d ?[j[hc_dWj_ed e\ >ecfh[ii_l[ Njh[d]j^ e\ CWhZ[d[Z >edYh[j[ >ob_dZ[hi

2+ <<NCOJ NjWdZWhZi

O // >ecfh[ii_l[ Njh[d]j^ e\ >ob_dZh_YWb >edYh[j[ Nf[Y_c[di

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O /0. >Wff_d] >ob_dZh_YWb >edYh[j[ Nf[Y_c[di

3+ <NOH NjWdZWhZi

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< 1.3 NjWdZWhZ Nf[Y_\_YWj_ed \eh Gem*M[bWnWj_ed) N[l[d*R_h[ Nj[[b NjhWdZ \eh Kh[ijh[ii[Z >edYh[j[

< 164 NjWdZWhZ Nf[Y_\_YWj_ed \eh Nj[[b R[bZ[Z R_h[ AWXh_Y) ?[\ehc[Z) \eh >edYh[j[ M[_d\ehY[c[dj

> 0. NjWdZWhZ KhWYj_Y[ \eh HWa_d] WdZ >kh_d] >edYh[j[ O[ij Nf[Y_c[di _d j^[ A_[bZ

> 06 NjWdZWhZ O[ij H[jêZ \eh >ecfh[ii_l[ Njh[d]j^ e\ >ob_dZh_YWb >edYh[j[ Nf[Y_c[di

> 61 NjWdZWhZ Nf[Y_\_YWj_ed \eh M[WZo*H_n[Z >edYh[j[ > .03 NjWdZWhZ O[ij H[jêZ \eh N_[l[ <dWboi_i e\ A_d[ WdZ >eWhi[

<]]h[]Wj[i > .05 O[ij H[jêZ \eh ?[di_jo &Pd_j R[_]^j') T_[bZ WdZ <_h >edj[dj

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j^[ Qebkc[jh_Y H[jêZ > /0. NjWdZWhZ O[ij H[jêZ \eh <_h >edj[dj e\ Ah[i^bo H_n[Z >edYh[j[ Xo

j^[ Kh[iikh[ H[jêZ > 262 NjWdZWhZ Nf[Y_\_YWj_ed \eh =b[dZ[Z CoZhWkb_Y >[c[dji

> 3.4 NjWdZWhZ KhWYj_Y[ \eh >Wff_d] >ob_dZh_YWb >edYh[j[ Nf[Y_c[di > ./0. NjWdZWhZ KhWYj_Y[ \eh Pi[ e\ PdXedZ[Z >Wfi _d Z[j[hc_dWj_ed e\

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>+ H?JO <YY_Z[dj Kh[l[dj_ed KbWd

25

1+..

1+..+-0+ LkWb_\_YWj_edi) M[ifedi_X_b_j_[i) ?kj_[i) WdZ @gk_fc[dj

<+ LkWb_\_YWj_edi e\ j^[ L<D s L<D f[h\ehc_d] j^[ \WXh_YWj_ed _dif[Yj_ed ckij feii[ii j^[ \ebbem_d] gkWb_\_YWj_edi7

.+ H_Y^_]Wd >edYh[j[ <iieY_Wj_ed &H><' G[l[b D A_[bZ O[ij_d] O[Y^d_Y_Wd Y[hj_\_YWj_ed eh <c[h_YWd >edYh[j[ Ddij_jkj[ &<>D' >edYh[j[ A_[bZ O[ij_d] O[Y^d_Y_Wd s BhWZ[ D &[nY[fj f[h_eZ e\ [\\[Yj_l[d[ii m_bb X[ h[ZkY[Z \hec 2 o[Whi je 0 o[Whi je cWjY^ H><'8 WdZ

/+ H_Y^_]Wd >[hj_\_[Z <]]h[]Wj[ O[Y^d_Y_Wd &H><O' G[l[b D &edbo h[gk_h[Z \eh W]]h[]Wj[ iWcfb_d]'+

=+ M[ifedi_X_b_j_[i e\ j^[ L<D s L<D f[h\ehc_d] j^[ \WXh_YWj_ed _dif[Yj_ed _i dej f[hc_jj[Z je cWa[ Y^Wd][i je j^[ YedjhWYj WdZ ^Wi j^[ \ebbem_d] h[ifedi_X_b_j_[i7

O^[ >edjhWYjeh) AWXh_YWjeh) WdZ H?JO m_bb WffheWY^ gkWb_jo Yedjheb WdZ gkWb_jo WiikhWdY[ Wi W j[Wc [\\ehj je \WY_b_jWj[ WYYkhWj[ WdZ j_c[bo YedijhkYj_ed+ L<Dvi l[h_\_YWj_ed Ze[i dej h[b_[l[ j^[ AWXh_YWjeh \hec j^[ h[ifedi_X_b_jo je f[h\ehc j^[ h[gk_h[Z j[ij_d] WdZ _dif[Yj_ed je fheZkY[ W fheZkYj iWj_i\o_d] j^[ YedjhWYj+ Oêk]^ L< _dif[Yj_ed cWo _dYbkZ[ Wbb Wif[Yji e\ \WXh_YWj_ed) j^[ L<D ckij dej ikf[hi[Z[ L>) m^_Y^ _i j^[ h[ifedi_X_b_jo e\ j^[ AWXh_YWjeh+ D\ L> _i dej WYYecfb_i^_d] _ji heb[ j^[d j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j) @d]_d[[h) >edjhWYjeh) WdZ AWXh_YWjeh ckij Z[j[hc_d[ j^[ d[Y[iiWho Yehh[Yj_edi+

L<D _i j^[ h[ifedi_Xb[ fWhjo) h[fh[i[dj_d] j^[ @d]_d[[h) mê f[h\ehci gkWb_jo WiikhWdY[ l[h_\_YWj_ed _dif[Yj_ed ed j^[ [b[c[dj W\j[h gkWb_jo Yedjheb &L>' _dif[Yji WdZ Wffhel[i j^[ _j[c e\ meha+ O^[ L<D ckij X[ Wj j^[ \WXh_YWj_ed \WY_b_jo Wj Wbb j_c[i Zkh_d] \WXh_YWj_ed Wi h[gk_h[Z Xo j^[ _dif[Yj_ed fheY[Zkh[ ijWj[Z X[bem+ D\ _iik[i Wh_i[) _j m_bb X[ Wj j^[ @d]_d[[hvi Z_iYh[j_ed m^[j^[h je _dYh[Wi[ j^[ b[l[b e\ L< _dif[Yj_ed+

Dj _i j^[ @d]_d[[hvi h[ifedi_X_b_jo je [d]W][ j^[ @d]_d[[h e\ M[YehZ &@JM' m^[d cWa_d] ijhkYjkhWb Z[Y_i_edi+ O^[ @d]_d[[h _i Wbie h[ifedi_Xb[ \eh \ebbem_d] _dj[hdWb H?JO fheY[Zkh[i \eh h[l_[m WdZ WffhelWb e\ iêf ZhWm_d]i) \WXh_YWj_ed fheY[Zkh[i) h[gk[ij \eh _d\ehcWj_ed &MAD') dedYed\ehcWdY[ h[fehji &I>M') WdZ \eh fhe\[ii_edWb Z[Y_i_ed cWa_d] ed \WXh_YWj_ed fheXb[ci j^Wj Wh_i[+ O^[ @d]_d[[h h[b_[i ed j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j je cWdW][ WdZ Wii_ij m^[d Wffhefh_Wj[+ O^[ @d]_d[[h ^Wi j^[ fh[he]Wj_l[ \eh êbZ_d] W fh[\WXh_YWj_ed c[[j_d] m_j^ j^[ AWXh_YWjeh je Z_iYkii WdZ YbWh_\o j^[ YedjhWYj fbWdi WdZ if[Y_\_YWj_edi+ O^[ @d]_d[[h _i j^[ h[ifedi_Xb[ fWhjo mê [dikh[i H?JOvi \WXh_YWj_ed L< fhe]hWc _i \ebbem[Z \eh _dif[Yj_ed WdZ WYY[fjWdY[ e\ j^[ [b[c[dj+

AWXh_YWj_ed iêkbZ fheY[[Z edbo m_j^ Wffhel[Z iêf ZhWm_d]i+ Cem[l[h) _\ j^[ AWXh_YWjeh ckij fheY[[Z fh_eh je h[Y[_fj e\ Wffhel[Z iêf ZhWm_d]i &f[h\ehc_d] meha Wj j^[_h emd h_ia') [dikh[ j^Wj j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j _i WmWh[ e\ j^_i WYj_l_jo WdZ WmW_j _dijhkYj_ed ed êm je fheY[[Z+ D\ j^[ @d]_d[[h f[hc_ji j^[ meha je fheY[[Z m_jêkj Wffhel[Z iêf ZhWm_d]i) fheY[[Z m_j^ XWi_Y L< \kdYj_edi ki_d] j^[ ded*Wffhel[Z iêf ZhWm_d]i+ GWj[h) l[h_\o dej[i W]W_dij Wffhel[Z ZhWm_d]i+ Iej_\o j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j _cc[Z_Wj[bo _\ \WXh_YWj_ed _i dej _d Yed\ehcWdY[ m_j^ j^[ Wffhel[Z iêf ZhWm_d]i+

>+ ?kj_[i e\ j^[ L<D s L<D f[h\ehc_d] j^[ \WXh_YWj_ed _dif[Yj_ed ^Wi j^[ \ebbem_d] Zkj_[i7

.+ L<D ckij jêhek]^bo kdZ[hijWdZ j^[ YedjhWYj+

/+ L<D ckij l[h_\o ij[[b cWj[h_Wb Y[hj_\_YWj_edi iêm Yecfb_WdY[ m_j^ =ko <c[h_YW YedjhWYj h[gk_h[c[dji+

26

1+..

0+ L<D ckij X[ fhe\_Y_[dj _d f[h\ehc_d] \h[i^ YedYh[j[ j[iji) iWcfb_d] W]]h[]Wj[ WdZ ej^[h cWj[h_Wbi) l[h_\o_d] cWj[h_Wb jhWY[WX_b_jo) WdZ _dif[Yj_d] YedYh[j[ fekhi+

1+ L<D ckij X[ fhe\_Y_[dj _d mh_j_d] h[fehji WdZ ki_d] Yecfkj[hi+

2+ L<D ckij dej_\o j^[ @d]_d[[h _\ fheZkYj_ed X[]_di X[\eh[ Wffhel[Z iêf ZhWm_d]i Wh[ ed j^[ iêf \beeh WdZ fhel_Z[Z je j^[ L<D+

3+ L<D ckij Yecckd_YWj[ Wbb YedY[hdi j^hek]^ L>D eh mêc[l[h j^[ AWXh_YWjeh Z_h[Yji Zkh_d] j^[ fh[\WXh_YWj_ed c[[j_d]+

4+ L<D ckij Yecckd_YWj[ m_j^ L>D je eXjW_d j^[ meha iY^[Zkb[+

5+ L<D ckij \ebbem MDOT’s Structural Fabrication E-Construction Process \eh Ybei_d] ekj \WXh_YWj_ed _dif[Yj_ed \_b[+

?+ ?[\_Y_[dY_[i ed GeYWb <][dYo Khe`[Yji s H?JOvi L<D ckij dej_\o j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j _\ j^[o eXi[hl[ \WXh_YWj_ed eh _dif[Yj_ed Z[\_Y_[dY_[i ed beYWb W][dYo fhe]hWc &G<K' fhe`[Yji+ O^[ NjhkYjkhWb AWXh_YWj_ed @d]_d[[h m_bb h[fehj j^[ Z[\_Y_[dY_[i l_W [cW_b je j^[ @d]_d[[h j^Wj _i h[ifedi_Xb[ \eh YedijhkYj_ed el[hi_]^j e\ j^[ beYWb W][dYo fhe`[Yj WdZ YWhXed Yefo j^[ Wffb_YWXb[ >AN WdZ ?[i_]d ?_l_i_ed G<K @d]_d[[hi+

@+ Ddif[Yj_ed AWY_b_j_[i WdZ <YY[ii s AWY_b_j_[i \eh j^[ L<D ckij X[ fhel_Z[Z Xo j^[ AWXh_YWjeh f[h YedjhWYj+ L<D ckij ^Wl[ WYY[ii je Wbb fWhji e\ j^[ meha Wj Wbb j_c[i+ O^[ Wkjêh_jo WdZ ][d[hWb Zkj_[i e\ j^[ L<D Wh[ if[Y_\_[Z _d N[Yj_ed .-1+-.+? WdZ @ e\ j^[ H?JO NjWdZWhZ Nf[Y_\_YWj_edi \eh >edijhkYj_ed+

A+ Ddif[Yj_ed @gk_fc[dj s L<D m_bb X[ \khd_i^[Z m_j^ j^[ \ebbem_d] _j[ci Xo j^[ @d]_d[[h7

.+ >edjhWYj &H?JO NN>) if[Y_Wb fhel_i_edi) ijWdZWhZ fbWdi) if[Y_Wb Z[jW_bi) fbWd i^[[ji) [jY+'

/+ <ffhel[Z iêf ZhWm_d]i &fhel_Z[Z Xo AWXh_YWjeh'

0+ <YY[ii je H?JOvi AWXh_YWj_ed Ddif[Yj_ed $ >edijhkYj_ed Noij[c &AD>N'

1+ H?JO iêf WffhelWb ijWcf

L<D ckij fhel_Z[ j^[ \ebbem_d] _dif[Yj_ed [gk_fc[dj7

.+ >ecfkj[h m_j^ ^_]^ if[[Z _dj[hd[j WYY[ii

/+ >[bb fêd[ m_j^ YWc[hW

0+ AbWi^b_]^j

1+ O[cf[hWjkh[ c[Wikh_d] Z[l_Y[i YWfWXb[ e\ Yel[h_d] j^[ hWd][ \hec -qA je /--qA

2+ Ah[i^ YedYh[j[ j[ij_d] [gk_fc[dj &j^[hcec[j[h) ibkcf Yed[ a_j) WdZ W_h*c[j[h'

3+ H[Wikh_d] Z[l_Y[i &/-- \eej WdZ /- \eej ij[[b jWf[ WdZ YWb_f[hi'

4+ NjhW_]^j[Z][ WdZ b[l[bi

5+ NW\[jo [gk_fc[dj

6+ Jj^[h Wi d[[Z[Z \eh j^[ fhe`[Yj

1+..+-1+ Ddif[Yj_ed KheY[Zkh[

<+ Kh[\WXh_YWj_ed H[[j_d] s Kh[\WXh_YWj_ed c[[j_d]i \WY_b_jWj[ [\\[Yj_l[ gkWb_jo Yedjheb WdZ gkWb_jo WiikhWdY[ ed j^[ fhe`[Yj WdZ Wh[ YedZkYj[Z Xo H?JOvi NjhkYjkhWb AWXh_YWj_ed Pd_j fh_eh je j^[ ijWhj e\ \WXh_YWj_ed WdZ fh[\[hWXbo W\j[h iêf ZhWm_d]i ^Wl[ X[[d

27

1+..

Wffhel[Z+ O^[ NjhkYjkhWb AWXh_YWj_ed Pd_j) L<D) AWXh_YWjeh) WdZ L>D ckij X[ fh[i[dj) m^[h[Wi j^[ @d]_d[[h WdZ >edjhWYjeh iêkbZ X[ fh[i[dj je [dikh[ W j[Wc [\\ehj je \WY_b_jWj[ WYYkhWj[ WdZ j_c[bo YedijhkYj_ed+ LkWb_jo WiikhWdY[ WdZ gkWb_jo Yedjheb YedjWYj _d\ehcWj_ed m_bb X[ i^Wh[Z Zkh_d] j^_i c[[j_d] je [dikh[ [\\[Yj_l[ Yecckd_YWj_ed+

=+ AWXh_YWj_ed Ddif[Yj_ed s Ied*fh[ijh[ii[Z YedYh[j[ ckij X[ \WXh_YWj[Z _d WYYehZWdY[ m_j^ j^[ H?JO NN> WdZ YedjhWYj+ L<D WdZ L>D ckij fWii H?JO _dZ[f[dZ[dj WiikhWdY[ j[ij_d] &D<O' fh_eh je f[h\ehc_d] \h[i^ YedYh[j[ j[ij_d] ed Wd WddkWb XWi_i+ AWXh_YWj_ed _dif[Yj_ed ckij X[ f[h\ehc[Z Wi iêmd X[bem7

.+ Ied*fh[ijh[ii[Z YedYh[j[ \WXh_YWj_ed _dif[Yj_ed Yedi_iji e\ l[h_\o_d] Yecfb_WdY[ m_j^j^[ Wffhel[Z iêf ZhWm_d]i) YedjhWYj) WdZ Wffhel[Z I>Mi+ MADi ckij X[_dYehfehWj[Z _dje j^[ Wffhel[Z iêf ZhWm_d]i \eh j^[ L<D je _dif[Yj je+

/+ <d Wffhel[Z HWj[h_Wbi NekhY[ G_ij &HNG' _i fhel_Z[Z je j^[ L<D Xo j^[ @d]_d[[h iej^Wj j^[ L<D ademi m^Wj cWj[h_Wbi Wh[ X[_d] _dYehfehWj[Z _dje j^[ fhe`[Yj WdZ m^Wjj^[ XWi_i e\ WYY[fjWdY[ _i+ O^[ HNG _i ki[Z je jhWYa cWj[h_Wb iWcfb_d] Xo j^[ L<DWdZ je \eij[h Yecckd_YWj_ed m_j^ L> je [dikh[ Wbb h[gk_h[Z iWcfb_d] WdZ j[ij_d]eYYkhi _d W j_c[bo cWdd[h je fh[l[dj _cfWYji je j^[ fhe`[Yj iY^[Zkb[+ Dj _i j^[AWXh_YWjehvi h[ifedi_X_b_jo je dej_\o j^[ L<D m^[d cWj[h_Wbi Wh[ WlW_bWXb[ \eh iWcfb_d]+

0+ L<D X[]_di Xo _dif[Yj_d] cWj[h_Wbi j^Wj m_bb X[ ki[Z _d j^[ \WXh_YWj_ed fheY[ii WdZ[dikh[i j^[o Wh[ X[_d] ijeh[Z Yehh[Yjbo) jW]][Z \eh jhWY[WX_b_jo fkhfei[i) WdZ Wh[ _dYed\ehcWdY[ m_j^ j^[ YedjhWYj+ I[nj) j^[ L<D _dif[Yji j^[ AWXh_YWjehvi ef[hWj_edi je[dikh[ j^[ YedZ_j_ed e\ j^[ [gk_fc[dj WdZ meha Wh[W \eh Yed\ehcWdY[ je j^[ YedjhWYj+

1+ H?JOvi <YY_Z[dj Kh[l[dj_ed KbWd ijWj[i) tH?JO [cfbeo[[i i^Wbb dej [d]W][ _d WdoWYj m^_Y^ mekbZ [dZWd][h Wdej^[h [cfbeo[[ eh j^[ci[bl[iu+ L<D ckij dej_\o j^[@d]_d[[h _cc[Z_Wj[bo _\ meha YedZ_j_edi [n_ij j^Wj Wh[ dej iW\[+ D\ j^[ b[l[b e\_dif[Yj_ed Z_c_d_i^[i X[bem m^Wj _i if[Y_\_[Z _d j^_i L< fheY[Zkh[) Zk[ je iW\[joYedY[hdi) j^[d j^[ [b[c[dj m_bb dej X[ Wffhel[Z \eh ki[+

>+ Aehc_d] WdZ >Wij_d]

.+ General Information * L<D ckij Yed\_hc j^[ Z_c[di_edWb h[gk_h[c[dji e\ j^[Xkba^[WZi) i_Z[ \ehci) X[Wh_d] fbWj[i) ij[[b h[_d\ehY[c[dj) le_Z Xen[i) _di[hji) WdZWdo ej^[h Z[l_Y[i f[h j^[ Wffhel[Z iêf ZhWm_d]i Wi fWhj e\ j^[_h feij*fekh_dif[Yj_ed+ O^[ edbo [nY[fj_ed _i j^Wj Wdoj^_d] j^Wj YWddej X[ _dif[Yj[Zfeij*fekh) ckij X[ _dif[Yj[Z Zkh_d] fh[*fekh+ Dj _i _cfehjWdj je [cf^Wi_p[ j^Wj L<ckij dej ikf[hi[Z[ L> ie j^[ L<Dvi _dif[Yj_ed ckij Yec[ W\j[h L> ^Wi Yecfb[j[Zj^[_h _dif[Yj_ed WdZ Wffhel[i j^[ [b[c[dj+ L<D j^[d ki[i j^[ L> _dif[Yj_ed h[fehji&_\ WlW_bWXb[' Zkh_d] j^[_h l[h_\_YWj_ed _dif[Yj_ed+

/+ Concrete Forms * >edYh[j[ \ehci ckij X[ cW_djW_d[Z WdZ h[cW_d jhk[ je j^[ i^Wf[iWdZ Z_c[di_edi Wi iêmd ed j^[ Wffhel[Z ZhWm_d]i+

W+ H[jWb \ehci ckij X[ ki[Z i_dY[ j^[o Wh[ Z[i_]d[Z je X[ h_]_Z \eh h[f[j_j_l[YWij_d]i m_jêkj Z[\ehc_d] eh m[Wa[d_d] Zk[ je j^[ ^[Wj \hec j^[ ôZhWj_edfheY[ii+ Aehci ckij X[ m[bb XhWY[Z WdZ ij_\\[d[Z W]W_dij kdZ[i_hWXb[Z[\ehcWj_edi kdZ[h fh[iikh[ e\ \h[i^ YedYh[j[ WdZ ckij ^Wl[ iceej^ è_djiWdZ _di_Z[ ikh\WY[i WYY[ii_Xb[ \eh WZ[gkWj[ Yb[Wd_d] W\j[h [WY^ ki[+

X+ Ee_dji X[jm[[d fWd[b \ehci ckij X[ cWZ[ WdZ cW_djW_d[Z iceej^ WdZj_]^j+ Pdb[ii ej^[hm_i[ iêmd ed Wffhel[Z iêf ZhWm_d]i) Wbb Yehd[hi eh_dj[hi[Yj_edi e\ ikh\WY[i [nfei[Z _d j^[ Yecfb[j[Z ijhkYjkh[ ckij X[Y^Wc\[h[Z m_j^ W c_d_ckc Z_c[di_ed e\ -+2- _dY^[i WdZ Wbb h[*[djhWdj Wd]b[ickij X[ hekdZ[Z m_j^ W c_d_ckc hWZ_ki e\ -+42 _dY^[i+

28

1+..

Y+ Aehci j^Wj Wh[ mWhf[Z) Z_ijehj[Z) ZWcW][Z) eh _cfhef[hbo Yb[Wd[Z ckij dej X[ ki[Z+ ReeZ \ehci cWo X[ ki[Z \eh Xkba^[WZi+ O^[ _di_Z[ \WY[i e\ Wbb \ehci ckij X[ YeWj[Z m_j^ Wd Wffhel[Z Y^[c_YWb h[b[Wi[ W][dj+

0+ Reinforcing Steel s L<D ckij Yed\_hc j^Wj j^[ h[_d\ehY_d] ij[[b _i e\ j^[ Yehh[Yj i_p[) \h[[ \hec Z[\[Yji) WdZ fhef[hbo fei_j_ed[Z+ O^[ h[_d\ehY_d] ij[[b ckij X[ \h[[ e\ e_b) bkXh_YWdji) \eh[_]d cWj[h_Wb) WdZ [nY[ii_l[ hkij+ D\ [feno YeWj[Z XWhi Wh[ je X[ ki[Z j^[d d_Yai _d j^[ YeWj_d] Wh[ dej f[hc_jj[Z+

L<D ckij ifej Y^[Ya j^Wj j^[ h[_d\ehY_d] ij[[b ^Wi X[[d fhef[hbo fei_j_ed[Z WdZ i[Ykh[Z _d WYYehZWdY[ m_j^ j^[ Wffhel[Z i^ef ZhWm_d]i WdZ cWa[ Y[hjW_d j^Wj _di[hji ^Wl[ X[[d fbWY[Z m^[h[ h[gk_h[Z+

1+ Tests on Fresh Concrete s L<D ckij f[h\ehc j[ij_d] Wi h[gk_h[Z _d j^[ YedjhWYj WdZ ZeYkc[dj j^[ h[ikbji _d H?JO Aehc -26-+ O^[ AWXh_YWjeh ckij Yebb[Yj WZZ_j_edWb \h[i^ YedYh[j[ \eh L<D je f[h\ehc j^[_h j[iji Wi d[[Z[Z+

2+ Placing of Concrete s O^[ YedYh[j[ ckij X[ fhecfjbo fbWY[Z m_j^ c_d_ckc ^WdZb_d] je Wle_Z i[]h[]Wj_ed e\ j^[ cWj[h_Wbi WdZ j^[ Z_ifbWY[c[dj e\ j^[ h[_d\ehY[c[dj+ @WY^ [b[c[dj ckij X[ YWij _d W Yedj_dkeki ef[hWj_ed m_j^ c_d_cWb _dj[hhkfj_ed X[jm[[d j^[ fbWY_d] e\ WZ`WY[dj fehj_edi e\ YedYh[j[ WdZ [WY^ bWo[h ckij X[ fbWY[Z WdZ Yedieb_ZWj[Z X[\eh[ j^[ fh[Y[Z_d] bWo[h ^Wi jWa[d _d_j_Wb i[j+

3+ Consolidation of Concrete s < c_d_ckc Wcekdj e\ l_XhWj_ed d[Y[iiWho je j^ehek]^bo Yedieb_ZWj[ j^[ YedYh[j[ ckij X[ ki[Z+ L<D ckij l[h_\o W hkXX[h YeWj[Z l_XhWjeh ^[WZ _i ki[Z m^[d [feno*YeWj[Z eh ej^[h YeWj[Z h[_d\ehY[c[dj _i ki[Z+

?+ Curing Requirements * >kh_d] h[gk_h[c[dji \eh ded*fh[ijh[ii[Z YedYh[j[ ckij X[ Wi if[Y_\_[Z _d j^[ YedjhWYj+ R^[d ij[Wc eh hWZ_Wdj ^[Wj Ykh_d] _i ki[Z) h[YehZ_d] j^[hcec[j[hi ckij X[ fhel_Z[Z Xo j^[ AWXh_YWjeh j^Wj ced_jehi j^[ j_c[,j[cf[hWjkh[ h[bWj_edi^_f j^hek]^ j^[ Ykh_d] f[h_eZ m^_b[ Whj_\_Y_Wb ^[Wj _i ki[Z+ O^[ L<D ckij l[h_\o j^Wj j^[ h[YehZ_d] j^[hcec[j[hi Wh[ fbWY[Z _d Yh_j_YWb beYWj_edi \eh ced_jeh_d] j^[ j_c[,j[cf[hWjkh[ h[bWj_edi^_f Zkh_d] j^[ Ykh_d] f[h_eZ+ <j b[Wij j^h[[ h[YehZ_d] j^[hcec[j[hi ckij X[ fbWY[Z Wj beYWj_edi m^[h[ j^[ Wdj_Y_fWj[Z ^[Wj ][d[hWj[Z Xo j^[ YedYh[j[ _i j^[ bem[ij WdZ ^_]^[ij `kij W\j[h _d_j_Wb YedYh[j[ i[j+ ?eYkc[djWj_ed \hec j^[ AWXh_YWjeh%i h[YehZ_d] j^[hcec[j[h ckij X[ ]_l[d je j^[ L<D \eh j^[_h h[l_[m+ O[cf[hWjkh[ h[gk_h[c[dji Zkh_d] j^[ Ykh_d] ef[hWj_ed ckij X[ _d WYYehZWdY[ m_j^ j^[ YedjhWYj if[Y_\_YWj_edi+

@+ Material Requirements s HWj[h_Wbi ckij c[[j j^[ h[gk_h[c[dji e\ j^[ YedjhWYj kdb[ii W MAD h[gk[ij_d] Wbj[hdWj[ cWj[h_Wbi ^Wi X[[d Wffhel[Z Xo j^[ @d]_d[[h+

A+ Shipping Requirements s @b[c[dji ckij WjjW_d j^[ h[gk_h[Z Yecfh[ii_l[ ijh[d]j^ Wi _dZ_YWj[Z Xo j[ij h[ikbji e\ L> Yecfh[ii_l[ ijh[d]j^ j[ij Yob_dZ[hi) m^_Y^ ^Wl[ X[[d YWij WdZ cWjY^ Ykh[Z \eh j^_i fkhfei[ Wi Z[iYh_X[Z f[h j^[ YedjhWYj+ O^[i[ Yob_dZ[hi ckij X[ YWij m_j^ c[jWb H?JO jW]i WdZ j^[ Yecfh[ii_ed j[ij_d] ckij X[ m_jd[ii[Z Xo j^[ L<D+

1+..+-2+ M[fehji

<+ O^[ @d]_d[[h cWo h[gk_h[ W f[h_eZ_Y ijWjki h[fehj \hec j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j8 j^[h[\eh[) Wbb h[fehji Wh[ h[gk_h[Z je X[ Yecfb[j[Z _d W j_c[bo WdZ ehZ[hbo cWdd[h ki_d] j^[ Wffb_YWXb[ \_bbWXb[ fehjWXb[ ZeYkc[dj \ehcWj &K?A' \ehci b_ij[Z X[bem j^Wj YWd X[

29

1+..

\ekdZ ed H?JOvi m[Xi_j[+ HWa[ [djh_[i Wi ieed Wi feii_Xb[ W\j[h Wd [l[dj eh Yedl[hiWj_ed je [dikh[ WYYkhWYo+ IkcX[h j^[ h[fehji Yedi[Ykj_l[bo kdj_b Yecfb[j_ed e\ j^[ meha+

=+ L<D ckij Yecfb[j[ Wd WYYkhWj[ WdZ Z[jW_b[Z WYYekdj e\ \WXh_YWj_ed \eh j^[ fhe`[Yj+ O^[ h[fehj ckij _dYbkZ[ W Z_iYkii_ed e\ \WXh_YWj_ed fhe]h[ii \eh Wbb Wif[Yji e\ j^[ meha+ Dj _i _dj[dZ[Z je X[ W Z[jW_b[Z h[YehZ e\ j^[ ijWjki e\ \WXh_YWj_ed WdZ iêkbZ _dYbkZ[ dkcX[h e\ [b[c[dji \WXh_YWj[Z) ZeYkc[djWj_ed e\ if[Y_\_YWj_ed WdZ fheY[Zkh[ Yecfb_WdY[ Wi m[bb Wi ZeYkc[djWj_ed e\ Yed\b_Yji) h[fW_hi) WdZ ej^[h fheXb[ci eh Z_iYkii_ed m^_Y^ YekbZ W\\[Yj j^[ fhe`[Yj _d WdomWo+ D\ \ehY[ WYYekdj meha _i jWa_d] fbWY[) ZeYkc[dj [WY^ ZWo j^Wj j^[ meha eYYkhi _d j^[ iêf WdZ m^_Y^ [b[c[dji Wh[ X[_d] meha[Z+

>+ ?eYkc[djWj_ed _i dej W ikXij_jkj[ \eh Wffhefh_Wj[ Z_Wbe]k[ m_j^ j^[ AWXh_YWjeh) Xkj iêkbZ fhel_Z[ W h[YehZ e\ _cfehjWdj Z_iYkii_edi+ Dd iec[ YWi[i) j^[ L<D _i ceh[ \Wc_b_Wh m_j^ j^[ [l[dji eh _iik[i WdZ j^[h[\eh[ iêkbZ h[l_[m WdZ Yecc[dj ed ZhW\j Yef_[i e\ j^[ NjhkYjkhWb AWXh_YWj_ed Pd_jvi Yehh[ifedZ[dY[+

?+ M[fehji ckij X[ Wii[cXb[Z _dje ed[ \WXh_YWj_ed _dif[Yj_ed fehjWXb[ ZeYkc[dj \ehcWj &K?A' \_b[ WdZ ijeh[Z _d H?JOvi Khe`[YjR_i[ ZeYkc[dj ijehW][ fhe]hWc f[h MDOT’s Structural Fabrication Unit’s E-Construction Process+ O^[ @d]_d[[h m_bb h[Y[_l[ W \WXh_YWj_ed _dif[Yj_ed c[cehWdZkc \hec j^[ NjhkYjkhWb AWXh_YWj_ed @d]_d[[h W\j[h \WXh_YWj_ed _dif[Yj_ed _i Yecfb[j[+ O^[ c[cehWdZkc _i \eh _d\ehcWj_edWb fkhfei[i WdZ _i dej ki[Z \eh WYY[fjWdY[+

@+ =[bem _i W b_ij e\ lWh_eki H?JO h[fehji,\ehci WdZ W Xh_[\ Z[iYh_fj_ed e\ j^[_h fkhfei[ WdZ ki[ h[gk_h[c[dj+ N_c_bWh \ehci YWd X[ ki[Z _d fbWY[ e\ j^[ ijWdZWhZ H?JO \ehc _\ dej[Z X[bem+

.+ Project Folder Checklist (Form 2001) s O^_i \ehc ckij X[ Yecfb[j[Z Xo L<D \eh [WY^ fhe`[Yj+ O^[ Y^[Yab_ij _i fbWY[Z ed jef e\ j^[ \WXh_YWj_ed _dif[Yj_ed \ebZ[h m^[d j^[ fhe`[Yj _i Yecfb[j[+

/+ Shop Inspection Report (Form 5617) – O^_i \ehc ckij X[ Yecfb[j[Z Xo L<D ed W m[[abo XWi_i \eh [WY^ fhe`[Yj WdZ iêkbZ YedjW_d W Xh_[\ dWhhWj_l[ e\ j^[ meha f[h\ehc[Z el[h j^[ h[fehj_d] f[h_eZ+ O^[ h[fehj ckij YedjW_d j^[ \ebbem_d] _d\ehcWj_ed7 R[Wj^[h YedZ_j_edi) [b[c[dji meha[Z ed) cWj[h_Wbi _dYehfehWj[Z _dje [b[c[dji &ckij ZeYkc[dj l_ikWbbo _dif[Yj[Z WdZ WYY[fj[Z') meha WYj_l_jo) dedYed\ehcWdY[i) i^_ff_d]) \ehY[ WYYekdj meha &hWh[') WdZ Wdoj^_d] [bi[ Z[[c[Z _cfehjWdj Xo j^[ L<D+

0+ Sample Identification (Form 1923) s O^_i \ehc ckij X[ ikXc_jj[Z m^[d cWj[h_Wb iWcfb_d] _i h[gk_h[Z ed W fhe`[Yj+ L<D ckij Yecfb[j[bo \_bb ekj j^[ \ehc WdZ a[[f W Yefo _d j^[ \WXh_YWj_ed _dif[Yj_ed \ebZ[h+

1+ Bar Reinforcement Report (Form 1985) s O^_i \ehc _i edbo ki[Z _\ L<D f[h\ehci L< l[h_\_YWj_ed _dif[Yj_ed ed XWh h[_d\ehY[c[dj \eh fh[\WXh_YWj[Z Xh_Z][ [b[c[dj ioij[ci &K=@N' eh ej^[h [b[c[dji j^Wj YedjW_d Yecfb[n h[_d\ehY[c[dj Wi Z_h[Yj[Z Xo j^[ @d]_d[[h+

5. Pre and Post Pour Inspection Checklist (Form 5616) s O^_i Y^[Yab_ij ckij X[ Yecfb[j[Z Xo L<D \eh W c_d_ckc e\ ed[ [b[c[dj f[h fhe`[Yj+ O^[ Y^[Yab_ij _i fbWY[Z _d j^[ \WXh_YWj_ed _dif[Yj_ed \ebZ[h m^[d j^[ fhe`[Yj _i Yecfb[j[+

3+ Field and Lab Test Report (Form 0590) s O^_i \ehc ckij X[ Yecfb[j[Z Xo L<D \eh [WY^ fekh m^_Y^ cWo YedjW_d i[l[hWb [b[c[dji+

30

1+..

4+ Repair Observation Report (Form 1981) s O^_i \ehc _i edbo ki[Z _\ L<D f[h\ehci L< l[h_\_YWj_ed _dif[Yj_ed ed h[fW_hi j^Wj ^Wl[ X[[d Wffhel[Z Xo j^[ @d]_d[[h+

5+ Material Source List (Form 0501) s O^_i \ehc _i i[dj _d Xo j^[ \WXh_YWjeh) j^[ L<D m_bb l[h_\o j^Wj j^[ \WXh_YWjeh \_bb[Z ekj j^[ \ehc Yecfb[j[bo) WdZ ZeYkc[dj j^[ XWi_i e\ WYY[fjWdY[ \eh Wbb cWj[h_Wbi+ D\ j^[h[ Wh[ Wdo cWj[h_Wbi j^Wj h[gk_h[ j[ij_d] j^[d j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j ckij X[ Yef_[Z ed j^[ Yecfb[j[Z HNG je YeehZ_dWj[ j^[ WYY[fjWdY[ j[ij_d]+

1+..+-3+ NjeYaf_b[ KWoc[dj

<+ O^_i ijeYaf_b[ fWoc[dj i[Yj_ed Z_h[Yji j^[ L<D ed j^[ h[gk_h[c[dji m^[d ijeYaf_b[ fWoc[dj _dif[Yj_ed _i h[gk[ij[Z Xo j^[ NjhkYjkhWb AWXh_YWj_ed Pd_j+ O^[ L<D ckij f[h\ehc j^[ \ebbem_d] ij[fi7

.+ Q[h_\o \WXh_YWj[Z cWj[h_Wb c[[ji Wffhel[Z iêf ZhWm_d]i &_\ Wffb_YWXb['8

/+ Q[h_\o ijeYaf_b[ gkWdj_jo WdZ _dYbkZ[ gkWdj_jo _d h[fehj8

0+ Q[h_\o cWj[h_Wb _i bWX[b[Z \eh H?JO ki[ edbo8

1+ Q[h_\o cWj[h_Wb _i Yehh[Yjbo ijeh[Z WdZ fhej[Yj[Z \hec j^[ [b[c[dji8 WdZ

2+ Khel_Z[ W h[fehj ikccWh_p_d] j^[ _dif[Yj_ed WdZ fhel_Z[ WZ[gkWj[ fêjei j^Wj h[fh[i[dj j^[ ][d[hWb YedZ_j_ed e\ j^[ [b[c[dji) êm j^[ovh[ X[_d] ijeh[Z) WdZ f_[Y[ cWhai+

1+..+-4+ <YY[fjWdY[

<+ O^[ AWXh_YWjeh _i h[gk_h[Z je fhel_Z[ j^[ L<D m_j^ W c_d_ckc e\ \_l[ &2' Yef_[i e\ j^[ =_bb e\ GWZ_d] \eh [WY^ i^_fc[dj+ L<D m_bb ijWcf [WY^ Yefo e\ j^[ =_bb e\ GWZ_d] m_j^ j^[ H?JO t<ffhel[Z \eh Pi[u ijWcf WdZ m_bb h[jW_d ed[ Yefo \eh j^[_h h[YehZi+ Dj _i j^[ AWXh_YWjehvi h[ifedi_X_b_jo je Z_ijh_Xkj[ j^[ h[cW_d_d] Yef_[i e\ =_bb e\ GWZ_d] je j^[ \ebbem_d] _dZ_l_ZkWbi7

.+ L<D

/+ >edjhWYjeh

0+ AWXh_YWjeh

1+ >edjhWYjeh

2+ OhkYa_d] YecfWdo

O^[ =_bb e\ GWZ_d] _i h[gk_h[Z je YedjW_d) Wj W c_d_ckc) j^[ \ebbem_d] _d\ehcWj_ed7

.+ N^_ff_d] ZWj[

/+ ?[iYh_fj_ed e\ YWh]e &gkWdj_jo) [b[c[dj i_p[) m[_]^j) [jY+'

0+ @b[c[dj kd_gk[ f_[Y[ cWha

1+ H?JO fhe`[Yj beYWj_ed &hekj[) Yheii heWZ,h_l[h) WdZ Y_jo'

2+ H?JO fhe`[Yj _d\ehcWj_ed &ijhkYjkh[ dkcX[h) Yedjheb i[Yj_ed) WdZ èX dkcX[h'

3+ HWdk\WYjkh[hvi dWc[ WdZ WZZh[ii

=+ <YY[fjWdY[ Yedi_iji e\ j^[ \ebbem_d] jme*fWhj fheY[ii7

.+ AWXh_YWj_ed Ddif[Yj_ed <YY[fjWdY[7 NjhkYjkhWb [b[c[dji ckij X[ _dif[Yj[Z Xo j^[ L<D W\j[h j^[o Wh[ beWZ[Z \eh i^_ff_d]+ D\ j^[ ijhkYjkhWb [b[c[dji c[[j j^[ YedjhWYj

31

1+..

h[gk_h[c[dji) j^[ L<D m_bb ijWcf j^[c t<ffhel[Z \eh Pi[u+ O^[ [b[c[dji ckij X[ ijWcf[Z t<ffhel[Z \eh Pi[u fh_eh je i^_ff_d]+ <ZZ_j_edWbbo) j^[ L<D ckij ijWcf Wj b[Wij \_l[ Yef_[i e\ j^[ =_bb e\ GWZ_d] j^Wj _i fh[fWh[Z Xo j^[ AWXh_YWjeh+ O^[ WffhelWb ijWcf _i \eh ki[ Xo j^[ ?[fWhjc[dj WdZ Ze[i dej h[b_[l[ j^[ >edjhWYjeh e\ j^[_h h[ifedi_X_b_jo je c[[j YedjhWYj h[gk_h[c[dji+

/+ Q_ikWb Ddif[Yj_ed &QD' <YY[fjWdY[7 O^[ @d]_d[[h ckij Yebb[Yj ed[ Yefo e\ j^[ijWcf[Z =_bb e\ GWZ_d] WdZ ki[ _j je l[h_\o j^[ Z[b_l[h[Z ijhkYjkhWb [b[c[dji+<ZZ_j_edWbbo) j^[ @d]_d[[h ckij l[h_\o j^Wj j^[ [b[c[dji Wh[ ijWcf[Z WdZ l_ikWbbo_dif[Yj j^[c \eh i_]di e\ ZWcW][ j^Wj cWo ^Wl[ eYYkhh[Z Wi W h[ikbj e\ i^_ff_d] WdZ^WdZb_d]+ O^_i l_ikWb _dif[Yj_ed i^ekbZ X[ ZeYkc[dj[Z _d j^[ \_[bZ _dif[Yjehvi ZW_boh[fehj+

32


V011717

REQUEST FOR INFORMATION PROCESS

PAGE 1 of 3


Structural Fabrication Request for Information Process

Description The purpose of this document is to provide the Michigan Department of Transportation (MDOT) with

statewide consistency managing and responding to a structural fabrication request for information (RFI).

MDOT’s Structural Fabrication Unit is responsible for implementing the Department’s quality assurance

program for structural elements that are required to be accepted based on “Fabrication Inspection” per

MDOT’s Materials Quality Assurance Procedures (MQAP) manual. MDOT utilizes vendor inspectors to

provide shop inspection for these structural elements. When information is requested, it is important for

MDOT to quickly respond to a RFI submittal in order to keep the project moving forward. This document is

broken down into the following sections:

1. Request for Information

2. RFI Report

3. RFI Submittal Process

4. Innovative Contracting

1. Request for Information Request for information is defined to be a request by the Fabricator seeking additional information or

proposing an alternate design, material, fabrication method, or inspection method for the structural

element. The Fabricator typically generates RFI submittals before shop drawings are produced, but they

are sometimes submitted after fabrication has begun. A RFI submittal is not to be confused with a

nonconformance report (NCR) that is defined to be an alteration in the work or a fabrication error that

results in the element not meeting project specifications. Each unique request should be submitted on a

separate RFI for housekeeping purposes.

The Structural Fabrication Unit is responsible for coordinating the RFI review process and should provide a

timely response or acknowledgement (explanation, decision, request for additional information, or

estimate of time needed to evaluate) within three business days after receiving the RFI submittal. The

Structural Fabrication Unit will distribute all RFIs that are design related to the Design PM for their

disposition and then the Design PM is responsible for engaging other MDOT areas, as applicable

(Roadside Development, Geometrics, etc.). MDOT will consider alternate fabrication methods or

configurations, materials, or inspection procedures proposed by the Fabricator provided the alternative

will result in improving or equaling the expected performance, maintenance, and longevity of the

structure; however, approval of a RFI may be contingent on a reduction in the contract unit price.

Contract modification due to approval of a RFI by the Fabricator requesting alternate material,

fabrication method, inspection method, or anything else that is not determined by the Engineer to be an

extra will be at no additional cost or time extension to MDOT. RFIs are resolved by providing an

appropriated response on the RFI form.

33


V011717


PAGE 2 of 3


2. RFI Report A RFI is generated by the Fabricator. The Fabricator is required to submit the RFI to MDOT as discussed in

Section 3 of this document.

MDOT has developed a standard Request for Information (Form 0558) form that should be used by the

Fabricator. Use of the form is recommended to facilitate a faster review process. RFIs submitted for

review are required to include, at a minimum, the following information:

" Follow MDOT’s file naming convention as shown on the RFI form;

" MDOT project information (structure number, control section, job number, project location, and

element mark);

" RFI number in ascending order for each project (resubmittals use a different RFI number);

" Clearly state what information is being requested or what is being proposed;

" Clearly state the required specifications if an alternate is being proposed;

" Include drawings (contract plan, sketches, etc.), numerous high resolution photos, product data

sheets, etc.;

" Indicate the urgency of a reply.

Approval of a RFI does not waive the contractual requirement to provide shop drawings prior to the start

of fabrication, nor is it sufficient information to allow MDOT’s quality assurance inspector (QAI) to stamp

elements approved for use. If the Fabricator elects to use an approved RFI then they need to

incorporate the RFI into the shop drawings for MDOT’s review and approval prior to the start of

fabrication. MDOT’s QAI is instructed to inspect using approved shop drawings and approved NCRs only.

The Fabricator is also required to obtain the Contractor’s acceptance of any contract modifications that

alter the finished product.

3. RFI Submittal Process Listed below is MDOT’s structural fabrication RFI submittal process:

1. Fabricator names RFI file per MDOT’s file naming convention shown on Form 0558.

2. Fabricator must send RFI to Structural Fabrication Unit and carbon copy the Engineer and Contractor. All correspondence to the Structural Fabrication Unit must be sent using the following email resource:

[email protected]

3. Structural Fabrication Unit distributes RFI to QAI and Design PM (if applicable) and begins reviewing.

4. Design PM distributes RFI to other areas (e.g. Geometrics, Load Rating, Roadside Development), as applicable, and provides all comments to Structural Fabrication Unit.

5. Structural Fabrication Unit provides response on RFI form via email to Fabricator and carbon copies the Engineer, Contractor, Design PM, and QAI.

34


V011717


PAGE 3 of 3


6. QAI places final RFI form and correspondence in the fabrication inspection file that will be stored in ProjectWise.

4. Innovative Contracting The request for information process described above applies to Design-Bid-Build projects. This section will

discuss subtle changes required to successfully submit RFIs for innovative contracting such as Design-Build

projects. Design-Build is an innovative construction method that pairs the Engineer of Record (EOR) with

the Contractor. The main difference between a Design-Build and a Design-Bid-Build project is that the

EOR on the Design-Build team is required to completely review and approve the RFI submittal prior to

MDOT’s review. Once the Design-Build team is satisfied with the submittal, the MDOT Design-Build Project

Manager (Design Build PM) acts as the MDOT RFI coordinator and distributes the submittal to the

Structural Fabrication Unit for review. The Structural Fabrication Unit returns any comments to the Design

Build PM. Once satisfied, the Structural Fabrication Unit stamps “Approved” on the RFI form. The Design

Build PM must be included on all correspondence related to a RFI, therefore Section 3 (RFI Submittal

Process) must be revised to reflect this for Design-Build projects.

35

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97A7E3? <A8BE@3G<BA

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EJ= ?@N>MDKODJI EJ= IPH=@M

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<ffhel[Z MAD) _\ _cfb[c[dj[Z Xo j^[ AWXh_YWjeh) ckij X[ _dYehfehWj[Z _dje j^[ i^ef ZhWm_d]i WdZ Wffhel[Z Xo j^[ @d]_d[[h fh_eh je j^[ ijWhj e\ \WXh_YWj_ed+

==N <ffhelWb =beYa

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Clear Form

36

V101915

NONCONFORMANCE POLICY

PAGE 1 of 5


Structural Fabrication Nonconformance Policy


statewide consistency in addressing material and fabrication nonconformance issues with structural steel

O\R ab`cQbcÒZ ^`SQOab Q]\Q`SbS SZS[S\ba+ C<EJja Ib`cQbcÒZ >OP`WQObW]\ K\Wb Wa `Sa^]\aWPZS T]`

W[^ZS[S\bW\U bVS <SÔ`b[S\bja _cOZWbg OaacÒ\QS ^`]UÒ[ T]` TOP`WQObW]\ W\a^SQbion and utilizes vendor

inspectors for inspection of structural steel and structural precast concrete elements at nationwide

fabrication facilities. When nonconforming material or fabrication issues are discovered the Structural

Fabrication Unit immediately notifies the Project Engineer (hereafter referred to as Engineer) overseeing

bVS Q]\ab`cQbW]\ ^`]XSQb ]T bVS RSTWQWS\QWSa+ Ab Wa bVS =\UW\SS`ja `Sa^]\aWPWZWbg b] `SXSQb ]` OQQS^b

nonconforming elements with consideration of imposing a negative price adjustment in accordance with

subsection 104.04 of the MDOT Standard Specifications for Construction. Bridge Field Services is available

to provide technical support to the Engineer when additional guidance is needed. Guidelines are

provided in this document for the Engineer and Structural Fabrication Unit to use when determining if a

price reduction is warranted. When a price reduction is warranted, the Structural Fabrication Unit

provides the recommended amount to ensure statewide consistency and alignment. Below is a list of the

structural elements inspected for acceptance by the Structural Fabrication Unit for which this document

applies (see contract documents for project specific information):

' Structural steel for bridges (plate, rolled, hollow structural shape, bridge tube railing, steel deck

grating, modular expansion joints, castings, forgings, etc.);

' Highway structures (sign structures, tower lighting units, mast arm traffic signals, DMS, etc.);

' Structural precast concrete (prestressed concrete beams, spun concrete poles, sound wall

panels/posts, MSE wall panels/posts, etc.);

' Precast concrete three-sided, arch, and box culverts (span lengths 20 feet and greater measured

parallel to the roadway centerline).

This document does not address fabricated elements cast by the contractor on the project site or non-

structural precast concrete (concrete pipe, manhole, etc.).

1. Control of Materials The service life of a highway is dependent upon the quality of the materials used in its construction as well

as the method of construction. Therefore, it is critical to ensure the materials incorporated into the work

meet the project specifications. Control of materials is discussed in subsection 105 of the MDOT 2012

Standard Specifications for Construction (hereafter referred to as Standard Specifications) with

information on approval of materials in subsection 105.05 and nonconforming materials in subsection

105.08. The Engineer may inspect materials that the contractor will incorporate into the work at any time

37

V101915


PAGE 2 of 5


and at any place during the preparation, storage, and use of the materials. The Engineer will perform

inspections of the materials, including sampling and testing, in accordance with the methods required by

the contract to determine if the material is approved for use. Approval of materials is discussed in the

<SÔ`b[S\bja CObS`WOZa GcOZWbg 8aacÒ\QS F`]QSRc`Sa CO\cOZ &CG8F'+

2. Nonconforming Materials i Acceptable and Unacceptable UseAb Wa bVS <SÔ`b[S\bja W\bS\b b] RWaQ]cÒUS bVS caS ]T \]\Q]\T]`[W\U [ObS`Wals from being incorporated

into the work even if they are found acceptable for use. Subsection 105.08 of the Standard

Specifications gives the Engineer the authority to either reject nonconforming materials or to allow the

nonconforming materials to remain in place. If materials are found to be unacceptable before or after

placement into the work, the Engineer may reject the materials, and the contractor must remove the

materials from the site at no cost to the Department. Materials that have been tested and approved at

their source or otherwise previously approved, but have become damaged or contaminated before use

in the project, are also subject to rejection by the Engineer.

Materials that are nonconforming, but determined by the Engineer to be acceptable for use may be

subject to a negative price adjustment. To ensure consistency in the decisions made for acceptance of

nonconforming material or workmanship, it is recommended the Engineer involve Bridge Field Services

before finalizing any decision. This communication will help keep the applicable technical sections of the

Bureau of Field Services informed about contractor or material problems that may require specification

changes, a Bridge Field Services Advisory, or discipline of a contractor. Additionally, this communication

will aid in the consistent treatment of nonconforming materials statewide. The Bureau of Field Services is

available to provide technical support if the Engineer has any questions regarding the acceptance or

rejection of nonc]\T]`[W\U [ObS`WOZa+ Ab Wa bVS =\UW\SS`ja `Sa^]\aWPWZWbg b] RSbS`[W\S eVSbVS` O

nonconforming material is acceptable for use; however, Bridge Field Services can assist with

recommendations.

2.1 Determining if Nonconforming Material can be Incorporated into the Work Good engineering judgment is required when making decisions on nonconforming materials. The

Engineer may choose to approve nonconforming materials, allow them to be incorporated into

the work, and impose a negative price adjustment. When making the decision to direct the

contractor to remove and replace the materials versus leave the materials in place, it is important

to consider the following:

' Safety;

' Long-term consequences on quality and durability;

' A[^ZWQObW]\a ]\ bVS ab`cQbcÒZ SZS[S\bjs life cycle costs, service life, serviceability, and

maintenance;

' Environmental and aesthetic considerations;

' A[ÔQba ]\ bVS ^`]XSQbja bÒTTWQ) abOUW\U) O\R Q]\ab`cQbW]\ bW[STÒ[Sa6

' Future costs associated with maintenance.

38


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2.2 Determination of Price Reductions After the Engineer has decided to allow nonconforming materials to remain in place, the

Structural Fabrication Unit will carefully evaluate each situation in deciding whether to

recommend a price reduction. The goal is to achieve statewide consistency in administering

price reductions for nonconforming materials that are allowed to remain place. The purpose of

the price reduction is to facilitate an environment that encourages the contractor to incorporate

materials meeting contract specifications and to make it fair for all contractors.

Results of retests and related quality tests should be considered. The following list includes some

examples of the types of factors the Structural Fabrication Unit will consider when deciding if a

price reduction is warranted:

' Has the contractor been conscientious to provide quality by carefully controlling materials

and construction operations?

' Has the contractor been proactive and made good use of quality control (QC) data to

maintain and improve quality?

' Did the contractor notify the Engineer of materials that needed to be tested in a timely

manner to ensure the test results would be reported prior to the materials being

incorporated?

' Did the Engineer process the test results within the industry accepted timeframe so the

contractor could make process or materials corrections?

' Upon becoming aware of a materials quality problem, has the contractor responded

quickly to correct it?

' Is the nonconforming test an isolated incident or a recurring situation?

' How does the nonconforming test compare to the rest of the project data:

o Have material test results been well within specification requirements or

consistently at the very limit of what is acceptable?

o How many tests are nonconforming versus how many tests have passed?

o How far out of specifications is the nonconforming test?

2.3 Nonconforming Structural Precast Concrete If the Engineer has decided to accept nonconforming material and it is determined that a

negative price adjustment is warranted then the final step is for the Structural Fabrication Unit to

determine a recommended price reduction. The following guidelines provide a list of common

nonconformance issues related to the structural precast concrete industry and are intended to

aid the Structural Fabrication Unit in determining the recommended price reduction. The goal of

these guidelines is to provide consistent price reductions independent of the type of project or

project office location.

The Engineer must justify and document the incorporation of any nonconforming materials into

the work. The Structural Fabrication Unit will provide the Engineer with the quantity and type of

\]\Q]\T]`[W\U [ObS`WOZ T]` bVS ^`]XSQb ]TTWQSja `SQ]`Ra+ E\Zg ]\S ^`WQS ORXcab[S\b aV]cZR PS

applied to a given quantity of material; however, if multiple nonconformance issues occur then

39


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the price reduction may be increased on a case by case basis. In general, if the quantity in

question is subject to more than one of the following price reductions then the greater price

reduction would apply.

Any structural precast concrete element judged to be structurally or otherwise unacceptable by

MDOT due to low strength, cracking, breakage, honeycombing, or other deficiency will be

rejected and replaced. Note that honeycombing with exposed prestressing strand automatically

falls into this category.

Any structural precast concrete element judged to be acceptable, but deficient by MDOT due to

any of the following issues will be subject to the pay deductions listed below. These guidelines for

standard deductions are intended to be applied to typical problem severity in the majority of

cases. In occasional cases where problem severity is lower or higher than typical, the pay

deduction may be decreased or increased, respectively. Standard deductions shown represent

a percentage of bid item price for the structural precast concrete element.

2.3.1 Nonconforming Compressive Strength Compressive strength below specified level at required test age for strand release,

stripping forms, shipping, etc. is subject to the greater of $500 or 20% deduction on the bid

item price if the elements are approved for use. This price reduction would apply for all

elements represented by the tested cylinders.

2.3.2 Nonconforming Fabrication Defects Price reduction for the following fabrication defects and nonconformance issues will be

recommended by the Structural Fabrication Unit and should be implemented by the

Engineer. The following table of deductions will be applied to infrequent occurrences of

the stated defects. In the event of repeated occurrences of the same defect, these

deductions will be doubled. Note that negative pay adjustments may be waived for

minor fabrication and nonconformance defects judged to be inconsequential. The

following price reduction percentages are deducted from the bid item price and are only

applicable to nonconforming structural precast elements determined by the Engineer to

be acceptable:

' Misalignment of form and soffit joints (1/8 inch or greater on flat surface) i 10%

deduction;

' Inadequately sealed joints with significant mortar washout i 10% deduction;

' Cracking/spalling caused by fabrication and curing i 10% deduction;

' Dimensional tolerance deviations outside contract documents i 10% deduction;

' Honeycombing i 10% deduction;

' * Curing temperature i 10% deduction;

' Broken/cracked components i 10% deduction.

* Structural precast concrete elements cured at elevated temperatures are suspect in

terms of durability. The Structural Fabrication Unit will make a recommendation to the

Engineer to either reject the element or accept it with a price reduction.

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2.3.3 Nonconforming Miscellaneous Items The Engineer must determine the quantity of nonconforming material. Only one price

adjustment will be applied to a given quantity of material. If the quantity in question is

subject to more than one of the following conditions, apply the adjustment with the

greater price reduction.

2.3.4 Minor Nonconformance If the structural element does not conform to the requirements of the contract, but is

accepted, apply one of the following two price reductions (if not already covered in part

2.3.1 or 2.3.2):

1. 20% price reduction on the bid item price;

2. 50% price reduction on all material (invoice) costs utilized to fabricate the structural

precast concrete element.

2.3.5 Major Nonconformance The Engineer should not pay for elements determined by the Department to be in major

nonconformance with the contract requirements.

2.4 Nonconforming Structural Steel Due to the specialized nature and track record of structural steel fabrication, acceptable

nonconformance rarely lends itself to recommended price reductions. In general, deficient

structural welds can be easily replaced and the homogenous nature of steel typically means if

the material does not meet specification then it is rarely accepted even with a price reduction.

However, the Structural Fabrication Unit would review and provide a recommended price

reduction to the Engineer on a case by case basis depending on the nature of the deficiency,

recurrence, etc. Dimensional tolerance deviations outside the contract documents is an example

of a workmanship nonconformance subject to a 10% price deduction from the bid item price if

the structural steel element is determined by the Engineer to be acceptable.

2.5 Special Cases For other nonconforming issues not covered above, consult personnel in the appropriate area of

the Bureau of Field Services for guidance. Some examples of items in which it may be

unacceptable to leave the nonconforming item in place, even at reduced cost, include the

following:

' Bar reinforcement;

' Anchor bolts;

' High strength bolts+

41


V092517

NONCONFORMANCE PROCESS

PAGE 1 of 6


Structural Fabrication Nonconformance Reporting Process


statewide consistency managing and responding to a structural fabrication nonconformance report

(NCR). B;DIi_ H`âOà^MX =MNÛOMÙ[Z JZU` U_ ^Q_\[Z_UNXQ R[^ UY\XQYQZÙZS `TQ ;Q\M^`YQZì_ ]aMXUè

assurance program for structural elements that are required to be accepted based on g=MNÛOMÙ[Z

@Z_\QOÙ[Zh \Q^ B;DIi_ BM`QÛMX_ FaMXUè 7__a^MZOQ E^[OQPa^Q_ %BF7E& YMZaMX. MDOT utilizes vendor

inspectors to provide shop inspection for these structural elements. When nonconformance occurs, it is

important for MDOT to quickly respond to a NCR submittal to keep the project moving forward. This

document is broken down into the following sections:

1. Nonconformance

2. QC Nonconformance Report

3. QA Nonconformance Report

4. NCR Submittal Process

5. MDOT Standard Repair Procedures

6. Innovative Contracting

1. Nonconformance Nonconformance is defined to be an alteration in the work or a fabrication error that results in the

element not meeting project specifications. A NCR is not to be confused with a request for information

(RFI) that is defined to be a request by the Fabricator seeking additional information or proposing an

alternate material, fabrication method, or inspection method. A RFI is typically submitted before

fabrication work begins, whereas a NCR is submitted after a nonconformance is observed by quality

control (QC). Nonconformance renders the affected element unacceptable until such time as the issue

is referred to MDOT for disposition. Nonconformance that results in the Fabricator rejecting an element

does not require a NCR to be submitted for review; however, MDOT does request the Fabricator to send

our quality assurance inspector (QAI) written correspondence that clearly documents who rejected the

element, why it was rejected, when it was rejected, and proposed changes to the piece mark naming

convention for the fabrication inspection records.

Nonconformance is generally defined to be material or workmanship in nature and is further classified by

MDOT to be minor or major. Minor nonconformance can be repaired by the Fabricator using a

preapproved MDOT standard repair procedure that can be found in the MDOT Structural Precast

Concrete Standard Repair Program and does not need to be approved by MDOT on a case by case

basis throughout the project. Major nonconformance can typically be repaired by the Fabricator using a

MDOT standard repair procedure that can be found in the MDOT Structural Precast Concrete Standard

Repair Program and does need to be approved by MDOT on a case by case basis throughout the

42

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project. Below are common minor nonconformances that can be repaired using a preapproved MDOT

standard repair procedure:

' Cosmetic and in-process weld defects;

' Concrete air hole;

' Epoxy coated reinforcing steel damage;

' Coating damage;

' Hot-dip galvanizing damage.

Examples of major nonconformances include, but are not limited to the following:

' Buy America;

' Material specifications;

' Element dimensions;

' Unauthorized repairs;

' NCR corrective action without adequate notification;

' Coating system requirements;

' Unauthorized welds;

' Defective structural welds;

' Unqualified welder or welding operator;

' Welding without approved weld procedure specifications (WPS);

' Overheating steel and not maintaining preheat;

' Fresh concrete properties;

' Strength requirements;

' Concrete curing requirements;

' Honeycombing, voids, and concrete damage (except air holes).

The QAI should obtain clarification from the Structural Fabrication Unit if the QAI has questions regarding

the proper disposition method for nonconformances. All nonconformance issues observed by the QAI

must be brought to the attention of the Fabricator immediately upon discovery; however, the QAI must

not direct corrective action. The QAI must notify the Structural Fabrication Unit immediately if the

Fabricator fails to take corrective action or continues to fabricate nonconforming elements. Verbally

notifying the Fabricator of nonconformance is sometimes sufficient; however major nonconformance

issues should always be followed up in writing to the Fabricator via email with a carbon copy to the

Structural Fabrication Unit. The Structural Fabrication Unit will decide if the Fabricatori_ [\Q^M`U[Z_

warrant notifying the MDOT Construction Engineer (Engineer) and MDOT Design Project Manager (Design

PM) to prevent schedule delays or potential claims. An internal conference call amongst the Structural

Fabrication Unit, Engineer, Design PM, and QAI may be needed to better understand the issue and to

discuss /,16KG 5HFI9HIF7A -78F?97H?DC 0DC9DC=DFB7C9< 2DA?9J to ensure statewide consistency with

acceptance of nonconforming materials and potential price reductions if nonconforming elements are

permitted to be incorporated into the project.

43


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The Structural Fabrication Unit is responsible for coordinating MDOTs NCR review process and should

provide a timely response or acknowledgement (explanation, decision, request for additional

information, or estimate of time needed to evaluate) within three business days after receiving the NCR

submittal. The Structural Fabrication Unit will distribute all NCRs that are design related to the Design PM

for their disposition and then the Design PM is responsible for engaging other MDOT areas (Roadside

Development, Geometrics, etc.), as applicable. All NCRs M^Q ^Q]aU^QP `[ NQ _`MY\QP g7\\^[bQPh by the

Structural Fabrication Unit on the coversheet if they are found to be acceptable to MDOT.

Unacceptable NCRs are returned to the Contractor with an appropriate response MZP _`MY\QP gC[`

7\\^[bQPh. Corrective action that requires use of a weld procedure specification (WPS) will require the

Structural Fabrication Unit to stamp the WPS in addition to the NCR.

2. QC Nonconformance Report QC NCRs are generated by the Fabricator after their QCI observes a nonconformance during their

inspection. The Fabricator is required to submit the NCR to MDOT as discussed in Section 4 of this

document if they intend to have the element considered by MDOT to be incorporated into the project.

Although not required, it is highly recommended that the QCI discuss the NCR submittal with the QAI to

ensure it is in general conformance with MDOT requirements. The QAI should not review the actual NCR

at this point in time since they will be asked to verify that the NCR is accurate by the Structural Fabrication

Unit after the Contractor submits it to MDOT.

MDOT has developed a standard Nonconformance Report (Form 0559) that should be used by the

Fabricator. Use of the form is recommended to facilitate a faster review process. NCRs submitted for

review are required to include, at a minimum, the following information:

' =[XX[c B;DIi_ RUXQ ZMYUZS O[ZbQZ`U[Z as shown on the NCR form;

' MDOT project information (structure number, control section, job number, project location, and element mark);

' NCR number in ascending order for each project (resubmittals use the same NCR number, but would have a different revision number);

' Clearly state the nonconformance;

' State the reason for nonconformance;

' State measures to prevent nonconformance from occurring again;

' Include supporting documentation (marked up shop drawings, QC reports, WPS, PQR, numerous high resolution photos showing all locations proposed to be repaired, etc.);

' State proposed corrective action (repair procedure, NDE, MDOT standard repair procedure, etc.);

' Indicate the urgency of a reply.

The Fabricator must notify the QAI, prior to performing repairs to the nonconforming element, so MDOT

has the opportunity to witness the repair. Elements containing repairs performed without adequate

notification for QA inspection may not be approved for use. All nonconformances must be properly

resolved before the element can be considered for acceptance.

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3. QA Nonconformance Report It is not common for MDOT to write a NCR; however, a QA NCR could be issued due to the following

reasons:

1. Fabricator does not acknowledge a material or workmanship nonconformance.

2. QAI verification inspection results in major nonconformance missed by QCI during their inspection.

The Structural Fabrication Unit uses the standard Quality Assurance Nonconformance Report (Form 0560)

for a QA NCR and submits the completed form to the Engineer and Design PM for their review and

subsequent discussion. It is important for QA to document when QC is ineffective so the appropriate

quality management system organization (AISC, NPCA, and PCI) specified by MDOT in the contract

documents can follow up with the complaint. The Fabricator is required to respond to the QA NCR by

either submitting their own NCR acknowledging they are in agreement with the QA NCR or in writing that

they are in disagreement. The Fabricatori_ C9G U_ ^Q]aU^QP `[ UZOXaPQ MXl of the information stated in

Section 2 of this document. A conference call may be requested by the Structural Fabrication Unit

between the Engineer, QAI, Contractor, Fabricator, and QCI to discuss the NCR.

Once all elements have been re-inspected by the QCI, they must notify the QAI via email or by submittal

of the QC report that the QC inspection is complete for the elements under consideration. The QAI will

start the QA verification inspection again and if major nonconformances are found then the process will

repeat itself. It is important to note that the QAI must not perform their QA verification inspection until

after QCI notifies them via email or by submittal of the QC report that their QC inspection is complete for

the elements under consideration. This prevents QA from inspecting prior to QC.

4. NCR Submittal Process AU_`QP NQX[c U_ B;DIi_ structural fabrication NCR submittal process:

1. Fabricator ZMYQ_ C9G RUXQ \Q^ B;DIi_ RUXQ ZMYUZS O[ZbQZ`U[Z shown on Form 0559.

2. Fabricator must send NCR to the Structural Fabrication Unit and carbon copy the Engineer and Contractor. All correspondence to the Structural Fabrication Unit must be sent using the following email resource:

[email protected]

3. Structural Fabrication Unit distributes NCR to QAI and Design PM (if applicable) and begins reviewing.

4. Design PM distributes NCR to other areas (e.g. Geometrics, Load Rating, Geotechnical, Roadside Development), as applicable, and provides all comments to the Structural Fabrication Unit.

5. Structural Fabrication Unit provides response on NCR via email to Fabricator and carbon copies the Engineer, Contractor, Design PM, and QAI.

6. QAI places final NCR and correspondence in the fabrication inspection file that will be stored in ProjectWise.

45

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5. MDOT Standard Repair Procedures The Structural Fabrication Unit has developed standard repair procedures to expedite the review process

for common repairs to structural elements. These repair procedures have been reviewed by industry and

should be used by Fabricators when applicable to speed up the review process. Standard repair

procedures for structural steel have not been developed at the time of this document, but will be added

in subsequent revisions.

Listed below are the MDOT standard structural precast concrete repair procedures, which can be found

in /,16KG 5HFI9HIF7A 2F<97GH +DC9F<H< 4<E7?F .I?;7C9< ,D9IB<CH on B;DIi_ H`âOà^MX =MNÛOMÙ[Z

JZUì_ cQN_U`Q:

1. * Procedure #1: Air Hole

2. Procedure #2: Minor Surface Defect

3. Procedure #3: Major Surface Defect

4. * Procedure #4: Hot-Dip Galvanize

5. Procedure #5: Fiber Reinforced Polymer

6. * Procedure #6: Epoxy Bar

7. Procedure #7: Epoxy Injection

* Indicates MDOT standard repair procedure for minor nonconformance. These procedures can be

preapproved by the Structural Fabrication Unit before the project begins and do not need to be

approved on a case by case basis throughout the project. Fabricator is required to notify the QAI when

the repairs will be performed so they can have the opportunity to witness. Fabricator must have copies

of the standard repair plan with them at all times while performing the repair.

Listed below is the MDOT standard structural steel repair procedure:

1. Procedure #1: Shop Coating Repairs

6. Innovative Contracting The nonconformance reporting process described above applies to Design-Bid-Build projects. This

section will discuss subtle changes required to successfully submit NCRs for innovative contracting such as

Design-Build projects. Fabrication nonconformance should already be addressed in the Design-Build

Design Quality Manual (DQM)5 T[cQbQ^( B;DIi_ H`âOà^MX =MNÛOMÙ[Z C[nconformance Policy provides

MDOT with statewide consistency in addressing material and fabrication nonconformance issues.

Design-Build is an innovative construction method that pairs the Engineer of Record (EOR) with the

Contractor. The main difference between a Design-Build and a Design-Bid-Build project is that the EOR

on the Design-Build team is required to completely review and approve the NCR submittal prior to

B;DIi_ ^QbUQc* DZOQ `TQ ;Q_USZ-Build team is satisfied with the submittal, the MDOT Design-Build Project

Manager (Design Build PM) acts as the MDOT NCR coordinator and distributes the submittal to the

Structural Fabrication Unit for review. The Structural Fabrication Unit returns any comments to the Design

46


V092517


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Build PM. If satisfied, the Structural Fabrication Unit stamps gApprovedh _`MY\ [Z `TQ C9G* The Design

Build PM must be included on all correspondence related to a NCR, therefore Section 4 (NCR Submittal

Process) must be revised to reflect this.

47

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49


V103015

STD REPAIR GUIDANCE DOCUMENT

PAGE 1 of 9


Structural Precast Concrete Repair Guidance Document

Description The purpose of this guidance document is to provide the Michigan Department of Transportation (MDOT)

with statewide consistency reviewing and approving structural precast (prestressed and non-prestressed)

concrete repair submittals. It provides internal guidance for the minimum acceptable procedures to

ensure a durable repair that will preserve the integrity of the fabricated structural element. MDOT uses a

minimum 75-year bridge design life and any proposed repairs to the element should be consistent with the

original design. MDOT’s Structural Fabrication Unit is responsible for implementing the Department’s quality

assurance program for structural elements required to be accepted based on “Fabrication Inspection” per

MDOT’s Materials Quality Assurance Procedures (MQAP) manual and utilizes vendor inspectors to provide

the shop inspection. The fabricator is required to notify MDOT’s quality assurance inspector (QAI) prior to

performing any approved repairs for the opportunity to perform verification inspection.

Structural precast concrete elements may contain defects from the fabrication process or are often

damaged during formwork removal or shipping and handling. The fabricator’s quality control inspector

(QCI) is required to notify the MDOT QAI of all defects/damages that occur to the elements. The

fabricator is responsible for submitting a NCR with proposed corrective action (repair plan) to bring the

element into conformance if it is to be considered for incorporation into the project. MDOT will consider

the corrective action and provide a response to the contractor in accordance with MDOT’s Structural

Fabrication Nonconformance Reporting Process. Submittal of a NCR does not guarantee approval since

the defect/damage may have resulted in structural, durability, or aesthetic concerns that is not

addressed by the repair plan. Repairs are not permitted to be performed until after the NCR has been

approved and the QAI has been notified in a timely manner when the repair will take place. See MDOT’s

Structural Fabrication Nonconformance Policy for more information on when nonconformances can be

incorporated into the project and associated price reductions. See MDOT’s Structural Fabrication

Nonconformance Reporting Process for more information on what NCR’s are and how to submit them.

Both of these documents can be found on the MDOT Structural Fabrication Unit website located inside

the Structural Precast Concrete Fabrication Inspection Portfolio document.

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50


V103015


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wyggiww>#

41 FEWJ#LF5#+jsvqivp}#Xlsvsg,#jsv#szivlieh#wxvygxyvep#vitemvw#erh#{lir#pexi|#vitemv#qm|xyviw#ger�x#fi#fmvh0

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61 Rsr0wxvygxyvep#gvego#vitemv>#Liepiv#wiepiv#mw#e#kssh#rsr0wxvygxyvep#gvego#vitemv#xs#ijjigxmzip}#mqtihi#

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71 Wiepmrk#i|tswih#ekkvikexi#we{#gyxw>#Liepiv#wiepiv#mw#e#kssh#tvshygx#jsv#wiepmrk#e#we{#gyx#ihki1##[exiv#

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81 Gsexmrk#i|tswih#wxiip#vimrjsvgiqirx>#Epyqmryq#qewxmg#its|}#mw#e#kssh#gsexmrk#w}wxiq#xs#gsex#i|tswih#

wxiip#vimrjsvgiqirx1#Xli#its|}#qywx#fi#jvsq#e#qeryjegxyviv#xlex#mw#pmwxih#mr#QHSX�w#QWK#UTP#+Wigxmsr#

=48>#Gsexmrk#W}wxiqw#jsv#Wxiip#Wxvygxyviw,1##Xli#wxiip#qywx#fi#gpierih#xs#WWTG#WT#9#sv#fixxiv1##Xli#

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its|}#+wii#qeryjegxyviv#jsv#vigsqqirhih#qmr2qe|#HJX,#wlsyph#fi#ettpmih#{mxl#xli#tvstiv#gyvi#xmqi#

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vimrjsvgiqirx1#

#

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Appendix A – Air Hole

#

Figure 1. Air holes greater than 3/4” in any direction and greater than 3/8” deep.

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Appendix B – Minor Surface Defect

#

Figure 2. Rubber gasket crease

53


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Figure 3. Moderate honeycombing along MI 1800 girder.

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Figure 4. Moderate honeycombing at end of PCI beam.

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Appendix C – Major Surface Defect

Figure 5. Broken corner at end of PCI beam.

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# #

Figure 6. Spalled bottom corner at end of box beam.

#

#

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# #

Figure 7. Spalled bottom corner at end of box beam. #

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Standard Structural Precast Concrete Repair Procedure #1: Air Hole

Description This structural precast concrete repair procedure is for patching air holes that exceed acceptable

dimensional tolerances. The repair plan is in accordance with subsections 406 and 708 of the 2012

Michigan Department of Transportation Standard Specifications for Construction (MDOT SSC) as

applicable.

The Type R-2 mortar used for patching air holes must be selected from the following locations:

" Cement: Approved Manufacturer or Test

" White Cement: Visual inspection

" Fine aggregate (2NS or 2MS): Prequalified Aggregate Source or Test

" Air entrainment: Qualified Products List

Procedure Below is the standard repair procedure for air holes:

1. Immediately patch all air holes larger than 3/4 inch in any direction and greater than 3/8 inch deep

with Type R-2 mortar after removing forms.

2. Perform the following steps prior to patching air holes if they are not filled immediately after forms are

removed:

o Flush the area with minimum 2500 psi pressurized clean water.

o Remove excess water from patch area by blasting with minimum 90 psi oil-free compressed air to

produce a saturated surface dry condition immediately prior to application of mortar.

3. Place mortar when substrate is at least 40 degrees, and maintain a temperature of at least 40 degrees

Fahrenheit during the placement and curing period.

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Standard Structural Precast Concrete Repair Procedure #2: Minor Surface Defect

Description This structural precast concrete repair plan is for minor surface defects defined to have a patch depth of

less than 1.5 inches. This repair plan is in accordance with the following subsections of the 2012 Michigan

Department of Transportation Standard Specifications for Construction (MDOT SCC):

" 712.03.F.2 - Hand Chipping Concrete Other Than Deck Concrete;

" 712.03.O - Mixing, Placing, Finishing, and Curing Concrete Patches;

" 712.03.R - Cold Weather Limitations for Placing SFMC or LMC Overlay Mixtures; and

" 712.03.S - Hot Weather Limitations for Placing Overlay Mixtures.

The latex bonding agent and cement used for patching mixtures must be selected from an Approved

Manufacturer in the MDOT Materials Source Guide (MSG). The aggregate must be from a MDOT

prequalified source or tested for acceptance.

Procedure Below is the standard repair procedure for minor surface defect:

1. Remove unsound or loose concrete with air hammers (15 pound class or smaller) or grinding. Saw-

cut areas requiring patching to an edge depth of at least ½ inch. Patch area must have vertical

edges (normal to the surface) and re-entrant corners rounded with a minimum 1 inch radius. Ensure

there are no voids or delaminated concrete by sounding. Clean exposed areas by sandblasting

to provide an anchor profile.

2. Remove loose material from patch area by blasting with minimum 90 psi oil-free compressed air.

Flush the area with minimum 3000 psi pressurized clean water. Remove excess water from patch

area by blasting with oil-free compressed air immediately prior to application of patching material.

3. Drill galvanized or epoxy coated anchors into the repair area spaced 2-3 inches apart and use

coated tie wire to create a floating mesh with spaces large enough for latex repair mixture to flow

through. Provide at least 1 inch concrete clear cover over the anchors and tie wire. Use extreme

care not to damage mild reinforcing steel or prestressing strand.

4. Patch the area with a F-L patching mixture in accordance to Table 703-1 (Structures Patching

Mixtures) of the 2012 MDOT Standard Specifications for Construction. Maintain a SSD (saturated

surface dry) condition prior to placing patching mixture. Vibrate forms or use a tamping rod to

consolidate the concrete patch.

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5. Place a layer of wet burlap immediately over the finished concrete patch. Burlap must be soaked

in water for at least 12 hours prior to placing patching mixture. Place a 4-mil thick layer of

polyethylene film immediately over the burlap to protect the top surfaces from evaporation.

6. Wet cure patches using burlap and polyethylene for 48 hours and allow concrete to air cure for an

additional 48 hours.

7. Air and concrete substrate temperatures must be at least 40o F and rising, but below 85oF. The

forecast air temperature during the curing period must be 35o F or higher. Use insulating blankets if

the curing period forecasted (or actual) air temperature is below 45o F.

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Standard Structural Precast Concrete Repair Procedure #3: Major Surface Defect

Description This structural precast concrete repair plan is for major surface defects defined to have a minimum patch

depth of 1.5 inches. This repair plan is in accordance with the following subsections of the 2012 Michigan

Department of Transportation Standard Specifications for Construction (MDOT SSC):

# 712.03.F.2 - Hand Chipping Concrete Other Than Deck Concrete;

# 712.03.O - Mixing, Placing, Finishing, and Curing Concrete Patches;

# 712.03.R - Cold Weather Limitations for Placing SFMC or LMC Overlay Mixtures; and

# 712.03.S - Hot Weather Limitations for Placing Overlay Mixtures.

The latex bonding agent and cement used for patching mixtures must be selected from an Approved

Manufacturer in the MDOT Materials Source Guide (MSG). The aggregate must be from a MDOT

prequalified source or tested for acceptance.

Procedure Below is the standard repair procedure for major surface defect:

1. Remove unsound or loose concrete with air hammers (15 pound class or smaller) or grinding. Saw-

cut areas requiring patching to an edge depth of at least ½ inch. Patch area must have vertical

edges (normal to the surface) and re-entrant corners rounded with a minimum 1 inch radius. Ensure

there are no voids or delaminated concrete by sounding. Clean exposed areas by sandblasting

to provide an anchor profile.

2. Do not damage any prestressing strand or mild steel reinforcement. If mild steel reinforcement is

exposed, remove concrete to provide ¾ to 1 inch of clearance around the steel for anchoring.

3. Remove loose material from patch area by blasting with minimum 90 psi oil-free compressed air.

Flush the area with minimum 3000 psi pressurized clean water. Remove excess water from patch

area by blasting with oil-free compressed air immediately prior to application of patching material.

4. Drill galvanized or epoxy coated anchors into the repair area spaced 2-3 inches apart and use

coated tie wire to create a floating mesh with spaces large enough for latex repair mixture to flow

through. Provide at least 3/4 inch concrete clear cover over the anchors and tie wire. Use extreme

care not to damage mild reinforcing steel or prestressing strand.

5. Repair damaged epoxy coating in accordance with subsection 706.03.E.8 of the MDOT SSC.

6. Patch the area with a C-L patching mixture in accordance to Table 703-1 (Structures Patching

Mixtures) of the 2012 MDOT Standard Specifications for Construction. Maintain a SSD (saturated

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surface dry) condition prior to placing patching mixture. Vibrate forms or use a tamping rod to

consolidate the concrete patch.

7. Place a layer of wet burlap immediately over the finished concrete patch. Burlap must be soaked

in water for at least 12 hours prior to placing patching mixture. Place a 4-mil thick layer of

polyethylene film immediately over the burlap to protect the top surfaces from evaporation.

8. Wet cure patches using burlap and polyethylene for 48 hours and allow concrete to air cure for an

additional 48 hours.

9. Air and concrete substrate temperatures must be at least 40o F and rising, but below 85oF. The

forecast air temperature during the curing period must be 35oF or higher. Use insulating blankets if

the curing period forecasted (or actual) air temperature is below 45oF.

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Standard Structural Precast Concrete Repair Procedure #4: Hot-Dip Galvanize

Description The following plan is for the repair of hot-dip galvanized components and is in accordance with

subsection 716.03.E of the 2012 Michigan Department of Transportation Standard Specifications for

Construction (MDOT SSC) and ASTM A780-09.

Procedure Below is the standard repair procedure for hot-dip galvanizing. The fabricator must select a zinc-rich paint

that meets ASTM A780 requirements and the following procedures:

1. Prepare the damaged galvanized area in accordance with paint manufacturer’s instructions or as

stated herein, whichever is stricter. Surface preparation must extend into the undamaged

galvanized coating to ensure a smooth reconditioned coating can be effected.

2. Surfaces to be reconditioned with paints containing zinc dust shall be clean, dry, and free of oil,

grease, preexisting paint, and corrosion by-products in accordance to SSPC-SP1 (Solvent Cleaning).

3. Clean the surface to bare metal, in accordance with SSPC-SP10 (Near-White Blast Cleaning) or

SSPC-SP11 (Power Tool Cleaning to Bare Metal). Use a grinder and wire wheel to grind burrs, fins,

tears, slivers, irregularities, or sharp edges. Sharp corners must be “broken” to ensure adequate

edge dry film thickness.

4. Use a clean cloth to remove any contaminant from the area being repaired. Oil free pressurized air

(90 psi minimum) must be used to remove any dust or any other particles.

5. If the area to be repaired includes welds, first remove all weld flux residue and weld spatter (of a

size that cannot be removed by wire brushing or blast cleaning) by mechanical means such as

chipping, grinding, or power scaling.

6. Hand coat the area according to the paint manufacturer’s instructions or as stated herein,

whichever is stricter.

7. Allow adequate cure time before recoating or placing the repaired component into service in

accordance with paint manufacturer’s product data sheet.

8. Use a magnetic, electromagnetic, or eddy-current gage to measure dry film thickness in

accordance with SSPC-PA2 (Measurement of Dry Paint Thickness with Magnetic Gages). QC must

calibrate the gage prior to each use. The repaired area must have a coating thickness of 1.5 times

the thickness or thickness equivalent specified or 5 mils, whichever is greater. Spot or area

measurements, as applicable, must be taken in accordance with the SSPC– PA 2 (Required Number

of Measurements for Conformance to a Thickness Specification). Record thickness measurements

for the job file on QC reports and provide to MDOT’s QAI.

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Standard Structural Precast Concrete Repair Procedure #5: Fiber Reinforced Polymer System

Description The following repair plan is for elements required to be reinforced with a fiber reinforced polymer (FRP)

sheet and adhesive composite system due to surface defect, honeycombing, damage, etc. and would

be used in conjunction with another MDOT standard structural precast concrete repair procedure or

approved unique repair procedure. This FRP repair plan is in accordance with the latest Michigan

Department of Transportation Special Provision for Fiber Reinforced Polymer System for Prestressed

Concrete Beam Repair (hereafter referred as FRP SP). A MDOT approved FRP system from Table 1 of the

FRP SP must be selected.

Submit the following items for MDOT’s review and approval:

1. FRP manufacturer’s product data sheet for the following: sheet, resin, and protective top coat;

2. Concrete surface coating manufacturer’s product data sheet, federal color number, and swatch

of the color proposed for coating. The coating color must match the color of the beam unless the

beam will be concrete surface coated, which would require the coating color to match the

concrete surface coating.

3. Manufacturer’s recommended installation procedures;

4. Details of any construction device that may be attached to the structure during construction;

5. Quality control inspector (QCI) information (at a minimum the full name, FRP training, and FRP work

history) for individual responsible for inspection and fabricator acceptance of FRP sheet and

adhesive composite system; and

6. FRP manufacturer’s on-site technical representative trained in the application of FRP sheet and

adhesive composite system installation on concrete substrate. Representative must be physically

on-site during startup of the FRP installation process to assist the fabricator and answer questions

from the Department’s representative.

Procedure Below is the standard repair procedure for the FRP sheet and adhesive composite system. In general, the

manufacturer’s recommended installation procedures must be followed. In the event of a conflict, the

more strict procedures must be adhered to:

1. Verify latex repair patches have been wet cured for 48 hours and air cured for 48 hours prior to

installation of FRP sheet and adhesive composite system.

2. Grind all rough edges on latex repair patches smooth after they have completely cured.

3. Remove concrete dust from surface by blasting with minimum 90 psi oil-free compressed air.

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4. Verify environmental conditions (dew point, humidity, concrete moisture content, and concrete

substrate temperature) are within the FRP SP prior to placing primer and FRP sheet. Fabricator’s QCI

must possess one of the following endorsements:

a. National Association of Corrosion Engineers (NACE) – National Coating Inspector Training

and certification Program Session I: Coating Inspection Training;

b. SSPC-C1 Fundamentals of Protective Coatings for Industry for Industrial Structures; or

c. National Highway Institute (NHI) – Bridge Coating Inspection Course.

5. Apply the FRP primer and FRP sheet in accordance with the FRP SP.

6. FRP sheet must extend past the patch area by at least 3 inches in all directions, but extend across

the entire bottom flange and up both sides of the web to the bottom of the top flange.

7. FRP sheet must be placed with fiber orientation perpendicular (90 degrees) to the beam’s

longitudinal axis.

8. Allow at least 24 hours for initial resin to cure prior to performing direct adhesion testing in

accordance with ASTM D7522.

9. Completely cure the FRP sheet and adhesive composite system per the manufacturer’s

recommendations before applying the protective top coat per the manufacturer’s

recommendations.

10. After curing, check entire FRP wrap for any delamination by acoustic tap inspection per the FRP SP.

11. Use the project’s Special Provision for Concrete Surface Coating, if available, to coat the FRP system

in accordance with the manufacturer’s product data sheet except as modified by subsection 716

of the MDOT SSC. If the project does not have concrete surface coating then a special provision

will be provided.

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Standard Structural Precast Concrete Repair Procedure #6: Epoxy Repair

Description The following plan is for the repair of epoxy coated reinforcing steel and is in accordance with subsection

706.03.E.8 of the 2012 Michigan Department of Transportation Standard Specifications for Construction

(MDOT SSC) and ASTM A775.

Procedure Below is the standard repair procedure for epoxy coating. The fabricator must select a patching or repair

material selected from the MDOT Qualified Products List (QPL) and follow the following procedures:

1. Prepare the damaged areas by cleaning to remove surface contaminants in accordance withmanufacturer’s instructions or as stated herein, whichever is stricter.

2. Roughen the area requiring patching before applying patching material.

3. Remove rust by dry blast cleaning or power tool cleaning immediately before applying patchingmaterial.

4. Immediately treat bars in accordance with the manufacturer’s recommendations and beforeoxidation occurs.

5. Overlap patching material onto the original coating by 2 inches, or as recommended by themanufacturer.

6. Provide at least 8 mils of dry film thickness on the patched areas.

7. Bars with 5 percent or more damaged in a 12 inch bar length is considered to be severely damagedand will be rejected.

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Standard Structural Precast Concrete Repair Procedure #7: Epoxy Injection

Description The following plan is for the repair of concrete cracks using epoxy injection in accordance with subsection

712.03.U of the 2012 Michigan Department of Transportation Standard Specifications for Construction

(MDOT SSC).

The epoxy resin used for injecting into the cracks must be selected from the Qualified Products List (QPL) in

the MDOT Materials Source Guide (MSG).

Procedure Below is the standard repair procedure for epoxy crack injection. The fabricator must follow the following

procedures or the manufacturer’s recommendations, whichever are more strict:

1. Remove leaching deposits from cracks by abrasive blasting or wire brushing.

2. Apply a temporary seal, with entry ports for adhesive, along the clean, dry crack without defacingthe concrete surface. Ensure the seal will contain the pumped adhesive.

3. Space ports farther apart than the estimated crack depth and close enough to allow adhesivematerial to travel between ports.

4. Flush the cracks with water by pressure washing through injection ports. Wash out concrete laitanceor contaminants in the crack. Remove free water by blowing oil-free air (90 psi minimum) throughthe crack after flushing.

5. Perform injection when the concrete and ambient air temperatures are above 50 degreesFahrenheit.

6. Begin injection at the lower entry port and continue until adhesive is visible at the port directlyabove, or next to the pumping port. Stop injection and seal the port. Transfer the injector fromboth sides of a cracked member to complete crack repair. Prevent leakage of the adhesive fromthe crack after injection is complete.

7. Cure adhesive at temperatures of at least 50 degrees Fahrenheit for the minimum cure timerecommended by the manufacturer. Remove the seal or grind flush with the concrete surface.

8. Clean areas repaired by injection of surface contamination caused by injections.

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Structural Fabrication Buy America Guidance Document

Description The purpose of this document is to provide the Michigan Department of Transportation’s (MDOT)

Structural Fabrication Unit with guidance to supplement MDOT’s 12SP-105A Special Provision for Source of

Steel and Iron (Buy America). The Structural Fabrication Unit is responsible for implementing the

Department’s quality assurance program for material required to be accepted based on “Fabrication

Inspection” per MDOT’s Materials Quality Assurance Procedures (MQAP) manual. It is important to note

that this document is not contractual and all project related decisions should be based on the contract.

This guidance document will be used to ensure statewide consistency in performing quality assurance

(QA) verification inspection at fabrication facilities for Buy America compliance. It provides a brief

background on FHWA’s Buy America policy, what step certification is, where more Buy America

information can be found, how foreign steel or iron could be incorporated into the project, and tables

that provide common steel and iron components used in the fabrication process of structural precast

concrete and structural steel elements. This document is broken down into the following sections:

1. Background

2. Step Certification

3. Foreign Steel or Iron

4. Documentation Requirements

5. Buy America Tables

1. Background The FHWA’s Buy America policy is based upon the statutory provisions in the Surface Transportation

Assistance Act of 1982, as implemented with a November 25, 1983 final rule. FHWA has since issued

clarifications and interpretations on the Buy America policy and standing waiver of 1983 with memo’s

issued on December 22, 1997, June 13, 2011 and December 21, 2012; however, the December 21, 2012

memo was rescinded on December 22, 2015. In general, FHWA’s Buy America policy requires a domestic

manufacturing process for all steel (including stainless steel; however, brass, bronze and copper are not

subject to Buy America) or iron manufactured products (including the application of protective coatings,

but not the coating itself) that are permanently incorporated into a Federal-aid highway construction

project.

Title 23 Section 313 and FHWA's regulations in 23 CFR 635.410 provide that the Administrator may issue a

waiver. Procedures for any waivers are in the FHWA guidance for Buy America on the FHWA website.

Waivers are very rare and typically take about 9 months to be issued, which would require them to be

submitted during the design stage. Additionally, the FHWA's regulations permit a minimal use of foreign

steel and iron in the amount of $2,500 or one-tenth of one percent (0.1%), whichever is greater, to be

used in a Federal-aid project. Note that application of Buy America is triggered by the obligation of

Federal funds. If any amount of federal funding is used in the project, then Buy America requirements

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apply. Map 21 requires all parts of a project to comply with Buy America if any previous parts of the

larger project used Federal funds. This includes environmental EIS, planning, design, small subparts, etc.

FHWA may issue a standing national or regional waiver if it is warranted, although it is extremely rare (only

4 ever issued). The waiver would be granted by the Secretary of Transportation if the product is not

manufactured in the United States and the public rulemaking process demonstrates that non-domestic

availability of the product would adversely impact the Federal-aid program in multiple states, specific

region, and/or nationwide.

2. Step Certification Step certification is the process under which each company (supplier, fabricator, manufacturer,

processor, etc.) of the steel and iron products certifies that their step in the manufacturing process was

domestically performed. Contractors must provide manufacturers’ step certifications to the Engineer

showing the steel and iron products are of domestic origin prior to permanent incorporation into the

Federal-aid highway project. MDOT requires step certification for all steel and iron related pay items,

materials, products, and components as specified on the Department website. The Department will

maintain a list of these pay items, materials, products, and/or components on the following website:

http://www.michigan.gov/documents/mdot/MDOT_BuyAmericaRequirements_387704_7.pdf

Raw materials are not required to meet Buy America; however, every step from melting through coating

application and anything else is subject to meet Buy America. If a steel or iron component has any step

performed by a non-domestic company then the total cost for the entire component would need to be

less than the allowable foreign limit in order to be incorporated into the project.

3. Foreign Steel or Iron It is the Contractor’s responsibility to seek approval from the Engineer to use foreign steel or iron prior to

incorporation into the project. Additionally, it is the Contractor’s responsibility to keep track of the

amount of foreign steel or iron used on the project.

For additional information on Buy America requirements, please refer to any project specific Special

Provision for Source of Steel and Iron (Buy America), MDOT Construction Manual, MDOT MQAP Manual,

and the FHWA website.

4. Documentation Requirements The Contractor is required to provide Buy America certification for the project and Buy America step

certification for all products and materials not designated as full compliant with the Buy America

requirements on the Qualified Products List (QPL), Approved Manufacturer’s, and Tested Stock Suppliers

List maintained by MDOT’s Construction Field Services Division.

Buy America certification letter or Bill of Lading must include the following language:

" Company name;

" Signature of company representative; and

" Following statement:

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I, (company representative), certify that the material shipped/provided to the project are in full

compliance with the Federal Highway Administration (FHWA) Buy America requirements as

specified in Title 23 of the Federal Code of Regulations (CFR) Section 635.410.

Buy America step certification letter must include the following language:

" Company name;

" Signature of company representative; and

" Following statement:

I, (company representative), certify that the (cutting, bending, punching, drilling, shearing,

machining, welding, galvanizing, coating) process/es, as specified in the purchase order, for

manufacturing or fabricating the material shipped/provided to the project are in full compliance

with the Federal Highway Administration (FHWA) Buy America requirements as specified in Title 23

of the Federal Code of Regulations (CFR) Section 635.410.

Mills and manufacturing plants that produce hot-rolled shapes, hollow structural sections (HSS), plate,

ingot, slab, billet, bloom, high-strength bolts, anchor bolts, prestressing strand, bar reinforcement, and

welded wire reinforcement are not required to provide the above stated Buy America step certification

letter. Instead, language located in the material test report (MTR) stating the material was melted and

manufactured in the United States is sufficient to meet Buy America step certification requirements.

Contractors are not permitted to write Buy America step certification letters for their subcontractors since

they do not have control over the work. This was determined based on discussions between MDOT

management and FHWA.

5. Buy America Tables Below are several tables displaying common steel and iron components used in the fabrication of

structural precast concrete and structural steel elements. This information has been prepared exclusively

for MDOT’s Structural Fabrication Unit to assist with the Buy America requirements. These tables are not

complete and do not relieve the contractor of their contractual obligations to meet Buy America

requirements for MDOT projects.

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Table 1. Steel components used in fabricating structural precast (prestressed and non-prestressed)

concrete elements.

STRUCTURAL PRECAST CONCRETE FABRICATION

Component Description Buy

America Cert

Buy America Step Cert

Comment

Prestressing Strand

High strength strand for prestressing

concrete Yes *Yes

Project BA cert from fabricator and language in MTR (e.g. melted

and manufactured in the USA)

Bar Reinforcement

Mild bar reinforcement for

strengthening concrete

Yes *Yes Project BA cert from fabricator

and language in MTR (e.g. melted and manufactured in the USA)

Welded Wire Fabric

Mild fabric reinforcement for

strengthening concrete

Yes *Yes Project BA cert from fabricator

and language in MTR (e.g. melted and manufactured in the USA)

Sole Plates

Steel plate cast over support and

bears on the elastomeric pad

Yes Yes Project BA cert from fabricator and BA step certs from each

company that performs a process

Position Dowels

Dowels used to provide translation restraint for beams

Yes Yes Project BA cert from fabricator and BA step certs from each


MSE Connection

Lug

Connects wall panel to

reinforcement Yes No Project BA cert from fabricator

Laminated Elastomeric

Pad

Steel shims used to reinforce

elastomeric pads Yes Yes

Project BA cert from fabricator and BA step certs from each


PCI Beam Lifting Strand

Device for moving beams

Yes No Project BA cert from fabricator

Culvert Lifting Device

Device for moving culverts


MSEW Lifting Device

Device for moving MSEW panels, posts,

and copings Yes No Project BA cert from fabricator

Sound Wall Lifting Device

Device for moving sound wall panels

and posts Yes No Project BA cert from fabricator

72 2019 Interim


V022818

BUY AMERICA

PAGE 5 of 6


Table 1 (continued). Steel components used in fabricating structural precast (prestressed and non-

prestressed) concrete elements.

STRUCTURAL PRECAST CONCRETE FABRICATION


America Cert


Comment

Tie Wire Secures bar


Bar Chair Supports bar


Screed Supporting

Frame (pipe)

Supports screed machine


SIP Deck Clip Support location for

attaching SIP decking


Half Hanger Anchor

Supports false work Yes No Project BA cert from fabricator

False Work Insert

Supports false work Yes No Project BA cert from fabricator

Safety Line Embed

Provides tie off Yes No Project BA cert from fabricator

Spun Pole Structural Steel

Mounts cameras, etc. to pole


Spun Pole Hardware

Mounts cameras, etc. to pole


Concrete Insert

Attach threaded bar reinforcement

or bolt Yes No Project BA cert from fabricator

* Denotes alternate Buy America step certification.

73 2019 Interim


V022818

BUY AMERICA

PAGE 6 of 6


Table 2. Steel components used in fabricating structural steel elements.

STRUCTURAL STEEL FABRICATION


America Cert


Comment

Hot Rolled Shape and

Plate

Structural steel used for fabrication of

bridge or highway elements

Yes Yes Project BA cert from fabricator and BA step certs from each company

that performs a process

HSS

Structural steel used for fabrication of

bridge or highway elements

Yes Yes Project BA cert from fabricator and BA step certs from each company


High Strength Bolts

Bolts for structural steel connections

Yes *Yes Project BA cert from fabricator and language in MTR (e.g. melted and

manufactured in the USA)

Anchor Bolts Bolts for anchoring structural elements

Yes *Yes Project BA cert from fabricator and language in MTR (e.g. melted and

manufactured in the USA)

Laminated Elastomeric

Pad

Steel shims used to reinforce

elastomeric pads Yes Yes

Project BA cert from fabricator and BA step certs from each company


Welding Rod Weld metal used in

SMAW process Yes No Project BA cert from fabricator

Welding Wire Weld metal used in

GMAW, SAW, or FCAW processes


* Denotes alternate Buy America step certification.

73a 2019 Interim



V020118

METALS LABORATORY SAMPLING GUIDANCE

PAGE 1 of 6

Metals Laboratory Sampling Guide

DescriptionThe following procedures provide step by step instruction on sampling all materials required to be tested

by the Michigan Department of Transportation Metals Laboratory.

Sampling Instructions

1. Samples must be selected randomly without bias, must be representative of the material

sampled, and can only represent the population of material available at the time of sampling

(e.g. makeup material must be resampled since the original sample cannot statistically

represent material not available at the time of sampling). Specific sample size and frequency

can be found in the Materials Acceptance Requirements table located in the MDOT Materials

Source Guide.

2. All samples must be securely tagged with a numbered zip tie. Zip ties are provided by MDOT

and are uniquely numbered for sample identification purposes. High strength bolt samples

must be placed in plastic bags and closed with zip ties. All other samples must have zip ties

placed directly on the sample.

3. Population of material sampled must be tagged or marked in accordance with subsection

1.08 of the MDOT Materials Quality Assurance Procedures (MQAP) Manual.

4. Sample Identification (Form 1923) must be electronically prepared and filled out in detail for

each sample, placing the zip tie number in the remarks section. All available information for

proper identification of the sample must be provided, including the heat number, lot number,

tag number, batch number, serial number, and any other unique identification marks.

5. All material documentation for the sample must be electronically combined with Form 1923

as the first page into one Adobe portable document format (PDF) file (naming convention in

#6 below) and submitted to the testing lab via email to [email protected]. If

the MDOT Standard Specifications for Construction do not apply to the sample, applicable

plan sheets, special provisions or shop drawings must be included in the PDF submittal. The

email must have the zip tie number in the subject line. The Contractor is responsible for

providing all material certification and test data reports to the MDOT inspector in PDF

format.

6. Materials Submittal File Naming Conventions:

" Acceptance Sample: Control Section_Job Number_Material_Size_Date

Example: 63172 123143 Anchor Bolt 2in 07-09-2018

" Tested Stock Sample: TS_Material_Size_Date

Example: TS Extruded 12in 07-09-2018

" Certification Verification Sample: CV_CV Number_Material_Size_Date

Example: CV 2015-31 Rebar #5 07-09-2018

" A glossary of standard material names is included on page 3 of this document.

" A Lab Number will be assigned by the Metals Lab and incorporated into file name. Example: 18M123 63172 123143 Anchor Bolt 2in 07-09-18

2019 Interim 77



V020118


PAGE 2 of 6

7. Form 1923 must be securely attached to the sample using a method which would ensure the

form remains with the sample and is readable when it arrives at the testing lab.

8. The method of transportation of the samples to the testing lab is at the discretion of the

Contractor. The Contractor is responsible for all associated shipping costs and must determine

shipment method in a manner deemed most appropriate. Non-MDOT employees dropping

off samples must check in with security at the loading dock gate or south entrance of the C&T

building prior to dropping samples off to the Metals Laboratory (room 122).

9. All samples must be consigned to:

MDOT Metals Lab

C/o MDOT – Operations Field Services

C&T Building – Mail Code E-020

8885 Ricks Road

P.O. Box 30049

Lansing, MI 48909

10. Test results can typically be expected within 2 weeks after the sample arrives in the testing lab.

Inquiries regarding test results may be directed to [email protected].

11. Metals Lab will place test reports into the ProjectWise MDOT In Box folder at the location

shown below. The Engineer will then place the report in the appropriate project folder.

$ Region

o TSC

" Project Specific JN

" Construction

o MDOT In Box

2019 Interim 78



V020118


PAGE 3 of 6

Glossary of Materials Tested by the MDOT Metals Laboratory

Spec Reference Material Name *File Name

712.03.L Mechanical Splicing Splice

713.02.A Temporary Support Hanger Rod Hanger Rod

905.03 Rebar Rebar

905.06 Welded Wire Fabric Welded Wire

905.07 Prestressing Strand Prestressing Strand

906.07 High Strength Bolts HS Bolt

907.05 High Tensile Wire Tensile Wire

908.09.A Bridge Rail Post Rail Post

908.09.A Bridge Rail Plate Rail Plate

908.09.B Bridge Tube Railing Bridge Tube

908.09.C Railing Anchor Studs Anchor Stud

908.11.A Guardrail Beam Guardrail

908.12 Guardrail Post Guardrail Post

908.14 Anchor Base Plate Base Plate

908.14.B Sign Support and Light Standard Anchor Bolts Anchor Bolt

908.14.C Traffic Signal Strain Poles Strain Poles

908.14.D Anchor Bolts for Other Purposes Anchor Other

909.05.A.1 Corrugated Steel Pipe Corrugated

914.07 Dowel Bars Dowel

918.11.A Guy Wire Guy Wire

919.02.A Extruded Aluminum Sign Planks Extruded Aluminum

919.02.A.3 Aluminum Sheet Aluminum Sheet

919.07.A Cantilever Pipe Wall Tubing

* This is to be used as the naming convention to save the file.

2019 Interim 79



V020118


PAGE 4 of 6

SampleManager login instructions (you must have a login name and password):

1. Open up Sample ID and certification paperwork.

2. In SampleManager, click on “MDOT/Sample Submission” and then pick sample type.

3. Click on “Contract” button to pull up list of job numbers to pick one.

4. Click on “Metals” radio button.

5. Click on pulldown labeled “Material” to pick type of material.

6. Click on “Spec Level” in order to pick size of sample.

7. If remarks are needed, enter them in the “Remarks” box.

8. If needed, under “Send Results To” you can pick a person and reason for sending results.

9. Click “OK” to go to the next page for sample details.

10. Click on “Date Sampled” to pick the dates sampled. You can type it in or pick from the calendar.

11. Pick the “Supplier” from the dropdown list.

12. Pick a location from the “Sampled From” list.

13. Put in a number for “Quantity Represented”, this usually comes from the Materials Source List.

14. If needed, pick “Quantity Units” from the list.

15. Pick the “Sampled By” person from the dropdown list.

16. Pick the “Submitted By” person from the dropdown list.

17. Fill in the zip tie tag number or deer tag number.

18. If applicable, pick the “Manufacturer” of the bolt, nut and washer.

19. Also fill out the lot and heat numbers of the bolt nut and washer. If one component is not present,

pick “Not Supplied” as the manufacturer name from the dropdown list. Use the certifications to

find lot and heat numbers.

20. If applicable, also attempt to identify the products markings and enter these. Common

manufacturer’s markings are listed following this page.

Note: You can view logged samples by expanding the “Metals Lab” icon at the left of SampleManager.

From there you will see different folders showing the state of testing for the samples. Also, if a company or

employee needs to be added to SampleManager or you have login questions, please email:

[email protected]

You can find SampleManager training videos on the MDOT YouTube page or they are available by request.

2019 Interim 80



V020118


PAGE 5 of 6

Metals Product Markings

Product, spec book section and ASTM

Required markings Commonly seen markings (and manufacturer)

Temporary Support Hanger Rod

712.02A, ASTM A193

15.1 See Specification A962/A962M. Thegrade symbol shall be as shown in Table 4.From Table 4: B7

Rebar

905.03, A706, A615

16.2 Each manufacturer shall identify thesymbols of his marking system. For Grade60 [420] bars, the marking shall be either thenumber 60 [4] or a single continuouslongitudinal line through at least five spacesoffset from the center of the bar. For Grade80 [550] bars, the marking shall be either thenumber 80 [6] or three continuouslongitudinal lines through at least fivespaces.

See rebar markings list below (Appendix A).

*If rebar is coated, then coating company is the manufacturer (ABC Coating Co.)

High Strength Bolts

906.07, ASTM F3125 grade A325

From Table 1: A325 5.1 At a minimum, all bolts shall be markedas required in Table 1. Marking shall be onthe bolt head and may be raised or depressedat the manufacturer’s option. The markingshall be visible after coating.5.2 Grade and Type marking, and themanufacturer’s mark shall be in separate anddistinct locations on the head. Othermarkings, if used, such as private labeldistributor’s mark shall also be separate anddistinct.

nA325 (Nucor)

SLA325 (St. Louis Screw & Bolt)

SLA325USA (St. Louis Screw & Bolt)

GA325 (Gaffney Bolt Co.)

Nuts

906.07, 908.14, ASTM A563 gr. DH or ASTM A194 gr. 2H

14.5 Nuts made to the requirements of GradeDH shall be marked with the grade symbol,DH (or 2H) (Note 4) on one face.14.7 In addition, nuts shall be marked with asymbol to identify the manufacturer orprivate label distributor, as appropriate.

DHU (Unytite)Dhn (Nucor)2HU (Unytite)DHn (Nucor)TDC2H (Dyson) 2HDHD/N (Dyson)DMCDH (Dyson) FSADH/2H (Foundation Systems)

Washers

906.07, 908.14 ASTM F436

15.1 Washers shall be marked with a symbol,or other distinguishing marks, to identify themanufacturer or private label distributor, asappropriate.

TSIF436 (Technical Stamping) PF436 (Prestige Stamping) Ws (Wrought Washer)

2019 Interim 81



V020118


PAGE 6 of 6

Product, spec book section and ASTM

Required markings Commonly seen markings (and manufacturer)

Anchor Bolts

908.14 ASTM F1554, grade 55 and 105

19.1 Unless otherwise specified (see Note 4),the end of each anchor bolt intended toproject from the concrete shall be colorcoded to identify the grade as follows:Grade 36 Blue, grade 55 Yellow, grade105 Red.S2. (not required by spec butinformational)S2.1 The end of the anchor bolt intended toproject from the concrete shall be steel diestamped with the manufacturer’sidentification.

AVA 55 (AA Anchor Bolt) ASI 55 (Alton Steel) 27 (“XX”) (Gerdau Ameristeel) S41 (“XXX”) (Cardinal Fabricating) FSA105 (Foundation Systems)

Bridge Tube Railing

908.09B, ASTM A500 grade B

908.09B The manufacturer of the structuralshape must identify the product as follows: 1. Place identification before galvanizing; 2. Include heat number or other codetraceable to the heat number; 3. Include manufacturer’s uniqueidentification code; 4. Place identification on only one sectionface; 5. Repeat identification a no more than 4-foot intervals; 6. Do not extend identification into thecurved surface at corners of section; and 7. Do not place identification on side facingtraffic or side opposite traffic.

BMT U65 (Bull Moose Tubing)

Railing Anchor Studs

908.09C, ASTM A449

16.1 Manufacturers Identification—All hexcap screws and bolts and one end of studs 3"8

in. and larger, and whenever feasible studssmaller than 3"8 in., shall be marked by themanufacturer with a unique identifier toidentify the manufacturer or private labeldistributor, as appropriate.16.2.1 Type 1 hex cap screws and bolts andone end of Type 1 studs 3"8 in. and larger, andwhenever feasible studs smaller than 3"8 in.,shall be marked “A449.”

BFA449 (Birmingham Fastener)

SLA449 (St. Louis Screw & Bolt)

JHBA449 (J.H. Botts)

Guardrail Beam

908.11A, AASHTO M180

11.1 Each beam element shall be identifiedby the following: Name or brand ofmanufacturer, identification symbols or codefor heat, number and coating lot, AASHTOspecification number, and class and type.

2019 Interim 82

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12345

123456 Oct 18, 2017

17A

Edward C. Levy Co. Aggregates/Ray Road 275 Ray Rd. Oxford, MI. 48371, 63-115

Structural Precast Concrete Fabrication Plant

Structural Precast Concrete Fabrication Plant

1000tons

person qualified to pull sample

person dropping off sample to lab

Coarse Aggregate used in fabrication of prestressed concrete beams

MTM 109, MTM 108, *MTM 110

natural aggregate must meet the physical properties of 6AA

[email protected]

Clear Form

%)$'(&%

84


V110515

E-CONSTRUCTION PROCESS

PAGE 1 of 2


Structural Fabrication E-Construction Process

Description The purpose of this document is to provide the Michigan Department of Transportation’s Structural

Fabrication Unit with a process for implementing e-construction for structural fabrication inspection

record retention. E-construction requires all fabrication inspection records to be provided by the

contractor to MDOT in Adobe portable document format (PDF) files and for MDOT to store the records in

ProjectWise.

1. Receiving Fabricator DocumentsThe fabricator must provide MDOT with electronic files in Adobe PDF. Documents are provided to

MDOT’s quality assurance inspector (QAI) in a timely manner (within 24 hours after the date

covered by the report for structural concrete) for their review prior to stamping structural elements

approved for use.

2. Creating Quality Assurance DocumentsThe QAI must convert all QA documents into PDF files. If fillable forms are used then the files must

be “flattened” to embed all form fields, comments, and any other type of annotation into the

page content prior to combining the PDF files to prevent the fields in similar forms from merging.

The stamped Bill of Lading must be scanned by the QAI for inclusion in the final documentation

package. The paper copy can be discarded after scanning.

3. Assembling and Bookmarking Fabrication Inspection FilesThe QAI combines, arranges, and bookmarks all project QA and QC documents in one PDF

fabrication inspection file using Adobe Acrobat. See MDOT document titled Structural Fabrication

Bookmarking Template for instructions on bookmarking.

4. Sending Fabrication Inspection File to MDOTQAI sends the fabrication inspection file to the MDOT Structural Fabrication Unit using a file transfer

protocol (FTP) program. The MDOT Structural Fabrication Unit randomly audits fabrication

inspection files and follows up with QAI to address any deficiencies.

5. Placing Fabrication Inspection Files into ProjectWiseThe MDOT Structural Fabrication Unit places the fabrication inspection file into ProjectWise at the

following location (in red) and assigns project attributes to the file:

$ Xxxxx Region

o Xxxxx TSC or Region Projects

" JN XXXXXX

" Construction

o Field Services

" Structural Fabrication

85


V110515

E-CONSTRUCTION PROCESS

PAGE 2 of 2


6. MDOT Fabrication Inspection MemorandumThe MDOT Structural Fabrication Unit works with the MDOT Structure Technical Section

Administrative Assistant to prepare the memorandum (memo) for the MDOT Structural Fabrication

Engineer’s digital signature. The assistant places a copy of the signed memo into ProjectWise at

the following location (in red below) and assigns project attributes to the files for the project

office’s records:

$ Xxxxx Region


" JN XXXXXX

" Construction

o Field Services


A copy of the signed memo is also placed into the Structural Fabrication Unit’s ProjectWise

storage folder for historical record.

7. Notification of Fabrication Inspection CompletionThe MDOT Structure Technical Section Administrative Assistant emails the ProjectWise link to the

structural fabrication folder (in red below) to the individuals listed on the fabrication inspection

memo:

$ Xxxxx Region


" JN XXXXXX

" Construction

o Field Services


86


V&&%,&+

BOOKMARKING TEMPLATE

PAGE 1 of 1


Structural Fabrication Bookmarking Template

Description Use this table of contents template for bookmarking final e-construction project documentation files. This

document is both the instructions for assembling a fabrication inspection file and the template for

bookmarking the file. It contains the bookmarks for structural concrete (prestressed and non-prestressed)

and structural steel so the bookmarks not needed must be removed.

Inspection File Assembly Instructions

1. Assemble the inspection file by inserting QC and QA files in PDF format into this document.

2. Using this document as the first page in the inspection file, arrange the files using the

bookmarks shown in this document.

3. Click on the Bookmarks Tab to display the default bookmarks. Scroll through your document

and locate the page (or first page of a section with multiple pages) that corresponds to the

bookmark. Highlight the corresponding bookmark in the list, single right click, and select Set

Destination. Repeat for each applicable bookmark until every section of the inspection file is

bookmarked.

4. Delete any bookmarks that are not needed for your particular project.

5. Delete this document after the file is complete as it is no longer needed in the file.

6. Once document is complete, electronically sign the Inspector’s Project Folder Checklist.

File Naming Convention: “SN-CS-JN Element Inspected Date”

" SN: Structure Number

" CS: MDOT Control Section

" JN: MDOT Job Number

" Element Inspected: Bearing-type, high mast tower, modular expansion joint, sign structure-

type, structural steel-type, culvert-type, prestressed beam-type, precast bridge element-

type, sound wall, spun concrete pole, etc.

" Date: Date file is completed

Examples of this naming convention are shown below:

" B03-82117-112703 Structural Steel-Pin & Hanger 093013

" W01-73022-156776 Sound Wall 111716

" S17-09031-121776 Bearing-Disc 021514

" C07-11015-126765 Culvert-Three Sided 070416

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January 0, 2015

To Whom It May Concern:

It has recently come to the attention of the Michigan Department of Transportation (MDOT) that structural precast concrete fabricators have been providing sole plates for prestressed concrete beams shorter than what is detailed and required in the contract plans. In some cases, the shorter sole plates were approved via a Request for Information (RFI), email correspondence, or a note in the shop drawings. MDOT has discussed this issue with several structural fabricators that perform work for MDOT and their reasoning for providing the shorter sole plates is to avoid additional machining required to get the sole plates to properly fit-up in the forms. Most forms are fabricated with a radius in the bottom soffit corners and the sole plate edge would need to bechamfered to accommodate this radius (see attached MDOT Bridge Design Guides 8.43.01 and 8.43.01A). After thoroughly reviewing the design intent and contract details, MDOT’s position is that full-width sole plates are required when detailed in the contract plans.

MDOT currently designs and details sole plates for prestressed concrete beams when the geometry warrants their use. Over the years, MDOT has noted excessive spalling at the bottom ends of prestressed concrete beams without sole plates. Spalling typically occurs after the side forms have been removed and the strands are detensioned. The large eccentric compressive force from the de-tensioning operation creates large horizontal and vertical shearing forces at the beam ends from the friction between the beam and formwork and a rotation about the beam ends from the ensuring positive deflection (camber). Spalling is more severe on skewed beam ends since the rotation occurs at the tip of the skewed beam end resulting in a point load versus evenly along the entire beam end for beams with no skew. Beams detailed with sole plates do not typically experience beam end spalling since they are armored by the sole plate to resist the shear forces and point loads. To reduce the number of occurrences where the beam ends spall and the ensuing beam repairs, MDOT is requiring all prestressed concrete beams to be designed, detailed, and fabricated with sole plates. This should be effective starting with the March 2015 Letting. Fabricators are welcome to propose the addition of sole plates on current projects at no additional cost to MDOT.

95

TO WHOM IT MAY CONCERN Page 2 of 2 January 0, 2015

Please contact me by phone at (517) 322-5709 or email at [email protected] with questions or concerns. Thank you for your patience and understanding during this transition.

Sincerely,

Matthew J. Filcek, P.E. Operations Field Services Structural Fabrication Engineer

MJF: jt

Enclosure

cc: M. Chynoweth J. Gutting D. Juntunen P. Jansson D. Papanek J. WeilerACEC CRAM MITA MML Structural Precast Concrete Fabricators

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15 | Handling and Identification

15.1 All systems for handling coated steel reinforcing bars shall have padded contact areas. All bundling bands shall be padded or suitable banding shall be used to prevent damage to the coating. All bundles of coated steel reinforcing bars shall be lifted with a strong back, spreader bar, multiple supports, or a platform bridge to prevent bar-to-bar abrasion from sags in the bundles of coated steel reinforcing bars. The bars or bundles shall not be dropped or dragged.

15.2 If circumstances require storing coated steel reinforcing bars outdoors for more than two months, protective storage measures shall be implemented to protect the material from sunlight, salt spray and weather exposure. If the manufacturer stores coated steel reinforcing bars outdoors without protective covering, the date on which the coated bars are placed outdoors shall be recorded on the identification tag on the bundled steel. Coated steel reinforcing bars, whether individual bars or bundles of bars, or both, shall be covered with opaque polyethylene sheeting or other suitable opaque protective material. For stacked bundles, the protective covering shall be draped around the perimeter of the stack. The covering shall be secured adequately, and allow for air circulation around the bars to minimize condensation under the covering.

15.3 Coated steel reinforcing bars, whether individual bars or bundles of bars, or both, shall be stored off the ground on protective cribbing.

15.4 The identification of all steel reinforcing bars shall be maintained throughout the coating and fabrication processes to the point of shipment.

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>JINOMP>ODJI $ O@>CIJGJBT =PDG?DIB r K+J+ =JS 0--16 r G<INDIB) HD>CDB<I 156.4mmm+c_Y^_]Wd+]el r &2.4'*0//*.-54

September 12, 2017

To Whom It May Concern:

It has recently come to the attention of the Michigan Department of Transportation (MDOT) that some welded sole plates for prestressed concrete beams are not meeting project requirements. MDOT requires structural precast concrete plants to be certified by either the Precast/Prestressed Concrete Institute (PCI) or National Precast Concrete Association (NPCA) depending on the type of work being performed. The American Concrete Pipe Association (ACPA) is considered an approved equal to NPCA for concrete culverts. PCI and NPCA state structural steel component welding requirements that must be followed by the Contractor. Below are excerpts from PCI and NPCA on structural steel welding:

" The first paragraph of subsection 2.3.1 of PCI MNL-116, 1999, 4th Ed. states, “Welding of steel plates, angles, and other shapes shall be in accordance with AWS D1.1. Welders qualified in accordance with AWS D1.1 and D1.4 shall perform all welds. Qualified engineers or quality control personnel shall write welding procedure specifications (WPS) for structural steel”. See PCI MNL-116 the additional information.

" Subsection 4.2.3 of NPCA, 2016, 12th Ed. States, “Welding of steel assemblies which are cast into or attached to precast concrete products shall be performed in accordance with American Welding Society D1.1, Structural Welding Code – Structural Steel”.

Please review your welding procedures and ensure structural steel welding required for structural precast concrete pay items meets the project requirements. Additionally, it is important to note that MDOT does not permit welding of reinforcing steel unless approved by the engineer due to the difficulty with obtaining sound welds. A detailed welding plan would be required to be submitted for MDOT’s Structural Fabrication Unit’s review prior to approval.

Please contact me by phone at 517-322-5709 or email at [email protected] with questions or concerns.

Sincerely,

Matthew J. Filcek, P.E.Bureau of Bridges and StructuresStructural Fabrication Engineer

cc: M. ChynowethM. BellgowanP. JanssonD. Papanek

J. WeilerACECCRAMMITA

MMLStructural Precast Concrete Fabricators

102


V111417

COMMENTARY FOR PROJECT FOLDER CHECKLIST

PAGE 1 of 8


Commentary for Project Folder Checklist

Description

The Inspector’s Project Folder Checklist is used to aid in the gathering and combining of fabrication

documents for submittal to the Structural Fabrication Unit upon completion of fabrication. This document

is intended to provide the inspector with additional information regarding different materials involved in

precast concrete fabrication.

Fabrication work should not begin until all certifications, calibrations, materials (including coatings) and

test reports are verified and visually inspected, stamped approved shop drawings are in hand and all

required steel meets "Buy America" requirements. Notify MDOT-Structural Fabrication Unit (structural

precast concrete specialist), via email, if there are any deficiencies at the time of the first concrete pour

(when materials are incorporated into the fabricated elements). Be sure to allow enough time at the

fabrication facility prior to fabrication to go through the entire checklist. The checklist is not all inclusive:

there may be specifications of materials on the shop drawing or items in a special provision that may not

be covered on the checklist. Be sure to get all required documentation and check what is given to you.

It is the responsibility of the inspector to know the basis of acceptance for all materials incorporated into

the project. The information in this document may have changed after this document was written. If you

have any questions the Structural Precast Concrete Fabrication Specialist is one resource you can get

answers.

I. Forms/Certifications/Calibrations and other Non-Material Items Materials that have Approved Manufacturer listed as the “Basis of Acceptance” in the Materials

Acceptance Requirements Table in chapter 7 of the Material Quality Assurance Procedures (MQAP)

manual and in the Materials Source Guide (MSG) must have a General Certification accompany the

material per the requirements of section 3.01.03 of the MQAP Manual (Suppliers and Contractors can

write the General Certification). In addition, the quantity shipped is required on the certification. This is

listed in section 3.02.04 of the MQAP manual. Some examples are steel reinforcement, cement, precast

concrete box sections, precast concrete 3 sided or arch.

I have attached a link to our forms page for each form. Always be sure to use the most current forms.

See the appropriate section of the MQAP for a thorough explanation of the forms.

A. Project Folder Checklist Form 2001

B. Shop Inspection Report Form 5617

C. Sample Identification Form 1923

D. Strand Tensioning Report (0513) Form 0513

E. Bar Reinforcement Report Form 1985

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V111417


PAGE 2 of 8


F. Pre and Post Pour Inspection Checklist Form 5616

G. Field and Lab Test Report (forms 0590 and 0551 have been merged) Form 0590

H. Repair Observation Report Form 1981

I. Material Source List Form 0501 This form is required to be filled out by the fabricator. The

fabricator submits the form to MDOT, MDOT/QAI then fills out the basis of acceptance

requirements for the materials, and then distributes the completed form to the fabricator (the

construction office must be copied if materials will need to be tested by the construction office –

example: mechanical reinforcement splices). QAI should notify MDOT-Structural Fabrication Unit

if there is any required acceptance testing needed.

J. Certifications

1. Plant Certification

a. Prestressed Concrete Institute (PCI)

b. National Precast Concrete Association (NPCA)

2. Approved Manufacturers General Certification

a. See 3.01 in the MDOT MQAP Manual for General Certification requirements

b. Precast Concrete Box Sections (909.04D)

c. Precast Concrete Tree-Sided Arch Culverts (909.04G)

3. QC Certifications

a.

b. MCA Level II certification for anyone making concrete mix adjustments

c. PCI Level II certification, temporary cards are not acceptable certifications

d. PCI Level III certification, temporary cards are not acceptable certifications

e. ACI, Concrete Strength Testing Technician

4. QA Certifications

a. ACI or

b. PCI Level II Certification ), required for any prestressing QA inspection

c.

K. Calibrations

1. Compression Testing Machine

a.

2. Stressing Jacks

a.

3. Air Meter

a. Calibration

b. QA & QC air meter calibration sheet

4. Scales used for Aggregate and Cement

a.

104


V111417


PAGE 3 of 8


b. Cement & Aggregates, measured on separate scales, follow 601.03.B.1.

c. Cement, cement and aggregates measured cumulatively, follow 601.03.A.2.

5. Volumetric Admixture Dispensers, Water Batching Devices (incl. water meters)

a.

b. Accuracy follow 601.03.B.5.

c.

6. Mixers, ensure have an attached metal plate showing the following information:

a. Serial number

b. Maximum mixing capacity in volume of mixed concrete

c. Mixing speed of the drum

d. Maximum agitating capacity in volume of mixed concrete, or on truck mixers and

agitators, the agitating speed of the drum or blades.

Note: frequency of scales checks can be less than the above if it is published in documents

from the plant certification organization (NPCA and PCI).

L. QC DocumentationDocumentation is required to be given to the Engineer within 24 hours of the date covered by the

record in a format acceptable to the Engineer. The list below may not be all inclusive.

1. Fresh Concrete Test Reports

2. Tensioning Report

3. Cylinder Test Reports

4. Curing Charts/Graph

5. Pre and Post Pour Checklists

M. Shop Drawings

1. The shop drawings must have an approval stamp on all sheets.

2. All revised sheets must have an approval stamp.

3. The stamp must have a name and date. It can either be an MDOT stamp or a stamp

that reads “Approved for MDOT”.

4. Design Build Projects will have a company name on the approval stamp on the shop

drawing sheets and a stamp from MDOT “Released for Construction”

N. Stamped Bill of Ladings Stamped bill of ladings are required for all projects with full-time inspection. Before stamping the

BOL’s the QA inspector should verify that the element mark listed on the BOL is unique to a

specific piece; there should not be any elements listed using the same element mark. If there are

any unstamped BOL’s, put them in the project folder and note why they are not stamped

“Approved for Use”, then sign and date.

II. Concrete

A. Fabricator Batched Concrete

1. Fabricator Mix Design

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PAGE 4 of 8


a. Cement (Approved Manufacturer)

b. Air entraining admixtures (QPL)(Gen Cert)

c. Water reducing and water reducing retarding admixtures (QPL)(Gen Cert)

d. Concrete accelerators (QPL & General Certification)

e. Fly ash and other pozzolanic admixtures (Approved Manufacturer)

f. Ground granulated blast furnace slag (Approved Manufacturer)

g. Verify batch to discharge times do not exceed allowable times. The time allowed

between charging mixer and placing concrete is in table 601-1 of the 2012 Standard

Specifications for Construction

B. RediMix Plant Concrete

1.

2. Concrete Tickets

a. All tickets must contain batch weights.

b. QAI Collects and signs all tickets when the trucks arrive.

c. Verify batch discharge times do not exceed allowable times (table 601-1 of the SSC)

3. Weekly Summary of Cert. Concrete from Central Mix and Transit Mix Plants Form 1155

The 1155 is filled out and signed by a representative from the redimix plant. It is needed for all

concrete pours for the project. The plant needs to know MDOT control section, job number

and construction engineer name. The fabricator should be getting the information to the

redimix plant, and if they don’t have the information then they can get it from the bridge

contractor or they can look it up themselves. Construction Contract Inquiry (select General

Contract Level Information and enter the project number). There is no need to check all

materials for the concrete. Verify that the materials not listed on the 1155 meet the basis of

acceptance. They are listed in the mix design that is required to be given by the fabricator.

III. Fine Aggregates Aggregates should be stockpiled at the fabrication facility so the stockpile is easily identifiable.

Multiple piles with different aggregates not identified are not acceptable.

A. Prequalified Aggregate Source

1. Aggregate Tickets

a. Collect signed ticket with a certified statement from the prequalified source.

b. Requirements of aggregate ticket can be found in Chapter 3 (MDOT Aggregate

Supplier Program) on page 32 of the Procedures for Aggregate Inspection

MDOT Procedures for Aggregate Inspection

2. Testing

Verify that a quality assurance (QA) test or an acceptance test has been completed by

MDOT on the material (Form 1900 or 1901).

a. The sampling schedule for MDOT Acceptance tests set up at the fabrication plant by

the Structural Fabrication Unit are 1 test per year on every aggregate being used at

every fabrication location. This will be pulled at the beginning of the construction year

to avoid any project delays.

106


V111417


PAGE 5 of 8


b. If the inspector notices a stockpile management problem (segregated aggregates,

contaminated aggregates) at the fabricator location, notify MDOT so additional

testing (acceptance testing) can be set-up.

3. Alkali Silica Reactivity Test

Alkali Silica Reactivity test, In addition to collecting the ASR information, you need to check

that documentation submitted is acceptable (not required for fine aggregate used in R-2

mortar). ASR test results are valid for 2 years from completion of testing. If the ASR test expires

after fabrication starts then the fabricator must stop incorporating the material until new

acceptable test data is provided.

" The QAI must verify that an applicable ASTM has been submitted and results are

current. Check the special provision “QC & Acceptance of…”

B. Non-prequalified Aggregate Source

1. Acceptance Test

a. Required (1 test represents 1,000 tons). This needs to be done before the material is

incorporated into the work.

2. If the inspector notices a stockpile management problem (segregated aggregates,

contaminated aggregates) at the fabricator location then notify MDOT so additional

testing (acceptance testing) can be set up.


In addition to collecting the ASR information, you need to check that what is submitted is

acceptable. ASR test results are valid for 2 years from completion of testing.



IV.Coarse Aggregates Aggregates should be stockpiled at the fabrication facility so the stockpile is easily identifiable.

Multiple piles with different aggregates not identified are not acceptable.

A. Prequalified Aggregate Source

1. Aggregate Tickets

a. Collect signed ticket with a certified statement from the prequalified source.

b. Requirements of aggregate ticket can be found in Chapter 3 (MDOT Aggregate Supplier

Program) on page 32 of the Procedures for Aggregate Inspection

MDOT Procedures for Aggregate Inspection

2. Testing

Verify that a quality assurance (QA) test or acceptance test has been completed by MDOT

on the material (Form 1900 or 1901).

a. The sampling schedule for MDOT Acceptance tests set up at the fabrication plant by the

Structural Fabrication Unit are 1 test per year on every aggregate being used at every

107


V111417


PAGE 6 of 8


fabrication location. This will be pulled at the beginning of the construction year to avoid

any project delays.

b. If the inspector notices a stockpile management problem (segregated aggregates,

contaminated aggregates) at the fabricator location, notify MDOT so additional testing

(acceptance testing) can be set-up.



acceptable. ASR test results are valid for 2 years from completion of testing. If the ASR test

expires after fabrication starts then the fabricator must stop incorporating the material until

new acceptable test data is provided. This is not needed for any coarse aggregates sources

from within the state of Michigan.



4.

a. Prestressed Elements: 0.010 percent per 100 cycles

b. Concrete Spun Poles: 0.030 percent per 100 cycles

c. Non-Prestressed Elements

" 0.030 percent per 100 cycles or less for box culverts and 3-sided culverts

" 0.067 percent per 100 cycles or less for all others

" A special provision may change the F.T. requirement (MSE walls requires 0.010 percent

per 100 cycles or less

B. Non-Prequalified Aggregate Source

1. Acceptance Test

a. Required (1 test represents 1,000 tons). This needs to be done before the material is

incorporated into the work.



acceptable. ASR test results are valid for 2 years from completion of testing. If the ASR test

expires after fabrication starts then the fabricator must stop incorporating the material until

new acceptable test data is provided. This is not needed for any coarse aggregates sources

from within the state of Michigan.



3. .)

a. Prestressed Beams: 0.010 percent per 100 cycles

b. Concrete Spun Poles: 0.030 percent per 100 cycles

c. Non-Prestressed Elements

" 0.030 percent per 100 cycles or less for box culverts and 3-sided culverts

" 0.067 percent per 100 cycles or less for all others

" A special provision may change the F.T. requirement (MSE walls requires 0.010 percent

per 100 cycles or less.

108


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4. Stockpile Management

a. If the inspector notices a stockpile management problem (segregated aggregates,

contaminated aggregates) at the fabricator location then notify MDOT so additional

testing (QA sample) can be set up.

V. Stockpiled Aggregates (Aggregate ticket is over 1 year old). In addition to Coarse and Fine Aggregate requirements stated above, an acceptance test needs to

be run to verify that the material is still acceptable every year.

VI. All Steel (basis of acceptance)

A. Buy America The Buy America requirements for Structural Precast Concrete materials is summarized in the

document “Structural Fabrication Buy America Guidance Document” located in the Structural

Precast Concrete QAI Manual and the Structural Precast Concrete Fabrication Portfolio found in

the Structure Technical Section website.

Structure Technical Section

Buy America Compliance Listing for Approved Manufacturers, Qualified Products

List and Tested Stock Suppliers

Buy America-Compliance Listing

The inspector is required to verify that all processes for steel that is required to meet “Buy America”

requirements are checked. If you identify a QPL, Approved Manufacturer or Tested Stock

Supplier listed on the “Buy America Compliance Listing document” list the material name, its

source and the rating given on the site, then list it on the Shop Inspection of Precast Concrete

(Form 5617). If the rating given is a BA- we require the fabricator to compile the invoice cost of

the “non-USA made steel” to be submitted for acceptance by the Construction Engineer. No Buy

America Step Certs are required of a BA+ manufacturer. Steel Materials 1-6 are required to be

step certified if not from a BA+ manufacturer.

1. Strand for Prestressed Concrete

a. Approved MFR, General Cert, and Test Data Certification: 0.6" Dia. ASTM A416 Grade 270

low relaxation with load elongation curve.

2. Steel Reinforcement

a. Epoxy coating, QPL and General Cert.

b. Steel reinforcement, Approved MFR and General Cert.

c. Coating Company, Approved MFR and General Cert. The coating company needs to

provide a written certification that the coated reinforcing bars were cleaned, coated,

and tested in accordance with ASTM A775 (see SSC 905.03C.3.).

3. Welded Steel Wire Reinforcement

a. Approved MFR and General Cert.

109


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4. Steel Sole Plates

a. Step Certification for Buy America: See Shop Drawings for requirements

b. Shear Developers or Studs: QPL and General Certification

5. Position Dowels

a. Step Certification for Buy America: See Shop Drawings for requirement

6. MSE Connection Lugs

a. Test Data Certification: See Special Provision for requirements

7. Anchor Bolts

a. Test or General Cert for Anchor Bolts for Other Purposes (see special instructions in MSG)

8. High Strength Bolts

a. Test

9. Mechanical Reinforcement Splices (QPL with General Cert and Test)

a. The contractor must make test splices, witnessed by the Engineer, on the largest bar sizes

that are to be spliced. See Bridge Field Services Advisory (BFSA) 2012-03. BFS Advisory-

Mechanical Reinforcement Splicing Test splice consists of 2 pieces of reinforcing bar joined

by the coupler with 12 inches of bar exposed on each end of the coupler. This is witnessed

by the construction field office staff.

10. Concrete Design Inserts:

a. Verify that the design inserts meet electro-galvanizing to ASTM B633 Service Condition 4

11. Contractor Add-Ons

a. Visual Inspection of coating (be sure to VI and Accept the coating on form 5617)

VII. Elastomeric Bearing Pads The entire section of 914.12 of the SSC is replaced entirely with the frequently used special provision

“Elastomeric Bearings”. Must have a Certification and Test Data Certificate.

VIII. Curing Compound Test Data Certification & verification by the inspector

date of manufacture (be sure to VI and Accept the curing compound [list the date of

manufacturer] on form 5617)

110

PROJECT FOLDER CHECKLIST

1. Forms, Certifications, Calibrations and Non-Material Items

2. Concrete

3. Fine Aggregates

111 2019 Interim

4. Coarse Aggregates

5. Stockpiled Aggregates

6. Steel

7. Rigid Debonding

8. Curing Compound

9. Carbon Fiber Composite Cable (CFCC)

1122019 Interim

113 2019 Interim

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114

STRAND TENSIONING REPORT

SEQUENCE LOCATION MEASURED

ELONGATION ACTUAL GAUGE

READING

TENSIONING CALCULATIONS

INPUTS

OUTPUTS

NOTES

*

**

115 2019 Interim

SEQUENCE LOCATION MEASURED

ELONGATION ACTUAL GAUGE

READING COMMENTS

1162019 Interim

STRAND TYPE SYMBOL QUANTITY DESCRIPTION

TOTAL STRANDS

117 2019 Interim

0

of 2

Michigan Department of Transportation

5616 (0 /18)

PRE AND POST POUR INSPECTION CHECKLIST

To be completed by the QA inspector, combined with all other fabrication documentation, and electronically submitted to the MDOT Structural

Fabrication Unit. REPORT #

GENERAL INFORMATION

INSPECTION AGENCY INSPECTOR DATE

FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION SIZE AND ELEMENT TYPE JOB NUMBER

INSPECTION ITEM PRE POST

FO

RM

/DIM

EN

SIO

NS

Cleanliness

Form Oil

Bulkhead Plan End Square/Skew

Bulkhead Vertical Deviation

Side Plum Vertical Deviation

Sweep (Stringline)

Length Final

Width

Depth

Camber/Haunch

CO

VE

R Reinforcing Steel

Box Beam Top Slab Thickness

Size

Location

Number

Lap Length

Epoxy Coating

Slab Tie (count and spacing)

Slab Tie Projection

Size

Location

Number

Pattern

Debonding Location

Debonding Length

Debonding Material

Mid-Span Top Cable Pocket

Mid-Span Top Cable Debond

Draped Strands

EN

DS

Bearing Assembly Orientation

Pavement Seat Size & Orientation

Dowel Pin & Slot Location

Blockout Provided

119 2019 Interim

of 2

INSPECTION ITEM PRE POST

CO

NC

RE

TE

Mix Design

Fresh Concrete Tests

Consolidation

Tining

Maximum Cure Temperature

Cylinder Tests

EM

BE

DD

ED

IT

EM

S

Lift Loop Location/Projection

PT Duct Size/Location

PT Duct Recess/Blockout

Keyway Size/Location

Styrofoam Void Size/Location

Drain Tube Installation

Drain Tubes Open After Casting

Insert Locations

Insert Size/Coating

Insert Threading (Coil/NC)

Deck Clip Spacing/Location

Forming Hanger Spacing/Location

Screed Pipe Spacing/Projection

Safety Line Bolt Spacing/Projection

INSPECTION ITEM AFTER LOADING

SH

IPP

ING

AP

PR

OV

AL

Face Finish

Back Finish

Cracks

Strands Cut Flush/Treated

Marked End

Top Finish Provided

Chamfers

Forms Seams Clean/Smooth

Surface Voids/Cracks

Keyways

Sealer Application

Stamped Approval For MDOT Use

COMMENTS:

120 2019 Interim

FIELD TEST REPORT

121 2019 Interim

REPAIR OBSERVATION REPORT

122 2019 Interim

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