AIRFIELD PAVING WORKSHOP

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CQC / QA Testing and Inspection
Presented by Gene Gutierrez
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Laboratory Requirements

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC / QA Laboratory

• Nationally Accredited
• ASTM D 3666 (HMAC) - ASTM C 1077 (Concrete)
• USACE Validated
• Host Nation Licensed / Certified
• Recommend Site Visit to Laboratory
• Confirm /Evaluate Test Method Differences
• Qualified / Experienced / Certified Technicians

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC / QA LABORATORY REQUIREMENTS
USACE Civil and Military Projects

• Mandatory To Utilize USACE Validated
  Laboratories to Perform Design Testing, Mix
  Designs and Routine Construction Control Testing.
• ERDC Listing Of All Validated Labs (US and
  OCONUS)
• http//www.wes.army.mil/SL/MTC/ValStatesTbl.htm
• Labs Not Listed Shall Be Inspected and Validated
  Prior to Approval For Use On USACE Projects.
• Main Facilities - On-Site Satellite Labs

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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LABORATORY REQUIREMENTS

• Identify Laboratory Early and Assure Current
  Validation and Check Expiration Date. Must Be
  Current Throughout Project.
• If Wanting to Use Non Validated Labs, Notify
  MTC As Soon As Possible for Procedures for
  Initiating Validation.
• Validation Takes Approx. 45 60 days
• Labs May Perform Only Those Tests for Which
  Validation was Issued. No Umbrella Approvals
  Issued.

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC Personnel Certifications

• - ACI Certified Transportation Inspector
• - ACI Certified Field Testing Technicians,
  Grade I
• ACI Certified Lab Testing Technicians, Grade I
  or II
• ACI Concrete Flatwork Tech / Finisher
• Licensed Surveyor (For Final grades)

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Production Testing

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC TESTING Aggregate Testing

• Fine and Coarse Aggregates
• - Twice per Shift
• - Sieve Analysis and Fineness Modulus (FM)
• - Sampling Location (CRD-C 100 / ASTM D 75)
• Corrective Action
• - Failures Shall Be Resampled and Retested
• - Immediate Notification if Retest Fails
• - Stop Paving Operations

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC TESTING - Concrete Mixtures

• Slump
• - Strength Test Specimens
• - Four per 8-hour Shift Random
• Air Content
• - Strength Test Specimens
• - Two per 8-hour Shift - Random
• Additional Testing
• - Variation in Workability
• Sample at Paving Site

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC STRENGTH TESTING Cylinder Correlation Ratio
Strength Testing - Random Sample at
Placement Site (ASTM D 3665) - One
Composite Sample per Sublot (4 Sublots per Lot)
- Four Cylinders ( 6 X 12) per
Sublot (16 per Lot) - Eight
Tested _at_ 7-Day Age (2 per Sublot) (CONTROL)
- Eight Tested _at_ 14-Day Age (2 per
Sublot)(ACCEPTANCE) - IN ADDITION, TWO BEAMS
PER 2000 CM
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC PCCP Aggregate TestingDuring Construction

• Quality Testing
• - Deleterious Materials, ASR, Quality
  Series
• - Once Every Month Thereafter OR
• - Change on Source or Quality
• Every Three Months
• - Previous Two Test Series Indicate
  Conformance
• Belt Sampling Required.
• Meet Minimum Sample Sizes for Petro Gradations

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Testing Issues

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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BASE COURSE MATERIALS ISSUES

• Gradation Acceptance Based on Completed Base
  or After Compaction Requirements Have Been Met.
• Make Supplier Aware of This Requirement.
  Crushing on Coarse Side May Be Necessary.
• Assure Minimum Test Gradation Sample Sizes Met
• When Using Sand Cone Test Method
• Minimum Volume Requirement
• Depth Checks

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Re-Compacting Base Materials
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Sampling Platforms
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Sampling Platform / Template
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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ON- SITE CURING FACILITIES
Denver International Airport
Box Trailer Holloman AFB, NM
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC PCCP Aggregate TestingDuring Construction

• Quality Testing
• - Deleterious Materials, ASR, Quality
  Series
• - Once Every Month Thereafter OR
• - Change on Source or Quality
• Every Three Months
• - Previous Two Test Series Indicate
  Conformance
• Belt Sampling Required.
• Meet Minimum Sample Sizes for Petro Gradations

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC Inspection Issues

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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CQC ISSUES

• Utilize Checklists (ie Concrete Pre-Placement)
• Timely Submission of Test Data Reports
• Minimum Testing Frequencies
• Test Location
• Documentation of Inspections

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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DOUBLE SAW CUT METHOD
First Cut Diamond Saw Full Depth
Second Cut Wheel Saw 1 ½ Kerf Full Depth
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Concrete Demolition
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Under Break Of Adjacent Slabs
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Lack of Full Depth Saw Cut
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Bridges for Consolidation
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Bridges for Consolidation
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Over Working Surface / Skin Patching
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Adding Water To Surface
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Bridge Deck Finishers
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Tachometer
Amplitude Gauge
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Consolidation
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Non-Uniform Application
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Tolerances Across Construction Joints
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Tolerances Across Construction Joints
Gouging / Shearing
Spalling / Gouging
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Edge Fill-in Lanes
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Protection of Pavement
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Protection of Pavement
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Protection of Work
Protect Initial Cut Joints
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Inclement Weather
Plan Ahead and Be Prepared
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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After the Storm
Be Prepared to Pump Water ASAP
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Rain Damage
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Incompatible Repair Materials

• Epoxy Repair - Correction of Construction
  Deficiencies
• Thermal Expansion Incompatibility FOD Generator
• Seek Technical Support AFCESA / ERDC/ TSCMX

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Hot Mix Roller Damage of New Pavement
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Keys To Success

• Open Communication
• Clear Understanding Of Requirements
• Planning Plan Ahead
• Prepare For Unexpected
• Adequate Number Of CQC Staff
• Team Commitment to the Three Phase Inspection
  System
• It Works..Its a Proven System

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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Helpful CQC References

• Engineer Pamphlets EP415-1-261
• http//www.usace.army.mil/inet/usace-docs/eng-pamp
  hlets/ep.htm
• - Volume 1 Quality Assurance Representative's
  Guide - General Information and Sitework
• Volume 2 Quality Assurance Representative's
  Guide - Pile Driving, Dams, Levees and Related
  Items
• Volume 3 Quality Assurance Representative's
  Guide - Architectural and Structural Features in
  Building Construction
• Volume 4 Quality Assurance Representative's
  Guide - Special Construction, Conveying Systems,
  Mechanical, and Electrical Features of Building
  Construction

US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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QUESTIONS??
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL
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THANK YOU

NEW MEXICO AIR POWER
US Army Corps of Engineers Albuquerque District
Transportation Systems 2004 Workshop, Ft
Lauderdale, FL