Material inspection guide

Material Inspection Guide

Revised September 2003

© by Texas Department of Transportation (512) 416-2055 all rights reserved

Material Inspection Guide

September 2003

Manual Notices Manual Notice 2003-1

To: Users of the Material Inspection Guide

From: Thomas R. Bohuslav, P. E., Director, Construction Division

Manual: Material Inspection Guide

Date: September 1, 2003

Purpose

To notify users of the Material Inspection Guide that the following revisions have been made.

♦ Section 28, Epoxies (Other than Paint)

♦ Section 35, Lime

♦ Telephone numbers and shipping information for the Materials & Pavements Section Cedar Park location.

♦ Hyperlinks to the Material Producer List information now published on the TxDOT internet site.

♦ Hyperlinks added to access the Guide Schedule of Sampling and Testing located in the Construction Contract Administration Handbook.

Contents

The manual change issues the above sections online.

Instructions

Access the new version through the TxDOT Online Manual System.

Contact

For more information or questions regarding the revised sections above, please contact:

♦ Asphalt, Chemical & Traffic Materials Branch—512/506-5870 for Section 28, Epoxies (Other than Paint)

♦ Business Management Section—512/416-2367 for questions regarding all other revisions.

Manual Notice 2002-1


From: Thomas R. Bohuslav, P. E.

Director, Construction Division

Manual: Material Inspection Guide

Date: May 1, 2002

Purpose

To notify users of the Material Inspection Guide that the following section and references have been revised:

♦ Section 11, Asphalt Inspection, Quality Control, and Quality Assurance

♦ Changed “Materials Section” to “Materials & Pavements Section” throughout manual.

Contents

The manual change issues the above sections online.

Instructions

Access the new version through the TxDOT Online Manual System.

Contact

For more information or questions regarding the revised sections above, please contact:

Asphalt/Chemical & Traffic Materials Branch—512/506-5884 for Section 11, Asphalt Inspection, Quality Control, and Quality Assurance.

Manual Notice 2000-1


From: Thomas R. Bohuslav, P. E. Director, Construction Division

Subject: Material Inspection Guide

Date: June 1, 2000

Purpose

To notify users of the Material Inspection Guide that the following sections have been revised:

♦ Section 22, “Construction Fabrics and Membranes”

♦ Section 27, “Elastomeric Materials”

♦ Section 35, “Lime”

♦ Section 49, “Preformed Joint Seals.”

Contents

The manual change contains the online version of the above sections.

Instructions

Access the new version through the TxDOT Manuals on “Crossroads.”

Contact

For more information or questions regarding the revised sections above, please contact the following branch of the Materials Section:

♦ Asphalt/Chemical Branch (512/465-7742).

Manual Notice 99-2


From: Thomas R. Bohuslav, P. E. Construction Division Director


Date: November 4, 1999

Purpose

To notify users of the Material Inspection Guide that the “Material Statement” (Form D-9-USA-1) referenced in this manual and viewed as a graphic, has been replaced with a Microsoft Word document.

Contents

The manual change contains the “Material Statement” as a Word document.

Instructions

Access the Word document through the TxDOT Manuals system.

Contact

Questions regarding the contents may be addressed to Mr. J. Jeffrey Seiders, Jr. (512/465-7617) of the Materials Section of the Construction Division.

Manual Notice 99-1




Date: September 27, 1999

Purpose

To notify users of the Material Inspection Guide that the following section has been revised:

♦ Roadside Sign Supports.

Contents

The manual change contains the online version of the above listed section.

Instructions

Access the new version through the TxDOT Manuals system.

Contact

Questions regarding the contents may be addressed to Mr. J. Jeffrey Seiders, Jr. (512/465-7617) of the Materials Section of the Construction Division.

Manual Notice 98-1




Date: November 5, 1998

Purpose

To notify users of the Material Inspection Guide that the information has been converted to an online format and is now accessible through the TxDOT Manuals system. The Material Inspection Guide was formerly part of the Construction Division, Materials Section D9MIFILE information.

Contents

The manual change contains:

♦ Online version of the Material Inspection Guide.

Instructions

Access the new version through the TxDOT Manuals system.

Contact

Questions regarding the contents may be addressed to Mr. J. Jeffrey Seiders, Jr. of the Materials Section of the Construction Division.

Material Inspection Guide 1-1 TxDOT 9/2003

Chapter 1 Material Inspection Guide

Contents: Section 1 — Overview.......................................................................................................... 1-4

Section 2 — Abbreviated Pavement Markings .................................................................... 1-5

Section 3 — Aggregate for Asphalt Stabilized Base............................................................ 1-6

Section 4 — Aggregate for Bituminous Mixes .................................................................... 1-8

Section 5 — Aggregate for Flexible Base .......................................................................... 1-10

Section 6 — Aggregate for Portland Cement Concrete...................................................... 1-11

Section 7 — Aggregate for Surface Treatment .................................................................. 1-13

Section 8 — Anchor Bolts.................................................................................................. 1-15

Section 9 — Anti-icer/De-icer Materials............................................................................ 1-16

Section 10 — Asphalt, Oils, and Emulsions....................................................................... 1-17

Section 11 — Asphalt Inspection, Quality Control, and Quality Assurance...................... 1-19

Section 12 — Bituminous Mixtures ................................................................................... 1-26

Section 13 — Bituminous Specialties ................................................................................ 1-27

Section 14 — Bridge Bearings ........................................................................................... 1-29

Section 15 — Buy America Documentation Program ....................................................... 1-30

Section 16 — Cement......................................................................................................... 1-33

Section 17 — Chain Link Fence......................................................................................... 1-35

Section 18 — Concrete Admixtures ................................................................................... 1-36

Section 19 — Concrete Membrane Curing Compound...................................................... 1-38

Section 20 — Concrete Surface Finish............................................................................... 1-40

Section 21 — Concrete Surface Treatment ........................................................................ 1-42

Section 22 — Construction Fabrics and Membranes ......................................................... 1-43

Section 23 — Construction Pavement Markings................................................................ 1-44

Section 24 — Corrugated Metal Pipe................................................................................. 1-45

Section 25 — Delineator and Object Markers.................................................................... 1-47

Section 26 — Delineator Posts ........................................................................................... 1-48

Section 27 — Elastomeric Materials .................................................................................. 1-49

Section 28 — Epoxies (Other than Paint)........................................................................... 1-50


Section 29 — Fly Ash......................................................................................................... 1-52

Section 30 — Galvanized Coatings.................................................................................... 1-53

Section 31 — High Mast Illumination Poles and Rings..................................................... 1-61

Section 32 — Hydraulic Cement ........................................................................................ 1-63

Section 33 — Joint Sealants and Fillers ............................................................................. 1-66

Section 34 — Lighting Assemblies .................................................................................... 1-67

Section 35 — Lime............................................................................................................. 1-68

Section 36 — Metal Beam Guard Fence ............................................................................ 1-70

Section 37 — Metal Railing ............................................................................................... 1-72

Section 38 — Mineral Spirits ............................................................................................. 1-74

Section 39 — Miscellaneous Pipe ...................................................................................... 1-75

Section 40 — Multi-Piece Tie Bars.................................................................................... 1-76

Section 41 — Overhead Sign Supports .............................................................................. 1-77

Section 42 — Paint and Painting ........................................................................................ 1-78

Section 43 — Pavement Markings (Reflectorized Paint)................................................... 1-80

Section 44 — Penetrating Concrete Surface Treatments ................................................... 1-81

Section 45 — Precast Concrete Safety End Treatments..................................................... 1-82

Section 46 — Precast Nonstressed Concrete...................................................................... 1-83

Section 47 — Prefabricated Pavement Markings............................................................... 1-84

Section 48 — Preformed Compression Seals..................................................................... 1-86

Section 49 — Preformed Joint Seals .................................................................................. 1-87

Section 50 — Prestressed Concrete.................................................................................... 1-88

Section 51 — Raised Pavement Markings ......................................................................... 1-89

Section 52 — Rapid Setting Mortar ................................................................................... 1-91

Section 53 — Reinforced Concrete Pipe ............................................................................ 1-92

Section 54 — Reinforcing Steel ......................................................................................... 1-95

Section 55 — Right of Way Markers ................................................................................. 1-97

Section 56 — Roadside Sign Supports............................................................................... 1-98

Section 57 — Roadway Illumination and Traffic Signal Pole Assemblies...................... 1-100

Section 58 — Sealed Expansion Joint .............................................................................. 1-102

Section 59 — Sign Walkways .......................................................................................... 1-103

Section 60 — Signs .......................................................................................................... 1-104

Section 61 — Soil Retention Blanket............................................................................... 1-105


Section 62 — Structural Steel........................................................................................... 1-106

Section 63 — Thermoplastic Pavement Markings ........................................................... 1-108

Section 64 — Traffic Beads ............................................................................................. 1-109

Section 65 — Traffic Signal Controllers .......................................................................... 1-110

Section 66 — Treated Timber Products ........................................................................... 1-111

Section 67 — Water.......................................................................................................... 1-113

Chapter 1 — Material Inspection Guide Section 1 — Overview


Section 1 Overview

A Look Ahead

This chapter outlines sampling, testing, inspecting procedures and instructions for specific roadway materials. These procedures and instructions aid the project engineer as well as the Construction Division, Materials & Pavements Section (CST/M&P) personnel in performing sampling, testing, inspecting, and related functions. Sections are further divided into the following subsections:

♦ Functions of the Project Engineer

♦ Functions of CST/M&P

♦ Sampling and Testing

♦ Remarks.

Other subsections appear as the subject warrants.

Chapter 1 — Material Inspection Guide Section 2 — Abbreviated Pavement Markings


Section 2 Abbreviated Pavement Markings

Functions of Project Engineer

The project engineer will inspect abbreviated pavement markings for conformance to the applicable specification requirements, including installation and maintenance.

Functions of CST/M&P

None.

Sampling and Testing

No sampling and testing of abbreviated pavement markings is required.

Chapter 1 — Material Inspection Guide Section 3 — Aggregate for Asphalt Stabilized Base


Section 3 Aggregate for Asphalt Stabilized Base


The project engineer performs the following functions:

♦ job control tests in addition to the quality tests and as required by the standard specifications, special specification, special provisions and/or plan notes

♦ takes samples for job control tests according to procedures outlined in “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral Aggregate.”


CST/M&P performs the following functions:

♦ If Los Angeles Abrasion is required for asphalt stabilized base aggregate, performs the L. A. when required by the standard specifications, special specifications, special provisions and/or plan notes

♦ administers the tests for quality, such as L. A., Polish Valve, or Soundness on samples as requested by the districts.


Quality Tests

♦ QM Sources • District laboratory samples aggregate sources which are under the Aggregate

Quality Monitoring Program (AQMP) when notified by CST/M&P. • Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral

Aggregates.”

♦ Non-QM-Sources • District samples each stockpile of material designated for a project. • Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral

Aggregates.”

Job Control Tests

♦ Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral Aggregates,” and ‘Table IA, Asphalt Stabilized Base’ of the Guide Schedule of Sampling and Testing of the Construction Contract Administration Handbook.

Chapter 1 — Material Inspection Guide Section 3 — Aggregate for Asphalt Stabilized Base


Remarks

When shipping samples to CST/M&P for quality tests, the project engineer will complete TxDOT Form 202, “Identification of Material Samples.”

Time required to test samples after being received:

♦ Los Angeles Abrasion – three (3) working days

♦ Polish Value – six (6) working days

♦ Soundness – fourteen (14) working days.

Chapter 1 — Material Inspection Guide Section 4 — Aggregate for Bituminous Mixes


Section 4 Aggregate for Bituminous Mixes



♦ job control tests in addition to the quality tests as required by the standard specifications, special specifications, special provisions and/or plan notes and when CST/M&P does not maintain resident inspectors at the producer’s plant

♦ take samples for job control tests according to procedures outlined in “Tex-221-F, Sampling Aggregate for Bituminous Mixtures, Surface Treatments and Limestone Rock Asphalt” or “Tex-400-A, Sampling Stone, Gravel, Sand, and Mineral Aggregates.”



♦ quality tests for aggregate for bituminous mixes when required by the standard specifications, special specifications, special provisions and/or plan notes

♦ administers AQMP as stated in “Tex-499-A, Aggregate Quality Monitoring Program”

♦ tests for quality on all samples submitted by the districts

♦ performs job control tests at commercial producers of aggregate for bituminous mixes where CST/M&P maintains resident inspectors and when production of the bituminous mixture is completed by the same producer. In this case, CST/M&P Plant Inspection test reports are forwarded directly to the project engineer indicating that the individual aggregates as well as the bituminous mixture has been tested and is acceptable for use.


Quality Tests

♦ QM Sources • District laboratory samples aggregate sources that are under the AQMP when

notified by CST/M&P. • Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral

Aggregates.”

♦ Non-QM Sources • For aggregate sources which are not under the AQMP, the district samples each

stockpile of material designated for a project according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral Aggregates” according to “Tex-499-A, Aggregate Quality Monitoring Program.”

Chapter 1 — Material Inspection Guide Section 4 — Aggregate for Bituminous Mixes


Remarks

When shipping samples to CST/M&P for quality tests, the project engineer completes TxDOT Form 202, “Identification of Material Samples.”

Allow 3 weeks for testing.

Chapter 1 — Material Inspection Guide Section 5 — Aggregate for Flexible Base


Section 5 Aggregate for Flexible Base



♦ job control tests as required by the standard specifications, special specifications, special provisions and/or plant notes

♦ takes samples for job control tests according to procedures outlined in “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral Aggregates.”


CST/M&P tests samples as requested by the project engineer.


♦ Quality Tests • District personnel tests flexible base such as Wet Ball Mill and Triaxial Strength.

♦ Job Control Tests • Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral

Aggregates,” and ‘Table I, Embankments, Subbases, and Base Courses’ of the Guide Schedule of Sampling and Testing of the Construction Contract Administration Handbook.

Remarks

When shipping samples to CST/M&P for tests, the project engineer completes TxDOT Form 202, “Identification of Material Samples.”

Chapter 1 — Material Inspection Guide Section 6 — Aggregate for Portland Cement

Concrete


Section 6 Aggregate for Portland Cement Concrete



♦ job control tests in addition to the quality tests as required by the standard specifications, special specification, special provisions and/or plan notes

♦ takes samples for job control tests according to procedures outlined in “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral Aggregates.”



♦ quality tests for Portland cement concrete aggregate when required by the standard specifications, special specifications, special provisions and/or plan notes

♦ administers the AQMP according to “Tex-499-A, Aggregate Quality Monitoring Program,”

♦ tests for quality on all samples submitted by the districts.


Quality Tests

♦ QM Sources • The district laboratory samples aggregate sources which are under the AQMP when

notified by CST/M&P. • Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral

Aggregates.”

♦ Non-QM-Sources • For aggregate sources which are not under the AQMP, the district samples each

stockpile of material designated for a project according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral Aggregates” according to “Tex-499-A, Aggregate Quality Monitoring Program.”

Job Control Tests

♦ Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral Aggregates,” and ‘Table III, Portland Cement Concrete; Structural & Miscellaneous,’ and Table ‘IV, Portland Cement Concrete Pavements,’ of the Guide Schedule of Sampling and Testing of the Construction Contract Administration Handbook.

Chapter 1 — Material Inspection Guide Section 6 — Aggregate for Portland Cement

Concrete


Remarks

When shipping samples to CST/M&P for quality tests, the project engineer completes and submits TxDOT Form 202, “Identification of Material Samples.”


Chapter 1 — Material Inspection Guide Section 7 — Aggregate for Surface Treatment


Section 7 Aggregate for Surface Treatment



♦ job control tests in addition to the quality tests as required by the standard specifications, special specifications, special provisions and/or plan notes when CST/M&P does not maintain resident inspectors at the producer’s plant

♦ takes samples for job control tests from bins, belts, stockpiles, railroad cars or trucks according to procedures outlined in “Tex-221-F, Sampling Aggregate for Bituminous Mixtures, Surface Treatments and Limestone Rock Asphalt.”



♦ quality tests for surface treatment aggregates when required by the standard specifications, special specifications, special provisions and/or plan notes

♦ administers AQMP according to “Tex-499-A, Aggregate Quality Monitoring Program”

♦ tests for quality on all samples submitted by the districts

♦ performs job control tests at commercial plants where CST/M&P maintains resident inspectors and forward plant inspection reports to the project engineer indicating that the aggregate has been tested and is acceptable for use.


Quality Tests

♦ QM Sources • District laboratory samples aggregate sources that are under AQMP when notified

by CST/M&P. • Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral

Aggregates” according to “Tex-499-A, Aggregate Quality Monitoring Program.”

♦ Non-QM Sources • District samples each stockpile of material designated for a project. • Sample according to “Tex-400-A, Sampling Stone, Gravel, Sand and Mineral

Aggregates.”

Chapter 1 — Material Inspection Guide Section 7 — Aggregate for Surface Treatment


Remarks

When shipping samples to CST/M&P for quality tests, the project engineer completes and submits TxDOT Form 202, “Identification of Material Samples.”

Include the following information on each Form 202, “Identification of Material Samples”:

♦ month, day and year the sample was taken

♦ name of area engineer

♦ name of TxDOT employee who obtained the sample, if not a TxDOT employee, state (informational)

♦ name of prime contractor

♦ project district

♦ project county

♦ project control, section and job number

♦ federal project number

♦ type of material (example: crushed stone)

♦ company name of material producer

♦ location – pit or quarry name or source number, if known

♦ sampled from (example – stockpile on project)

♦ quantity – estimated quantity of stockpile sampled

♦ units – cubic yards or tons (C.Y. preferred)

♦ specification item relating to this sample

♦ identification marks or district number of this sample.


Chapter 1 — Material Inspection Guide Section 8 — Anchor Bolts


Section 8 Anchor Bolts

Reference

Refer to the Spec Book for information on the following:

♦ Standard Specification “Item 449, Anchor Bolts.”



♦ checks all anchor bolts inspected by CST/M&P for the TxDOT monogram

♦ inspects anchor bolts for full threading, dimensions, fit of the nuts, and length of galvanizing/zinc coating

♦ contacts CST/M&P when: • fit of bolts and nuts appears to be improper such as too loose or too tight • material, threads, or coating appear questionable.



♦ obtains the Form D-9-USA-1, Material Statement, MTRs, and certifications on all anchor bolts inspected for structural applications

♦ inspects and stamps, with the TxDOT monogram, anchor bolts fabricated at locations where CST/M&P performs inspection

♦ issues General Test Reports to the project engineer for all material inspected or tested by CST/M&P

♦ assists the project engineer when requested.


The project engineer contacts CST/M&P for sampling instructions when questionable material is found.

Chapter 1 — Material Inspection Guide Section 9 — Anti-icer/De-icer Materials


Section 9 Anti-icer/De-icer Materials



♦ samples each shipment of salt or anti-icer/de-icer at the destination • takes sample at random from the shipment with a sampling thief or other means

which will assure a representative cross-section of the material.



♦ tests samples of salt and any other chemical deicer submitted by the project engineer

♦ ensures that each magnesium chloride manufacturer has been pre-qualified

♦ issues test reports to the project engineer.


The project engineer submits a 2 L (1/2 gal.) sample of salt or any other chemical de-icer for each shipment.

Remarks

Place the solid sample in a plastic bag, which shall be sealed and placed in a 4 L (1 gal.) friction lid bucket for shipment.

Place the liquid sample in a plastic container, which shall be sealed.

Allow seven working days for testing from the time the sample is received in the laboratory.

Obtain the list of pre-qualified manufacturers for magnesium chloride from CST/M&P.

Chapter 1 — Material Inspection Guide Section 10 — Asphalt, Oils, and Emulsions


Section 10 Asphalt, Oils, and Emulsions

Overview

This section describes general sampling and approval requirements for asphalt, oils, and emulsions.

Asphalt, oils and emulsions are sampled and approved at point of origin by CST/M&P unless field sampling for approval is indicated by the governing specifications.

Each preapproved load shall be accompanied by the producer’s invoice or bill of lading showing the grade of material, tank number, tank seal numbers (or batch number) and the laboratory number.



♦ samples any asphalt, oil or emulsion which is not properly identified by the producers’ invoice as being the material specified

♦ samples any asphalt, oil or emulsion suspected of being contaminated or not conforming to specification requirements.



♦ samples, tests and approves asphalt, oils and emulsions at the source prior to shipment to TxDOT projects

♦ tests and reports any samples submitted by the project engineer.


Sample according to Test Method “Tex-500-C, Sampling Bituminous Materials, Pre-molded Joint Fillers, and Joint Sealers.”

Use the following sample sizes:

♦ Asphalt • Take one 0.946 L (1 qt.) in a double friction top can.

♦ Oils and Emulsions • Take two 0.946 L (1 qt.) samples in screw-top cans.

Chapter 1 — Material Inspection Guide Section 10 — Asphalt, Oils, and Emulsions


Remarks

Take samples dipping well below the surface or from lines and sampling cocks that have been fully purged of any previous material.

Chapter 1 — Material Inspection Guide Section 11 — Asphalt Inspection, Quality Control,

and Quality Assurance


Section 11 Asphalt Inspection, Quality Control, and Quality Assurance

Overview

TxDOT maintains asphalt binder quality through a combination of inspection, quality control, and quality assurance described in this document.

An authorized inspector of TxDOT normally samples or witnesses the sampling of asphalt materials for quality assurance testing at the point of manufacture. Exceptions are cases where TxDOT does not maintain inspection personnel located near the source, or where the project or material specifications define other sampling procedures.

In the context of this document, the terms producer and supplier are used interchangeably. The point of manufacture is that place at which the product is made to meet the requirements of a materials specification.

For asphalt products, Quality Control is the responsibility of the supplier and represents all testing deemed necessary for the supplier to insure that products meet specification requirements and any tests required by TxDOT for sampling, testing, and approval.

For asphalt products, Quality Assurance is the responsibility of TxDOT and represents all testing necessary to confirm that materials meet specification requirements. This may consist of complete or partial specification testing.

The producer/supplier may elect to:

♦ batch the material in storage tanks, utilize automatic blending to produce the finished grades of asphalt into storage tanks or transports, or

♦ blend materials on site at the point of consumption with no intermediate storage.

Quality control and quality assurance requirements differ depending on which of these methods the producer/supplier utilizes for asphalt manufacture.

This document describes the requirements and procedures for inspection at the point of manufacture for producers/suppliers desiring to furnish asphalt materials on TxDOT projects.

The Director of the Materials and Pavements Section (CST/M&P) must approve any variation from the procedures described below. Address any questions regarding asphalt sampling and inspection to the Asphalt Laboratory at 512-506-5818, 512-506-5821, or TxDOT, CST/M&P (CP51), 125 E. 11th Street, Austin, TX 78701-2483.




Asphalt Batched in Tanks or Blended into Tanks or Transports

The following requirements are for asphalt batched into tanks or manufactured utilizing automatic blending equipment into tanks or transports. Two systems are described, testing of individual products or an approved quality control program.

Blending of the finished product directly into transports with no intermediate tank storage is allowed only after sufficient samples have been taken to demonstrate that the blending system consistently produces asphalt complying with specification requirements.

Testing of Individual Products

Producers operating under ‘Testing of Individual Products’ must adhere to the following requirements.

♦ Storage • Use storage tanks for the finished asphalt or blending stocks of a size

commensurate with the quantity of material produced so that excessive sampling will not be required.

• Set storage and loading temperatures as desired, as long as they are within the limits specified in the current TxDOT specifications.

• Provide a satisfactory means of effectively sealing the inlet or fill line. • Equip tanks with convenient sampling cocks according to their approximately

capacity as follows:

Tank Capacity Tank Capacity (gallons) Sampling Cocks

Up to 50,000 1 Above 50,000 to 400,000 2 Above 400,000 3

♦ Sampling • Material Batched in Tanks. The sampling and inspection of finished asphalt

batched in tanks is as follows:

Material Batched in Tanks Step Action

1 ♦ Notify the TxDOT inspector when a tank is ready for sampling. The TxDOT inspector will usually have producer personnel draw the samples in his presence, or he may take them himself.

♦ Sample according to “Tex-500-C, Sampling Bituminous Materials, Pre-Molded Joint Fillers, and Joint Sealers.”

2 Seal the inlet line with a railroad-type, numbered seal at the time of sampling.

• Material Blended to Produce Finished Grades of Asphalt. The sampling and inspection of material blended to produce finished grades of asphalt is as follows:

Material Blended to Produce Finished Grades of Asphalt




Step Action 1 ♦ Assign a batch number to each individual grade of asphalt produced through an

automatic blender. ♦ Change the batch number each time either of the blending stocks changes.

2 ♦ After assigning a batch number to a grade of asphalt, contact the TxDOT inspector to for sampling from a trial blend or as the first truck from this batch is loaded.

♦ Obtain the sample from a sampling valve on the loading riser or from the truck after loading.

NOTE: It is not necessary to sample and seal the inlet lines of blending stock tanks unless these stocks individually represent a given grade, e.g., AC-3 and AC-10 are being blended to produce AC-5. In this case, handle the AC-3 and AC-10 as material batched in tanks.

• Transport Sampling

Transport Sampling Step Action

1 ♦ The TxDOT inspector samples or witnesses the sampling of loaded transports on a random basis before departure from the plant.

♦ Assist the inspector in obtaining these samples.

♦ Testing and Approval • It is the producer’s responsibility to test his or her product for specification

compliance. Obtain a list of required quality control tests for each product from the CST/M&P Asphalt Laboratory. Perform quality control tests and forward the test results to the Asphalt Laboratory. The test results may accompany the sample or be faxed (512-506-5825) before the sample arrives. Unless TxDOT grants the producer the privilege of advance acceptance (see ‘Advance Acceptance’), TxDOT will not test or approve materials before receipt of producer data.

• The TxDOT inspector forwards all samples and any producer test reports to the Materials & Pavements Section by bus or parcel delivery service. The Asphalt/Chemical & Traffic Materials Branch will conduct quality assurance tests for specification compliance. TxDOT will notify the producer directly or through the inspector if quality assurance testing shows that the material complies with specification requirements. TxDOT approves materials meeting specification requirements for shipment.

• TxDOT approves asphalt cements for a period up to 60 days. TxDOT approves cutbacks and emulsions for a maximum period of 30 days. Treat materials exceeding these time limits as unapproved product requiring testing by the producer, re-sampling and re-testing by TxDOT for approval.

• Unless TxDOT grants the producer the privilege of advance acceptance (see ‘Advance Acceptance’), all material must have be tested and approved before shipment. The Asphalt Laboratory assigns TxDOT laboratory numbers to all materials before shipment.




• A transport sample that fails to conform to specification requirements will result in immediate cancellation of shipment rights from the originating tank. Treat the originating tank as unapproved product requiring testing by the producer, re-sampling and re-testing by TxDOT for approval.

• TxDOT bears the expense of sampling and testing asphalts that are acceptable and meet the specification requirements. In the event that an asphalt fails to meet the requirements of TxDOT specifications, the cost of sampling and testing will be charged to the producer/supplier. Charges will be at published rates, which are based on actual costs to the state, and an additional charge to cover the costs of billing for failing tests. Concurrence in and agreement to this policy and procedure is required from companies that desire to supply asphalt.

♦ Loading and Shipping • Ensure that material is loaded from properly sampled and approved tanks and that

transports are clean. Ensure that the proper grade, as ordered, is loaded and shipped.

• Provide a separate loading system for asphalt cements, cutbacks and emulsions. • Furnish the TxDOT inspector a legible copy of the invoice or loading certificate

within five working days of material shipment. Make available one copy of the loading invoice, marked “Texas Department of Transportation Copy,” to the designated Department representative on delivery and before use of the asphalt.

• The invoice should be a printed, numbered series for easy identification of the load and show the following information:

Invoice Information 1. Supplier’s name and location 2. Producer’s name and location (if different from supplier) 3. Consignee and destination 4. Type and grade asphalt 5. Tank and seal numbers or batch number from which loaded 6. Temperatures, date, and time of loading 7. Laboratory number 8. Highway project number and/or requisition number 9. Specific gravity of AC and PG binders at 25 ºC (77 °F), and cutbacks and emulsions at 15.5

ºC (60 °F) 10. Penetration at 25 ºC (77 °F) for AC's 11. Net weight.

♦ Advance Acceptance • There normally will be a period of several days between obtaining the asphalt

samples and receiving approval to ship the material. • During periods of heavy shipment, it may be difficult for a producer to maintain a

sufficient supply of approved material.




• After a producer has established a good record of compliance with the specification requirements, the producer may request ‘Advanced Acceptance.’ Make this request directly to the Asphalt Laboratory.

• To qualify for advanced acceptance of a particular grade of material, the Asphalt Laboratory must have verified the three most recent consecutive samples as meeting the specification requirements.

• Furnish test results on the asphalt at the time of the request. The results should be well within the specification limits.

• Under this procedure, once the producer has tested a new tank or blend of a particular grade of material and found it to be in compliance and the TxDOT inspector has obtained a sample, the Asphalt Laboratory may assign a laboratory number. This laboratory number allows the producer to ship the material before quality assurance testing by the Asphalt Laboratory.

• If a producer has qualified for advanced acceptance and a sample of a material does not meet specification requirements, TxDOT will withdraw the advanced acceptance privilege for that material.

• TxDOT will only consider reinstatement of advance acceptance privileges when three consecutive samples of the specific material meet specification requirements at the CST/M&P Asphalt Laboratory.

• TxDOT only extends advance acceptance privileges for producers with an establish history of specification compliance.

NOTE: The producer must furnish their own test results on the asphalt each time a request for advanced acceptance is made.

Approved Quality Control Plan

Operating under an ‘Approved Quality Control Plan’ changes TxDOT’s quality assurance philosophy from testing of individual products, to monitoring of product production. To operate under a quality control plan, the supplier must have:

♦ operated under the testing of individual products plan described above,

♦ developed testing agreement with TxDOT,

♦ developed a quality control plan, and

♦ received approval from TxDOT, CST/M&P that the plan adequately addresses quality concerns.

As a minimum, the supplier’s plan, must address:

♦ a mechanism to notify the Asphalt Laboratory of products to be supplied

♦ frequency of supplier testing for all products

♦ what QC tests will be performed




♦ what training and calibration procedures will be used (and records kept) to assure that technicians perform tests according to correct procedures and equipment is maintained and calibrated

♦ how supplier tests are monitored and reported to the Asphalt Laboratory

♦ a sampling frequency for TxDOT split samples, requirements for testing these samples as “split” samples, and required supplier test results for these samples

♦ a mechanism for TxDOT authorization of product shipments (assignment of laboratory numbers)

♦ what will be done if supplier testing shows products do not meet specification requirements, and

♦ what will be done if TxDOT testing shows products do not meet specification requirements.

Suppliers not maintaining adequate quality control, in the opinion of TxDOT, may result in changing back to testing of individual product or in severe cases, job site testing for approval.

Asphalt Materials Manufactured at the Point of Consumption

Manufacturing asphalt materials at the point of consumption includes blending of binders at the jobsite using temporary tanks or addition of modifiers into the asphalt line at the hot mix plant. In these instances there is no storage facility or time lag between manufacture of the binder and consumption to allow for testing in a manner described in the ‘batch or blend into tanks’ scenario described previously. In some instances, the asphalt contractor becomes the manufacturer and the binder will first meet the product specifications in the pipeline leading to the hot mix plant.

If binders are manufactured at the point of consumption, for example where SBR latex is injected at the hot mix plant, the following quality measures are required (antistrip agents are not considered asphalt modifiers).

Preconstruction

Provide the engineer with a 1 L (1 qt.) sample of the proposed binder and a test report showing compliance with the required specifications. The engineer will forward the sample and test report to the CST/M&P Asphalt Laboratory for quality assurance testing. The Asphalt Laboratory will complete quality assurance testing within ten working days after receipt of the sample. Quality assurance tests shall show compliance with specification requirements before job site production may begin.

Construction

♦ Construction Sampling




• Provide a sampling port meeting the requirements of AASHTO "T 40, Practice for Sampling Bituminous Materials," Section 9, "Sampling from Pipelines During Loading or Unloading."

• Locate the sampling port at a point before binder consumption and down stream from the addition of any modifiers and any dispersing or mixing equipment associated with their introduction.

• Provide clean, round, 4 L (1 gal.) cans for sampling. Provide clean, round, double friction top, 1 L (1 qt.) cans for samples. Obtain all samples with witness by the engineer.

• Obtain all samples from the sampling port after a sufficient amount of asphalt is run out and wasted, in order to clear any residual asphalt that builds up in the sampling port.

• Take all samples in a clean, 4 L (1 gal.) can. Immediately stir the sample and fill three 1 L (1 qt.) sample cans. Deliver the cans to the engineer. The engineer will choose one sample can for testing and retain others until testing is complete. If the original sample is lost or damaged, use a retained sample for testing.

♦ Sampling Frequency • Take a sample of the binder from each production day, at a time determined by the

engineer. TxDOT will perform quality assurance testing on the sample from the first day's production.

• Additionally, the engineer will randomly select a minimum of one sample from every nine daily binder samples (or a minimum of one sample per project if there are less than nine mixture production days) for quality assurance testing.

♦ Quality Assurance Testing • The CST/M&P Asphalt Laboratory conducts all quality assurance testing within

ten working days after receipt of the sample. • For quality assurance testing which fails to confirm specification compliance,

review the manufacturing process to locate the source of the problem. The engineer may stop production until the producer can show that the next binder produced will meet the specifications. The engineer may require materials not meeting the specification requirements to be removed and replaced at the producer's expense.

Chapter 1 — Material Inspection Guide Section 12 — Bituminous Mixtures


Section 12 Bituminous Mixtures

Overview

Bituminous mixtures include hot mix asphaltic concrete, hot mix-cold laid asphaltic concrete, cold mix limestone rock asphalt, precoated aggregate and patching mixes.

Function of Project Engineer


♦ Plant inspection and sampling except at commercial producers of bituminous mixtures where authorized inspectors are maintained by the Materials & Pavements Section of the Construction Division (CST/M&P).



♦ tests samples submitted by the project engineer

♦ samples and inspects bituminous mixtures where CST/M&P maintains field office inspectors

♦ issues Plant Inspection test reports indicating that the material has been inspected and tested and can be unloaded upon arrival at destination.


When it is necessary for the project engineer to sample at destination, sample according to:

♦ "Tex-400-A, Sampling Stone, Gravel, Sand, and Mineral Aggregates" or

♦ "Tex-222-F, Sampling Bituminous Mixtures" and

♦ ‘Table V, Asphaltic Concrete Pavement’ of the Guide Schedule of Sampling and Testing of the Construction Contract Administration Handbook.

Chapter 1 — Material Inspection Guide Section 13 — Bituminous Specialties


Section 13 Bituminous Specialties

Overview

This section describes sampling and testing of miscellaneous materials, including some pre-molded joint and waterproofing materials.

Manufacturer’s Certification

The project engineer accepts the following bituminous specialties on the basis of Manufacturer’s Certification:

♦ sewer joint compound

♦ plastic cement

♦ cold applied preformed plastic gaskets

♦ primers for concrete pipe

♦ adhesive for butyl rubber

♦ splicing cement

♦ asphalt mat

♦ butyl rubber membrane

♦ asphalt plank

♦ pre-molded expansion joint filler

♦ asphalt backerboard.

Quality Monitoring (QM) Materials

The project engineer accepts the following materials provided that the manufacturer has been pre-approved by CST/M&P to supply the material:

♦ rubber asphalt crack sealer

♦ bituminous marker adhesive.

Indicate a pre-approved status by a valid QM test report.

CST/M&P samples these materials every six months to determine compliance with appropriate specifications, and will make the QM test reports available as described in “Tex-538-C, Quality Monitoring for Joint Sealers and Related Materials.”

Chapter 1 — Material Inspection Guide Section 13 — Bituminous Specialties


Sampled at Destination

Sample according to “Tex-500-C, Sampling Bituminous Materials, Pre-molded Joint Fillers, and Joint Sealers.”

Project engineer or other responsible district personnel samples the following materials at the destination, unless other arrangements have been made with CST/M&P prior to use:

♦ waterproofing fabric

♦ waterproofing membrane for pavement joints and cracks

♦ self-adhering polyethylene

♦ rubberized asphalt and plastic film membrane

♦ mopping asphalt

♦ cold asphalt base emulsion

♦ asphaltic polymer and coal tar modified urethane coating.

Chapter 1 — Material Inspection Guide Section 14 — Bridge Bearings


Section 14 Bridge Bearings

References

Refer to the Spec Book and TxDOT special specifications for information on the following:

♦ “Item 434, Sliding Elastomeric Bearings

♦ “Item 435, Elastomeric Materials”

♦ Special Specification.



♦ accepts plain or laminated elastomeric bridge bearings, sliding elastomeric bearings and pot bearings on the basis of the following: • Plain or Laminated Elastomeric Bearings – Checks each plain or laminated bearing

for the TxDOT monogram, checks for shipping damage, and verifies proper field installation of pads (i.e. direction of pad slope, location, etc.)

• Sliding Elastomeric Bearings – Checks each sliding bearing for the TxDOT monogram and checks for shipping damage

• Pot Bearings – Checks each pot bearing for the TxDOT monogram and checks for shipping damage

♦ advises CST/M&P if questionable materials are received on the job-site.



♦ obtains the Form D-9-USA-1, Material Statement, MTRs, and certifications for all inspected steel components of bridge bearings

♦ samples, inspects and stamps, with the TxDOT monogram, bridge bearings fabricated at locations where CST/M&P performs inspection

♦ issues general test reports to the project engineer for all material inspected or tested by CST/M&P



Sampling and testing are not required.

Chapter 1 — Material Inspection Guide Section 15 — Buy America Documentation Program


Section 15 Buy America Documentation Program

Overview

“Item 6, Control of Materials,” Article 6.1. ‘Sources of Supply and Quality of Materials,’ requires that:

All manufacturing processes for steel or iron materials, or for the “action of applying a coating” to these materials (i.e., epoxy coating, galvanizing, painting, and any other coating that protects or enhances the value of the steel or iron material) permanently incorporated into the finished project must occur in the Unites States.

This specification requirement, however, allows a minimal use of foreign materials.

CST/M&P developed this documentation program for the verification of this domestic origin requirement for steel and iron materials.

Reference


♦ “Item 6, Control of Materials.”

Definitions

Refer to the glossary for definitions of the following:

♦ Certification - Certification is a document furnished by the manufacturer containing the following information: Name and address of the manufacturer and the location where the manufacturing process occurred (if different from the address); manufacturing step(s) performed by the manufacturer; heat number(s), lot number(s), or any other identification used to identify the material; a notarized statement from the manufacturer, attesting to the domestic origin of the material and signed by a person who can legally represent the manufacturer.

♦ Domestic origin - Domestic origin means having all manufacturing processes occurring in the United States of America.

♦ Mill test report (MTR) - Mill Test Report for steel is a report from the producing mill of the base metal listing the chemical analysis, physical analysis; heat or lot number; specification used to manufacture the material; "Domestic Clause" stating that the steel or iron was melted and manufactured in the United States of America. Reporting of the chemical and physical analysis shall be as required by the applicable ASTM, AASHTO, ANSI, etc., specification.

♦ Supplier - A supplier is one who offers a material or finished product to TxDOT or contractors of TxDOT. A supplier may be a prime contractor, sub-contractor, producer, fabricator, manufacturer, approved warehouse, etc.



Responsibilities

For each situation listed below, the responsibilities of the project engineer and CST/M&P are as follow:

Steel and Iron Items Inspected and Tested by CST/M&P

♦ The project engineer: • receives CST/M&P general test report as proof of compliance with the

requirements of the specification.

♦ CST/M&P: • obtains, from the supplier, a completed Form D-9-USA-1, Material Statement (see

‘Documentation’ ) with attached MTRs, certifications, galvanizing reports, etc.

Steel and Iron Items Received and Sampled by the Project Engineer for Testing by CST/M&P

♦ The project engineer: • submits samples with the required documentation obtained from the supplier:

completed Form D-9-USA-1, Material Statement, with attached MTRs, certifications, galvanizing reports, etc. to CST/M&P for testing

• receives CST/M&P General Test Report for all passing material (proof of compliance with the requirements of the specifications).

Steel and Iron Items Received, Inspected, and Accepted by the Project Engineer

♦ The project engineer: • obtains, from the supplier, the completed Form D-9-USA-1, Material Statement

(see ‘Documentation’ ), with attached MTRs, certifications, galvanizing reports, etc.

♦ CST/M&P: • assists the project engineer when requested.

Steel and Iron Items Received from Regional or District Warehouse (Pretested) Stock

♦ The project engineer: • obtains documentation verifying the material was obtained from a regional or

district warehouse • when requested to inspect and test, obtain from the supplier the completed Form D-

9-USA-1, Material Statement, with attached MTRs, etc.

Documentation

TxDOT uses the following forms for verifying domestic origin requirements of steel and iron Materials.

♦ Form D-9-USA-1, Material Statement



This form is available from TxDOT and shall be completed by the supplier. This form, when completed, should contain the requested information with attached MTRs, certifications, galvanizing reports, etc. Refer to “Steel and Iron Items” for further information.

♦ Form D-9-PS-1, “Domestic Certification”

All TxDOT approved seven-wire strand (stress-relieved and low relaxation) manufacturers generate their own version of this form and furnish it with all shipments of seven-wire strand to the TxDOT project. The minimum required information on this form shall be:

• the project information • the type, size, and quantity of steel strand • heat numbers associated with the rod used to make the strand • reel numbers or lot numbers associated with the strand furnished • notarized statement attesting to the domestic origin for the base metal for steel

strand furnished.

WARNING: In the event a supplier is possibly providing improper or falsified documentation, the TxDOT entity responsible for acceptance of the material (division or district warehouse, project engineer, General Services Division and/or CST/M&P) shall notify the supplier in writing regarding the problem and take appropriate action. The Texas Attorney General’s Office shall be notified of major violations.

Chapter 1 — Material Inspection Guide Section 16 — Cement


Section 16 Cement



♦ ensures that cement is furnished only from sources certified by CST/M&P. The certified sources for cement can be found in Concrete Admixtures and Cement of the Material Producer List.

♦ samples any cement received on the job site which appears to be of questionable quality.

NOTE: Cement from certified sources will not require sampling by the project engineer.



♦ maintains quality control of certified sources at the mill or terminal


♦ issues test reports on samples submitted by the project engineer.


The following information pertains to sampling and testing cement:

♦ Sample size • loosely filled 4 L (1 gal.) friction lid bucket.

♦ Refer to “Tex-300-D, Sampling Hydraulic Cement.”

Remarks

Do not combine samples into a composite sample under any conditions and take care to ensure that the sample is representative of the cement actually used.

Indicate on the Form 202, “Identification of Material Samples”:

♦ cement type

♦ producer

♦ mill location

♦ trailer and/or rail car number

♦ date of sampling

Chapter 1 — Material Inspection Guide Section 16 — Cement


♦ quantity represented

♦ project and/or job numbers

♦ project or area engineer.

Chapter 1 — Material Inspection Guide Section 17 — Chain Link Fence


Section 17 Chain Link Fence

References


♦ “Item 550, Chain Link Fence.”



♦ accepts chain link fence on the basis of a certification from the manufacturer stating that all fencing materials comply with the requirements of “Item 550

♦ obtains MTRs (see NOTE) and visually inspects for the following: • red rust – look for damaged or defective coatings • white rust (white powdery residue) – Small areas acceptable but large areas require

investigation • zinc daggers or icicles – Long, sharp projections of zinc, if minor, are acceptable if

removed by filing. Watch for brittle coating • excessive roughness, blisters, and flaking (brittleness) of the coating, if present to

any considerable extent, shall provide a basis for rejection of that material

♦ advises CST/M&P if questionable material is received on the job-site.

NOTE: Chain link fence delivered to the job-site shall be accompanied: • by TxDOT Form D-9-USA-1, Material Statement • MTRs for the base metal • a certification for the coating.


CST/M&P assists the project engineer when requested.


If the material is of questionable quality, the project engineer obtains and submits samples according to “Tex-708-I, Sampling Galvanized Metal Products for Coating Weight.”

Chapter 1 — Material Inspection Guide Section 18 — Concrete Admixtures


Section 18 Concrete Admixtures



♦ ensures concrete admixtures are preapproved and any admixture listed in Concrete Admixtures may be used without further testing • contractors furnish copies of the invoice to the project engineer showing the

admixture or admixtures to be used on the project • when changing brands of admixtures, make pilot tests using the materials that will

be used on the project

♦ samples any admixture which is of questionable quality and submit to CST/M&P for testing.



♦ samples, pretests and approves concrete admixtures in the laboratory

♦ maintains list of approved concrete admixtures

♦ tests concrete admixture samples submitted by project engineer.


The following guidelines are for sampling concrete admixtures:

♦ Sampling Frequency • Sample if questionable quality.

♦ Sample Size • 4 L (1 gal.) plastic bottle.

Remarks

Follow the manufacturer’s storage instructions and agitate any admixture stored for an extended period prior to use.

Do not mix different brands or types of admixtures together prior to use or introduced into the mix at the same time.

Any admixture proposed for use that is not on the approved list will require a minimum of 12 months to test.

Chapter 1 — Material Inspection Guide Section 18 — Concrete Admixtures


The list of approved admixtures may be found in Concrete Admixtures.

Chapter 1 — Material Inspection Guide Section 19 — Concrete Membrane Curing

Compound


Section 19 Concrete Membrane Curing Compound

Overview

Concrete membrane curing compound is sampled at the point of manufacture and samples are submitted to CST/M&P for testing.

Curing compound will be delivered to the project only in the manufacturer’s original containers, which shall be clearly labeled with the brand name of the compound, the type of compound, and a producer’s batch number with which test samples may be correlated.

All approved containers will be stamped with the TxDOT approval stamp, the laboratory number, and the date when retesting will be required.



♦ samples containers which do not bear the TxDOT approval stamp

♦ ensures that curing compounds are thoroughly agitated prior to use and/or sampling.



♦ samples, tests, and approves at point of manufacture

♦ stamps containers with TxDOT approval stamp

♦ tests samples submitted by the project engineer.


The following are sampling and testing requirements.

♦ Sampling Frequency • each batch or shipment.

♦ Sample Size • take three 0.473 L (1 pt.) samples per batch • take a 0.473 L (1 pt.) sample from three randomly selected drums • use only lined friction top cans.

♦ Refer to “Tex-718-I, Sampling Liquid Membrane-Forming Compounds for Curing Concrete.”

Chapter 1 — Material Inspection Guide Section 19 — Concrete Membrane Curing

Compound


Remarks

CAUTION: Curing compounds must be thoroughly agitated prior to sampling and samples must be shipped in friction top buckets.

The project engineer completes a TxDOT Form 202, “Identification of Material Samples.”

Chapter 1 — Material Inspection Guide Section 20 — Concrete Surface Finish


Section 20 Concrete Surface Finish

Overview

Concrete surface finish is sampled at the point of manufacture and samples are submitted to CST/M&P for testing.

The surface finishes shall be delivered to the project only in the manufacturer's original containers, which shall be clearly labeled with the brand name of the surface finish, the class and type of finish and a producer’s batch number with which test samples may be correlated.

All approved containers will be stamped with the TxDOT approval stamp and the expiration date.


The project Engineer performs the following functions:

♦ samples containers which do not bear the TxDOT stamp

♦ ensures containers of surface finish are thoroughly agitated prior to use and/or sampling.



♦ samples, tests and approves at the point of manufacture

♦ stamps containers with the TxDOT approval stamp



The following are sampling and testing requirements:

♦ Sampling frequency • each batch or shipment.

♦ Sample size • 4 L (1 gal.) in clean friction top paint cans.

♦ Sample according to “Tex-736-I, Sampling Structural Coatings.”

NOTE: Additional samples may be submitted for testing when questionable material is received at the job site.

♦ Test according to “DMS-8110, Coatings for Concrete.”

Chapter 1 — Material Inspection Guide Section 20 — Concrete Surface Finish


Remarks

CAUTION: Concrete surface finishes must be thoroughly agitated prior to sampling and/or use. Samples must be shipped in clean friction top buckets/cans.

The project engineer completes a TxDOT Form 202, “Identification of Material Samples.”

Inquiries should include the type of concrete surface finish, quantity, name of manufacturer, product destination, and batch number.

Chapter 1 — Material Inspection Guide Section 21 — Concrete Surface Treatment


Section 21 Concrete Surface Treatment



♦ samples concrete surface treatment at the job-site if the quality of the material is questionable

♦ samples material which does not bear the TxDOT approval stamp.

NOTE: Containers of approved concrete surface treatment which have been sampled at origin or at approved warehouses will bear the TxDOT approval stamp and the project engineer will be advised of approved batch numbers.




♦ issues test reports for samples submitted by the project engineer

♦ samples concrete surface treatment at origin or at approved warehouses and issues test reports when prior arrangements have been made.

Remarks

The project engineer shows the liters (gallons) received per load and batch or lot numbers of drums or buckets sampled on a TxDOT Form 202, “Identification of Material Samples.”

Chapter 1 — Material Inspection Guide Section 22 — Construction Fabrics and Membranes


Section 22 Construction Fabrics and Membranes



♦ has rolls unloaded and placed in 100 roll lots

♦ ensures all rolls have lot or roll numbers.



♦ randomly tests samples to ensure quality of material

♦ prequalifies producers and fabric styles



Perform sampling and pre-qualification of materials.

Remarks

Allow five working days for testing, from the time material is received in the laboratory.

The list of pre-qualified manufacturers for Silt Fence, Filter Fabric, and Fabric for Underseal may be obtained from CST/M&P.

Chapter 1 — Material Inspection Guide Section 23 — Construction Pavement Markings


Section 23 Construction Pavement Markings


The project engineer inspects construction pavement markings for conformance to the applicable specification requirements, including installation and maintenance.


None.


None.

Chapter 1 — Material Inspection Guide Section 24 — Corrugated Metal Pipe


Section 24 Corrugated Metal Pipe

References


♦ “Item 460, Corrugated Metal Pipe

♦ “Item 467, Safety End Treatment.”



♦ obtains MTRs (see NOTE)

♦ inspects corrugated metal pipe or corrugated metal end sections for compliance with the specifications (dimensions, type, gauge, etc.), damage, and for workmanship

♦ rejects pipe or end sections, which have been damaged during fabrication or in shipping, unless satisfactory repairs are made. Defects constituting poor workmanship are: • variation from a straight centerline • elliptical shape in pipe intended to be round • dents or bends in the metal • damaged galvanized, bituminous, or polymer coating • lack of rigidity • illegible or omitted brand markings (brand shall show: Name of Manufacturer,

Heat #, and AASHTO Specification) • ragged or diagonal sheared edges • uneven laps in riveted or spot welded pipe • loose, unevenly lined, or unevenly spaced rivets • defective spot welds or continuous welds • loosely formed lockseams.


NOTE: Corrugated metal pipe delivered to the job-site shall be accompanied by: • TxDOT Form D-9-USA-1, Material Statement • MTRs for the base metal • a certification for the coating.

Chapter 1 — Material Inspection Guide Section 24 — Corrugated Metal Pipe




♦ obtains periodic samples of corrugated metal pipe for testing from manufacturers



If the material is of questionable quality, the project engineer obtains and submits samples according to “Tex-708 I, Sampling Galvanized Metal Products for Coating Weight.”

Chapter 1 — Material Inspection Guide Section 25 — Delineator and Object Markers


Section 25 Delineator and Object Markers



♦ samples delineator and object markers at the job site, unless prior arrangements have been made to sample at origin

♦ checks for cracked or broken lenses or moisture inside lenses

♦ advises CST/M&P if material of questionable quality is received at the job site.





♦ samples delineators and object markers at origin or an approved warehouse (when prior arrangements have been made) and issues test reports.



♦ Sampling • at a rate of 25 minimum lenses of each color and size • according to “Tex-725-I, Sampling Delineator and Object Marker Reflector Units.”

NOTE: If less than 25 lenses of a particular color are to be used on a project, the lenses shall not be sampled but shall be visually inspected and certifications of compliance furnished by the lens manufacturer.

Remarks

Inquiries should include the type of delineator or object marker, quantity, name of the manufacturer of the lens(es) and/or reflective sheeting.

When samples are required, the project engineer completes TxDOT Form 202, “Identification of Material Samples.”

Chapter 1 — Material Inspection Guide Section 26 — Delineator Posts


Section 26 Delineator Posts



♦ Delineator Posts (Steel) • accepts the steel delineator posts on the basis of the manufacturer's certification and

visually inspects for damaged coating, section size, holes, etc. (see ‘Remarks’ ).

♦ Delineator Posts (Flexible) • inspects each shipment of flexible delineator posts for damage and samples flexible

delineator posts at the job-site (see ‘Remarks’).

NOTE: Flexible delineator posts must be prequalified and on the approved list maintained by GSD.




♦ prequalifies flexible delineator posts and maintains quality control on samples submitted

♦ issues test reports to the project engineer.


Sampling and testing requirements:

♦ Steel Delineator Posts • None.

♦ Flexible Delineator Posts • three flexible delineator posts from each lot or shipment • sample according to “Tex-737-I, Sampling Delineator and Object Marker Posts.”

Remarks

When established in the proposal and specifications, certain items in this section may be purchased by the contractor from stock of a TxDOT regional supply center, in which case, the items are pretested and approved for use.


Chapter 1 — Material Inspection Guide Section 27 — Elastomeric Materials


Section 27 Elastomeric Materials

References


♦ “Item 435, Elastomeric Materials.”



♦ accepts elastomeric materials by: • obtaining and verifying the Manufacturer’s Certification according to the

specification • visually inspects for cuts, damage, and proper dimensions

♦ advises CST/M&P if questionable materials are received on the job-site.

NOTE: Elastomeric materials may be waterstops, nylon reinforced neoprene sheet, or elastomeric pads.



♦ ensures quality of material

♦ assists the project engineer when requested

♦ issues test reports for elastomeric pads only.


If the project engineer requests job-site samples of elastomeric pads, sample according to “Tex-601-J, Sampling and Testing Elastomeric Materials.”

Remarks

Obtain the list of prequalified manufacturers for Elastomeric Bearings from CST/M&P.

Information concerning elastomeric bearings is located in “Bridge Bearings.”

Chapter 1 — Material Inspection Guide Section 28 — Epoxies (Other than Paint)


Section 28 Epoxies (Other than Paint)

Overview

This section describes sampling procedures for epoxy materials specified under "DMS-6100, Epoxies and Adhesives."

Epoxies and adhesives fall under a quality monitoring program, "DMS-6110, Quality Monitoring Program for Epoxies and Adhesives." CST/M&P prequalifies and monitors the material directly from the manufacturer. Prequalified materials can be found on a prequalified producers list. Epoxies will not require a stamp indicating TxDOT approval. Epoxies on the prequalified list will not require sampling for testing unless deemed necessary by the engineer.



♦ checks prequalified list for prequalified epoxy materials. Samples and send epoxy to CST/M&P if the material is not on the list.

♦ samples epoxy purchased by the contractor on the open market unless prior arrangements have been made to sample at origin.



♦ tests samples submitted by the project engineer according to "Tex-614-J, Testing Epoxy Materials"

♦ tests and pre-approves TxDOT general warehouse stock

♦ maintains a quality monitoring program of epoxy manufacturers and a prequalified list of epoxy materials.

NOTE: Tested material will bear the TxDOT monogram and test reports will be issued.


Sample epoxies according to "Tex-734-I, Sampling Epoxy." CST/M&P will test epoxies according to "Tex-614-J, Testing Epoxy Materials."

♦ Sampling Frequency • One sample per each shipment

♦ Sample Size • Minimum of 2 L (2 qt.) each of the resin and hardener.

Chapter 1 — Material Inspection Guide Section 28 — Epoxies (Other than Paint)


NOTE: Epoxy on the prequalified list needs no further testing unless deemed necessary by the engineer.

Remarks

The list of prequalified epoxy materials may be obtained from CST/M&P or found in Epoxies and Adhesives.

Allow 15 days for testing from the time material is received in the laboratory.

Epoxy purchased from TxDOT general warehouses is pretested and approved and does not require sampling.

CAUTION: Epoxy materials may cause skin irritation; avoid contact with skin, eyes or clothing. Wash material on skin or clothing immediately and thoroughly with soap and water. Flush material in eyes with plenty of water. Seek medical attention.

Chapter 1 — Material Inspection Guide Section 29 — Fly Ash


Section 29 Fly Ash


The project engineer verifies fly ash designated for use is from an approved fly ash source.

NOTE: The project engineer does not need to submit job control samples unless the fly ash is of questionable quality.



♦ prequalifies fly ash sources

♦ maintains quality control of approved fly ash sources by sampling production at a predetermined frequency



Sampling and testing requirements:

NOTE: Job control samples are not required. The project engineer may submit samples when the quality of the fly ash is suspect.

♦ Sample Size • loosely fill a 4 L (1 gal.) friction lid bucket.

♦ Refer to “Tex-733-I, Sampling Fly Ash.”

Remarks

Do not combine samples into a composite sample under any conditions.

TxDOT Form 202, “Identification of Material Samples,” should contain:

♦ name and location of approved source

♦ name of ready-mix plant when applicable

♦ storage unit or tanker when applicable

♦ sampling location (top, bottom, etc.)

♦ date

♦ project identification

♦ quantity represented in tons.

Chapter 1 — Material Inspection Guide Section 30 — Galvanized Coatings


Section 30 Galvanized Coatings

References


♦ “Item 445, Galvanizing.”



♦ performs visual inspection of galvanized items received at the project

♦ inspects galvanizing according to ‘Checking for Coating Thickness and for Defects in the Coating Finish’ for items not previously inspected by CST/M&P


♦ The ‘Checking for Coating Thickness and for Defects in the Coating Finish’ displays some common defects and causes associated with hot-dip galvanizing and the correction actions to be used.



♦ inspects items with galvanized coatings at manufacturing plant prior to shipment to the job-site. Approved items bear the TxDOT monogram




If the material is of questionable quality, the project engineer obtains and submits samples according to “Tex-708-I, Sampling Galvanized Metal Products for Coating Weight.”

Checking for Coating Thickness and for Defects in the Coating Finish

Coating thickness checks are not required if CST/M&P has previously inspected the material. When questionable material is found, contact CST/M&P for information regarding coating thickness inspection.



Perform visual checks for coating finish defects prior to installation. Use good judgment in determining acceptable coating. Different steels (i.e., chemical composition, thickness, shape, cold working, etc.) will galvanize differently, and uniformity may not be possible due to these factors. This, however, does not excuse poor galvanizing procedures or improper material handling. Below are some common defects and causes associated with hot-dip galvanizing and the corrective actions to be used.

♦ Alligator Cracking/Dull Gray Coating

Figure 1-2. Alligator Cracking/Dull Gray Coating.

Alligator Cracking/Dull Gray Coating Appearance Potential Cause Action

Apparent dark lines resembling alligator skin on coating.

Generally associated with composition of base metal.

Refer to “Item 445, Galvanizing.”

♦ Ash Inclusion



Figure 1-3. Ash Inclusion.

Ash Inclusion Appearance Potential Cause Action

Gray/Black spots on coating. Generally associated with bare spots. Unacceptable if numerous.

♦ Bare (Ungalvanized) Area

Figure 1-4. Bare (Ungalvanized) Area.

Bare (Ungalvanized) Areas Appearance Potential Cause Action



Voids in the zinc coating that expose base metal.

Insufficient degreasing or pickling, weld slag deposits, articles in contact during galvanizing.

Bare spots not greater than 3 mm (1/8 in.) across are acceptable, unless numerous. Larger bare spots may be repaired (see “Item 445, Galvanizing”)

♦ Dross Protrusions

Figure 1-5. Dross Protrusions.

Dross Protrusions Appearance Potential Cause Action

Protrusions that are sharp and gritty like sand or lumps.

Agitation of the dross layer at the bottom of the kettle, or by iron salts carried from the pickling tank.

Minor protrusions are acceptable, but, if excessive, the item is unacceptable.

♦ Flux Inclusions



Figure 1-6. Flux Inclusions.

Flux Inclusions Appearance Potential Cause Action

Lumps or globules. Uneven drainage, bath temperature too low, articles in contact with each other.


♦ Heavy Runs/Drips

Figure 1-7. Heavy Runs/Drips.



Heavy Runs/Drips Appearance Potential Cause Action

Lumps or Globules. Uneven drainage, bath temperature too low, articles in contact with each other.


♦ Red Rust

Figure 1-8. Red Rust.

Red Rust Appearance Potential Cause Action

Red rusty stains. Coated items in contact with rusty steel items, weeping of pickling acid from seams and joints or presence of uncoated areas.

Not detrimental; remove my cleaning. Unacceptable if numerous; power brush or grind to bare metal and repair if small.

♦ Surface Roughness



Figure 1-9. Surface Roughness.

Surface Roughness Appearance Potential Cause Action

Sandpaper appearance on surface. Chemical composition of the base metal, excessive pickling or sand/shot blasting.

Accept if the chemistry of the steel meets specifications. Check coating for proper thickness and adhesion.

♦ White Rust

Figure 1-10. White Rust.



White Rust Appearance Potential Cause Action

White powdery deposit. Moisture in closely packed articles or standing water.


Remarks

A Manual of Inspection for Galvanizing publication is available from CST/M&P (512/ 506-5923).

Chapter 1 — Material Inspection Guide Section 31 — High Mast Illumination Poles and

Rings


Section 31 High Mast Illumination Poles and Rings

Reference


♦ “Item 613, High Mast Illumination Poles

♦ “Item 614, High Mast Illumination Assemblies.”



♦ inspects high mast illumination poles and rings for: • the TxDOT monogram for poles and rings inspected by CST/M&P • proper dimensions and general fabrication • damage or defects in the galvanized coatings (bare spots, peeling, flaking, etc.) • proper fit, especially of items such as motors, cables, etc. which cannot be checked

in fabrication.

♦ advises CST/M&P of any unacceptable material received at the job-site.



♦ obtains the Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected high mast illumination poles and rings

♦ inspects and stamps, with the TxDOT monogram, high mast illumination poles and rings fabricated at locations where CST/M&P performs inspection (see NOTE)



NOTE: Lighting assemblies and other electrical items are NOT INSPECTED by CST/M&P.


Sampling and testing are not required except for lighting assemblies, which shall be sampled as outlined in “Tex-1110-T, Sampling Lighting Assemblies.”

Chapter 1 — Material Inspection Guide Section 31 — High Mast Illumination Poles and

Rings


Remarks

Refer to “Galvanized Coatings” for information concerning inspection of galvanizing.

Chapter 1 — Material Inspection Guide Section 32 — Hydraulic Cement


Section 32 Hydraulic Cement

Overview

This method covers the procedure of sampling hydraulic cement. This method is a modification of ASTM C 183, to satisfy the requirements of governing specifications or conditions in the CST/M&P laboratory.

Sampling

The following guidelines describe sampling hydraulic cement.

General

♦ Authorized TxDOT representative performs sampling.

♦ Sample shall be of sufficient quantity to loosely fill a 4 L (1 gal.) friction lid bucket which is moisture proof and free of contamination.

♦ Sample cement by one of the procedures described below exercising care to assure that the sample is representative of the cement being sampled or used.

♦ Do not combine individual samples into a composite sample under any condition.

Prequalification Samples

♦ Secure a minimum of nine (9) samples over a two-day period.

♦ Take samples from silos, already filled, as trucks or rail cars are being loaded and/or from the mill stream into the silo.

♦ Approximately two weeks later, secure three (3) more samples.

♦ A minimum of 45,359 kg (100,000 lbs.) shall be loaded between each sample.

Quality Monitoring Sampled from Certified Sources

♦ Take samples preferably from bulk trucks or rail cars as they are being loaded (using the procedure described below) or from the storage silos.

Job Samples (on cement of questionable quality)

When job samples are desired, take by one of the following methods:

♦ Obtain bills of lading and certification statements accompanying each shipment to verify that the material is the type specified for the job.

♦ Information from these documents will facilitate identifying the source and type of cement for inclusion on Form 202, “Identification of Material Samples” to accompany the sample submitted for testing.

♦ Retain the bills of lading and Certification statements in the samplers' files.



Sampling from Sacks

♦ Take a sample from one sack representing the lot or shipment.

Sampling from Bulk Trucks or Rail Cars

♦ Take sample from a top hatch of the truck or rail car.

♦ Take sample after brushing aside approximately two inches of the top layer and then scooping down as deeply as possible to fill the sample bucket.

♦ Do not take samples from the discharge outlet at the bottom of trucks or rail cars.

♦ Samples may be taken by means of a valve which has been installed in the transfer pipe between the truck and silo storage.

♦ Sample from the valve only after the flow of cement is well established.

Sampling from Ready-mix or Batching Plants

The cement sampled at ready-mix or batching plants should represent, in so far as possible, cement actually being used in TxDOT stock.

When production is such that sampling from trucks or rail cars can adequately represent the cement being used, use the sampling procedure for ‘Sampling from Bulk Trucks or Rail Cars.’

When production is intermittent or when initially beginning batching operations, it may not be feasible to sample from trucks or rail car.

Sampling under these conditions should be accomplished by taking a sample from the cement bin, weigh box, the point of discharge into the ready-mix truck or other accessible points during the actual batching of concrete for TxDOT use. (In this case, bills of lading and Certification statements should be obtained from the Ready-mix or batching plants which reflect the deliveries of cement used to fill the bins.)

Submission of Samples

Frequency

♦ Job Samples • Submit samples to CST/M&P for quality tests according to the frequency

established in the Guide Schedule of Sampling and Testing in the Construction Contract Administration Handbook.

♦ Quality Monitoring Samples • Take a minimum of one sample per month of all certified cements. Take additional

samples if results are questionable.

Procedure



♦ Complete three copies of Form 202, “Identification of Material Samples,” showing complete information pertaining to the sample. It is important that the cement type, actual producer and mill or terminal location be shown.

♦ Seal one copy of the Form 202, “Identification of Material Samples” inside the bucket containing the sample.

♦ Seal the original Form 202, “Identification of Material Samples” inside Form 517, (tag envelope) and attach securely to the outside of the sample bucket and submit to: Texas Department of Transportation; Construction Division, Materials & Pavements Section (CP51), 9500 Lake Creek Parkway, Austin, TX 78717.

♦ The third copy of Form 202, “Identification of Material Samples” is for the sampler’s files.

Reporting Test Results for Job Samples

Report test results, in the form of a cement test report over the computer terminals, for each job sample upon completion of testing.

The following table describes the tests and sampling frequency for samples associated with quality monitoring of certified cement sources.

Quality Monitoring Tests And Frequency For Certified Cement Sources Test Method Frequency* Comments

“Tex-301-D, Normal Consistency of Hydraulic Cement”

Once a month

“Tex-302-D, Time of Setting of Hydraulic Cement by Gillmore Needles”

Once a month Blended cements excluded

“Tex-303-D, Time of Setting of Hydraulic Cement by Vicat Needle”

Once a month Blended cements only

“Tex-305-D, Air Content of Hydraulic Cement Mortars”

Once a month

“Tex-307-D, Compressive Strength of Hydraulic Cement Mortars”

Each sample

“Tex-308-D, Autoclave Expansion of Portland Cement”

Once a month

“Tex-310-D, Specification for Chemical Requirements on Portland Hydraulic Cement”

Each sample Type III cements excluded

“Tex-889-B, Alkali Oxide Analysis of Portland Cement for Na2O and K2O by Flame Photometry” (Alkalis)

Total alkalis on last three consecutive samples

Once a month 0.55 - 0.59 Once every three months 0.5 - 0.55 Once every six months Less than 0.50 ASTM C114 Initially On prequalification samples

*These are minimum frequencies; additional tests may be run as deemed necessary.

NOTE: Monthly mill certification reports are reviewed also.

Chapter 1 — Material Inspection Guide Section 33 — Joint Sealants and Fillers


Section 33 Joint Sealants and Fillers

Overview

Refer to “Tex-538-C, Quality Monitoring for Joint Sealers and Related Materials” for information regarding sampling and inspecting joint sealants, fillers and related materials.

Chapter 1 — Material Inspection Guide Section 34 — Lighting Assemblies


Section 34 Lighting Assemblies

Overview

A lighting assembly is defined as a complete lighting fixture unit consisting of the housing, reflector, lens, and ballast. A lighting assembly may or may not include a lamp.



♦ Issue a passing test report for pretested stock of lighting assemblies purchased through an approved warehouse within three working days of receipt of Form 9.42, “Daily Report of Shipments” from warehousing agent. No further action is required.

♦ If assemblies are not pretested, samples and submits to CST/M&P for acceptance testing.

NOTE: Refer to Lighting Assemblies for more information.



♦ tests lighting components and assemblies submitted by the project engineer

♦ issues test report to the project engineer.


The following pertains to sampling and testing lighting fixtures:

♦ take one sample consisting of a complete lighting assembly at random for each 25 units, or fraction thereof for each type, wattage and voltage

♦ take a minimum of two and a maximum of five samples from each lot

♦ refer to “Tex-1110-T, Sampling Lighting Assemblies.”

Remarks

Indicate on TxDOT Form 202, “Identification of Material Samples”:

♦ name and address where the samples are to be returned

♦ voltage required for project.

If you have any questions, please contact the Asphalt, Chemical, & Traffic Materials Branch of CST/M&P at (512) 506-5884 or fax (512) 506-5896.

Chapter 1 — Material Inspection Guide Section 35 — Lime


Section 35 Lime

Overview

This section describes the sampling procedures for all three types of lime: hydrated lime, commercial lime slurry, and quicklime.

Lime producers are prequalified and monitored by CST/M&P. Thus, only producers listed in Lime will be allowed to supply lime to TxDOT projects.



♦ ensures the lime is supplied by a prequalified producer

♦ samples lime at the jobsite and submits to CST/M&P for testing.

NOTE: Shipments from non-approved sources must be tested and prequalified prior to use.



♦ samples lime at origin when deemed necessary

♦ maintains list of prequalified producers

♦ tests samples submitted by the project engineer according to "Tex-600-J, Sampling and Testing Hydrated Lime, Quicklime, and Commercial Lime Slurry."

♦ issues test reports. For hydrated lime and quicklime, issues only one report for each producer/type of lime/project. For commercial lime slurry, issues a report for every 200 tons (180 Mg).


The following information pertains to sampling and testing lime:

♦ Sampling Frequency • hydrated lime and quicklime: one sample for each producer per type of lime per

project • commercial lime slurry: one sample per 180 Mg (200 tons) or fraction thereof

(when using 50 tons or less of commercial lime slurry, sampling is not required if lime supplied is from a prequalified source)

• lime from non-prequalified sources: must be tested and prequalified before use on TxDOT projects.

Chapter 1 — Material Inspection Guide Section 35 — Lime


♦ Sample Size • Hydrated Lime: 2 to 3 L (1/2 to 3/4 gal.) in a 4 L (1 gal.) double friction top bucket. • Quicklime: 2 to 3 L (1/2 to 3/4gal.) in a plastic bag closed by a rubber band and

placed in a 4 L ( 1 gal.) double friction top bucket labeled “Caustic Quicklime.” • Commercial Lime Slurry: 1 L (1/4 gal.) sample in a 2 L (1/2 gal.) wide-mouthed

polyethylene bottle.

Remarks

For commercial lime slurry, indicate on Form 202, “Identification of Material Samples,” the grade or solids content specified for that project, and the seal number assigned to the load.

Allow 5 working days for testing.

The list of pre-approved sources may be obtained from CST/M&P or found in the Material Producer List under Lime.

NOTE: Lime sample chemical contents may be altered by exposure to air and/or moisture, use dry buckets for sampling, keep tightly closed and submit for test without delay.

CAUTION: Quicklime is a strong irritant and evolves heat on exposure to moisture. Use caution when handling.

Chapter 1 — Material Inspection Guide Section 36 — Metal Beam Guard Fence


Section 36 Metal Beam Guard Fence

Reference


♦ “Item 540, Metal Beam Guard Fence.”



♦ inspects metal beam guard fence components (i.e. rail elements, steel and timber posts, steel and timber spacers, and connection hardware)

♦ visually inspects steel posts and spacers for shipping damage. TxDOT monogram shall appear on material, tags, or packaging for steel posts and spacers inspected by CST/M&P.

♦ verifies that approved timber treating plants furnish timber posts and spacers (see Timber Treating Plants in the Material Producer List).

♦ visually inspects timber posts and spacers (see “Treated Timber Products” )

♦ visually inspects for bare spots, peeling, flaking, or handling damage to the galvanized coating of steel rail elements, posts, and spacers

♦ visually inspects hardware (bolts, nuts, washers, and back-up plates) for coating and handling damage

♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications on all W-beam rail elements and hardware

♦ advises CST/M&P of any material received at the job-site, which is of questionable quality.

NOTE: Fabricated W-Beam rail elements are not inspected by CST/M&P but should bear approved brands. The list of TxDOT monitored steel W-beam manufacturers may be found in Metal Beam Guard Fence Rail Element Manufacturers. Rail elements are branded with the following information: • Identification symbols or insignia of manufacturer • AASHTO Specification Number M-180 • AASHTO class and type.



Chapter 1 — Material Inspection Guide Section 36 — Metal Beam Guard Fence


♦ obtains the Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected metal posts and spacers

♦ inspects and stamps, with the TxDOT monogram, steel posts and spacers fabricated at locations where CST/M&P performs inspection


♦ inspects treated timber posts and spacers fabricated at locations where CST/M&P performs inspection (see “Treated Timber Products” ).

♦ maintains a list of approved timber treating plants (Timber Treating Plants) and a list of prequalified rail element manufacturers (Metal Beam Guard Fence Rail Element Manufacturers).



CST/M&P generally performs sampling at the manufacturer. However, when the project engineer requests testing of the rail element, perform sampling according to “Tex-713-I, Sampling Metal Beam Guard Fence Rail Element.”

A copy of the MTRs shall accompany all samples.

Chapter 1 — Material Inspection Guide Section 37 — Metal Railing


Section 37 Metal Railing

Reference


♦ “Item 450, Railing.”



♦ inspects steel and aluminum railing elements and posts for the following: • TxDOT monogram for railing inspected by CST/M&P • proper dimensions, hole sizes and location, and general fabrication • bare spots, peeling, flaking, or handling damage to the galvanized or paint coating.

♦ checks aluminum rail finish for uniformity with no discoloration

♦ checks cast aluminum rail posts heat or lot numbers against the MTRs. If heat or lot numbers die stenciled on the web or top of the base of each post do not correspond to those on the test report, contacts CST/M&P. MTRs shall contain the following information: • heat or lot number • chemical analysis of base metal • physical properties of cast metal • number of items per heat or lot

♦ checks cast aluminum rail posts: • for cracks, blowholes, warpage, and other defects which affect their use • to assure they are free of burrs, fins, and discoloration, and have a smooth and

uniform appearance and texture

♦ advises CST/M&P of any posts or panels received at the job site, which are of questionable quality.

NOTE: Steel W-beam elements welded into a tubular shape (i.e. for T-6 rail) are inspected at the fabricator by CST/M&P. All other steel W-beam elements (i.e. for T-101, C-101, etc.) are not inspected by CST/M&P and should bear brands from approved manufacturers. The list of approved steel W-beam manufacturers may be found in Metal Beam Guard Fence Rail Element Manufacturers.



Chapter 1 — Material Inspection Guide Section 37 — Metal Railing


♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected steel railing and posts

♦ inspects and stamps, with the TxDOT monogram, metal railing and posts fabricated at locations where CST/M&P performs inspection




CST/M&P will generally perform sampling at the manufacturer. However, when the project engineer at the job-site requires sampling, it shall be performed according to “Item 450, Railing,” Article 450.4, ‘Tests.’

A copy of the MTRs shall accompany all samples.

Chapter 1 — Material Inspection Guide Section 38 — Mineral Spirits


Section 38 Mineral Spirits


The project engineer samples all mineral spirits received at the job-site.


CST/M&P tests and reports samples submitted by the project engineer.



♦ Sampling frequency • Each lot or batch number.

♦ Sample size • 0.946 L (1 qt.).

Remarks


Chapter 1 — Material Inspection Guide Section 39 — Miscellaneous Pipe


Section 39 Miscellaneous Pipe

Overview

Miscellaneous pipes are of the following types:

♦ PVC pipe for bridge drains

♦ Perforated steel, aluminum, ABS, polyethylene plastic, or PVC pipe and non-perforated pipe.

References


♦ “Item 481, PVC Pipe for Bridge Drains

♦ “Item 556, Pipe Underdrains.”



♦ visually inspects for damage, cracks, and proper diameter

♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications for all steel pipe

♦ obtains test reports and certifications for all other pipe.

NOTE: Test reports and certifications shall certify that the material was manufactured, tested, inspected, and meets the requirements of the appropriate TxDOT specification.




Sampling and testing are not required unless material is of questionable quality. Contact CST/M&P for sampling instructions.

Chapter 1 — Material Inspection Guide Section 40 — Multi-Piece Tie Bars


Section 40 Multi-Piece Tie Bars



♦ receives a completed Form D-9-USA-1, Material Statement, from the manufacturer, certifying that the multiple piece tie bars meet specification requirements and that the product complies with the “Buy America Documentation Program” requirements

♦ visually inspects a random sampling of the multiple piece tie bars and verifies that they can easily be fully threaded and properly tightened

♦ verifies proper installation, fit and tightening of the tie bars as they are used on the project

♦ samples tie bars when multiple tie bars are furnished by a manufacturer (other than those listed under Multiple Piece Tie Bar Producers) according to “Tex-711-I, Sampling Multiple Piece Tie Bars” and submits to CST/M&P for testing prior to use.

NOTE: When multiple piece tie bars are furnished by an approved manufacturer as identified in Multiple Piece Tie Bar Producers, testing by CST/M&P is not required, but may be sampled and tested if the project engineer has a question concerning the quality of the product being furnished.



♦ publishes and maintains a list of approved manufacturers in the Material Producer List

♦ monitors the approved manufacturers to verify continued compliance with specification requirements by randomly sampling and testing their product and reviewing their quality control procedures

♦ offers technical assistance and support to the project engineer upon request.

Chapter 1 — Material Inspection Guide Section 41 — Overhead Sign Supports


Section 41 Overhead Sign Supports

Overview

Overhead sign supports include balanced tee, bridge, cantilever, and combined bridge and cantilever structures.

References


♦ “Item 650, Overhead Sign Supports.”



♦ inspects overhead sign supports for • TxDOT monogram for sign supports inspected by CST/M&P • damage to members or coating • proper installation bolting, and camber

♦ advises CST/M&P of unacceptable material received at the job-site.



♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected overhead sign supports

♦ inspects and stamps, with the TxDOT monogram, overhead sign supports at locations where CST/M&P performs inspection




Bolts, nuts, and washers for overhead sign support truss components may be sampled, at the discretion of the project engineer, according to “Tex-719-I, Sampling High Strength Bolts, Nuts, Washers.”

Rotational Capacity (RC) testing of fasteners for overhead sign support truss components shall be performed at the project site according to “Item 447, Structural Bolting.”

Chapter 1 — Material Inspection Guide Section 42 — Paint and Painting


Section 42 Paint and Painting



♦ samples paints required to conform to the TBPC specifications, only if questionable

♦ samples paints required to conform to federal specifications and purchased on the open market and submit to CST/M&P for testing

♦ samples proprietary paints and/or paints to meet a special specification which are purchased on the open market and submit to CST/M&P for testing

♦ ensures that all paints are thoroughly mixed prior to use and/or sampling.

NOTE: Paints obtained from a TxDOT regional supply center are pretested and need not to be sampled unless questionable material is received at the job-site.



♦ samples and tests paints (at the source) required to conform to TxDOT specifications and purchased on the open market

♦ performs in-plant inspection and testing

♦ tests paints purchased on the open market

♦ provides technical assistance for resolving field problems

♦ assists in the inspection of coatings application

♦ assists in the training inspectors in new techniques and materials

♦ issues test reports for paints sampled by the project engineer and paints purchased on the open market.


Paint is normally pretested by CST/M&P prior to shipment to TxDOT general warehouses and containers will bear the requisition number and TBPC number.

Contact CST/M&P for instructions regarding field sampling special paints and federal specification paints.

Chapter 1 — Material Inspection Guide Section 42 — Paint and Painting


Remarks

Pay particular attention to surface preparation, application, coating thickness, and final appearance requirements.

Inquiries should include the type of paint, quantity, name of manufacturer, batch number, and requisition number.

When samples are required, the project engineer should complete TxDOT Form 202, “Identification of Material Samples.”

Chapter 1 — Material Inspection Guide Section 43 — Pavement Markings (Reflectorized

Paint)


Section 43 Pavement Markings (Reflectorized Paint)



♦ inspects pavement markings (reflectorized paint) for conformance to the applicable specification requirement

♦ approves purchases of paint and beads by the contractor for TxDOT from approved sources

♦ approves the supply of paint and beads by TxDOT to the contractor at no cost

♦ advises CST/M&P if questionable quality material is received at the job-site.



♦ inspects and tests traffic paint and beads supplied to TxDOT regional warehouses

♦ pretests and approves traffic paint and beads supplied to approved warehouses as pretested stock

♦ assists the project engineer when requested

♦ tests samples of questionable material when submitted by the project engineer.


For questionable materials, the project engineer shall submit 3.785 L (1 gal.) of each color for testing (see “Paint and Painting” ).

Remarks

Pay particular attention to surface preparation, alignment, spacing, application rate of paint and beads, and reflectance characteristics ( “Tex-828-B, Determining Functional Characteristics of Pavement Markings”) of the installed markings.


Chapter 1 — Material Inspection Guide Section 44 — Penetrating Concrete Surface

Treatments


Section 44 Penetrating Concrete Surface Treatments



♦ verifies surface treatments designated for use is from an approved surface treatment source

♦ after treatment, ensures that the testing and acceptance procedure outlined in TxDOT Special Specification “Item 4010, Penetrating Concrete Surface Treatment” is followed.



♦ tests products submitted by manufacturers for pre-approval

♦ maintains list of approved products

♦ tests job samples of the liquid material prior to use on the job

♦ tests core samples after application is completed.



♦ Sampling Frequency • submit a 0.473 L (1 pt.) sample per lot of material for test prior to use • take a minimum of one sample (two cores taken within a 0.3048 m [1 ft.] radius of

each other) for every 502 m2 (600 yd2) of treated bridge slab • take a minimum of four samples for bridge slabs less than 502 m2 (600 yd2 ).

Remarks


Chapter 1 — Material Inspection Guide Section 45 — Precast Concrete Safety End

Treatments


Section 45 Precast Concrete Safety End Treatments

Reference


♦ “Item 467, Safety End Treatments.”



♦ inspects precast concrete safety end treatments for reinforced concrete pipe structures by checking for the following: • manufacturer’s brand mark, size, class, and casting date • proper diameter, slope, or bevel • broken ends, which would prevent proper jointing • longitudinal cracks • proper jointing (out of round pipe)

♦ inspects the components for safety end treatment (pipe runners, plates and angles, bolts and nuts) for proper sizes, dimensions, coating quality and acceptability.

NOTE: Precast concrete safety end treatments shall be accompanied by a certification from the manufacturer stating that the end sections conform to the size and class as shown on the plans and applicable specifications. Form D-9-USA-1, Material Statement, and attached MTRs or certifications shall also be furnished for all steel components (pipe runners, plates and angles, bolts and nuts).





Chapter 1 — Material Inspection Guide Section 46 — Precast Nonstressed Concrete


Section 46 Precast Nonstressed Concrete



♦ inspects precast nonstressed concrete items for the following: • TxDOT monogram for items inspected by CST/M&P • damage or excessive cracking • proper fit and aesthetics

♦ visually inspects and accepts the following items NOT inspected by CST/M&P: • inlets • manholes • headwalls

♦ advises CST/M&P if items of questionable quality are received on the job-site.



♦ inspects and stamps, with the TxDOT monogram, the following precast nonstressed concrete items fabricated at locations where CST/M&P performs inspection: • box culverts and sewers • traffic barrier • retaining wall panels, copings, etc. • sound wall panels

♦ issues General Test Reports to the project engineer for all material inspected by CST/M&P



Sampling and testing are not required for precast concrete items.

Chapter 1 — Material Inspection Guide Section 47 — Prefabricated Pavement Markings


Section 47 Prefabricated Pavement Markings



♦ verifies that prefabricated pavement markings designated for use are from an approved material source

♦ samples prefabricated pavement markings (in rolls or legend material) at the job-site, unless prior arrangements have been made to sample at origin

♦ selects samples from each color and each type of material

♦ takes random samples throughout the entire lot or shipment.

NOTE: The approved prefabricated pavement markings source list may be found in Permanent Prefabricated Pavement Markings.




♦ samples prefabricated pavement markings at origin or warehouse and issues test reports, when prior arrangements have been made.


Following are sampling and testing requirements:

Sampling Frequency

♦ Legend Material • One sample per 25 words or symbols.

♦ Linear Material • 0-5000 LF – One sample per 500 linear ft., minimum of five and maximum of 10

samples • 5001-20,000 LF – One sample per 1000 linear ft., minimum of five and maximum

of 10 samples • 20,001-60,000 LF – One sample per 2000 linear ft., minimum of 10 and maximum

of 15 samples • Over 60,000 LF – Contact CST/M&P for sampling instructions.

Sample Size

Chapter 1 — Material Inspection Guide Section 47 — Prefabricated Pavement Markings


♦ Legend Material • A sample shall be one word or symbol.

♦ Linear Material • For material less than 12 in. in width, a sample shall be three ft. in length. For

material 12 in. or greater in width, a sample shall be two ft. in length

♦ Refer to “Tex-732-I, Sampling Prefabricated Pavement Marking Materials.”

Remarks

Package samples so as to prevent damage to the material.

Indicate on TxDOT Form 202, “Identification of Material Samples,” the name and address where samples of legend material are to be returned.

Chapter 1 — Material Inspection Guide Section 48 — Preformed Compression Seals


Section 48 Preformed Compression Seals


The project engineer accepts compression seals and the lubricant-adhesive on the basis of the manufacturer’s certification that the material meets specification requirements.


None.


None required.

Chapter 1 — Material Inspection Guide Section 49 — Preformed Joint Seals


Section 49 Preformed Joint Seals



♦ visually inspects seals for damage or distortions

♦ measures each seal for dimensions as shown on the plans

♦ submits samples of each size and configuration of seal.

NOTE: Lubricant-adhesive will be accepted on the basis of a manufacturer's certification that the material meets specification requirements.



♦ ensures that each seal submitted for testing has been prequalified



The following information pertains to sampling and testing preformed joint seals:

♦ sample one 1 m (3 ft.) length of each size and configuration of seal

♦ submit to CST/M&P for testing when requested by engineer.

Remarks

Allow ten (10) working days for testing, from the time material is received in the laboratory.

Refer to Joint Sealers for a list of prequalified seals.

Chapter 1 — Material Inspection Guide Section 50 — Prestressed Concrete


Section 50 Prestressed Concrete

Reference


♦ “Item 425, Prestressed Concrete Structures.”



♦ inspects prestressed concrete items for the following: • TxDOT monogram near the member identification information • damage such as spalled concrete or cracking that exceeds specification tolerances • proper fit and location of diaphragms, dowel holes, and appurtenances

♦ advises CST/M&P if items of questionable quality are received on the job-site.



♦ inspects and stamps, with the TxDOT monogram, the following prestressed concrete items fabricated at locations where CST/M&P performs inspection: • I - beams and U - beams • box beams • tee beams • bridge deck panels • piling • sound wall panels




Sampling and testing are not required for prestressed concrete items.

Chapter 1 — Material Inspection Guide Section 51 — Raised Pavement Markings


Section 51 Raised Pavement Markings


The project engineer samples pavement markers (reflectorized) traffic buttons and jiggle bars (reflectorized or nonreflectorized) at the job site, unless prior arrangements have been made to sample at point of origin or pretested markers are obtained from an approved storage area.

NOTE: Samples will not be required when project quantities of a particular size, color or type of marker are 50 or less. A manufacturer’s certification and visual inspection by the project engineer will be adequate.




♦ samples and tests markers at the point of origin, when prior arrangements are made. Markers which have been pretested at origin will bear the TxDOT approval stamp on each container.

♦ issues test reports.



♦ Sampling frequency • Each shipment.

♦ Sample Size (if not pretested) • Job quantity 50 or less – manufacturer’s certification • Job quantity 51 to 20,000 – sample 25 units. For jiggle bars – 15 units. • Job quantity over 20,000 – Sample 25 units per each 20,000 units or fraction

thereof. For jiggle bars – 15 units.

♦ Refer to “Tex-729-I, Sampling Traffic Markers.”

NOTE: Samples not destroyed will be returned to shipper.

Chapter 1 — Material Inspection Guide Section 51 — Raised Pavement Markings


Remarks

When established in the proposal and specifications, certain items in this section may be purchased by the contractor from stock of a TxDOT regional supply center, in which case, the items are pretested and approved for use.


Chapter 1 — Material Inspection Guide Section 52 — Rapid Setting Mortar


Section 52 Rapid Setting Mortar

Overview

This material is a dry packaged material requiring the addition of a liquid prior to use. The container or packages should be clearly marked with the product name, manufacturer name, and other information as set forth in the applicable specifications.


The project engineer samples material.

Function of CST/M&P

CST/M&P tests samples submitted by the project engineer.



♦ submit one unopened sack per each shipment or lot.

Remarks

Show complete information on TxDOT Form 202, “Identification of Material Samples.”

Chapter 1 — Material Inspection Guide Section 53 — Reinforced Concrete Pipe


Section 53 Reinforced Concrete Pipe

Reference


♦ “Item 464, Reinforced Concrete Pipe.”



♦ inspects reinforced concrete pipe sections received on the job-site for the following: • TxDOT monogram on each pipe section • the proper size, and class or D-load • damage/defects

♦ Rejects pipe sections furnished to the project for any of the following: • fractures or cracks passing through the shell, except for a single end crack that does

not exceed the depth of the joint (see ‘Depth of Joint’). • defects that indicate imperfect proportioning, mixing, and ,molding. These defects

cause conditions such as: delamination, form misalignment, or inadequate cover of reinforcing steel.

• surface defects indicating honeycombed or open texture (see‘Honeycombed or Open Texture’)

• damaged ends, where such damage would prevent making a satisfactory joint.

NOTE: The damage must “prevent” the making of a satisfactory connection (joint) before the pipe section is to be considered unacceptable for use. • any continuous crack having a width of 0.3 mm (0.01 in.) or more and extending

for a length of 300 mm (12 in.) or more, regardless of position in the wall of the pipe.

NOTE: These cracks do not need to pass through the shell in order for the condition to be rejectable.

♦ advises CST/M&P when pipe sections of questionable quality are received on the job-site.

The following are examples for rejection of pipe sections furnished to the project.



Figure 1-11. Depth of Joint.

Figure 1-12. Honeycombed or Open Texture.





♦ inspects and stamps, with the TxDOT monogram, reinforced concrete pipe fabricated at locations where CST/M&P performs inspection





Chapter 1 — Material Inspection Guide Section 54 — Reinforcing Steel


Section 54 Reinforcing Steel

Reference


♦ “Item 440, Reinforcing Steel.”



♦ inspects uncoated reinforcing steel for: • proper size and grade of steel • material is from TxDOT approved producing mill (see Reinforcing Steel Mills),

then indicate the source in the Contract Information Segment (CIS)

♦ inspects epoxy coated reinforcing steel to verify: • requirements listed above for uncoated reinforcing steel • material is from TxDOT approved epoxy applicator (see Epoxy Applicators for

Reinforcing Steel), then indicate the source in the Contract Information Segment (CIS)

• all visible damage to epoxy coating from handling or placement is properly repaired prior to the placement of concrete

♦ obtains MTRs and certifications for all uncoated and epoxy coated reinforcing steel furnished to the project

♦ contacts CST/M&P when: • uncoated or epoxy coated reinforcing steel is of questionable quality • uncoated or epoxy coated reinforcing steel is from an unapproved producing mill or

an unapproved epoxy applicator.



♦ administers the qualification procedures for all TxDOT approved reinforcing steel producing mills and epoxy applicators (see “Tex-741-I, Qualification Procedure for Reinforcing Steel Producing Mills” and “Tex-742-I, Qualification Procedure for Reinforcing Steel Epoxy Coating Applicators”)

♦ maintains the lists of TxDOT approved reinforcing steel producing mills and epoxy applicators (see Reinforcing Steel Mills and Epoxy Applicators for Reinforcing Steel).

♦ issues Quality Monitoring (QM) test reports for all uncoated and epoxy coated reinforcing steel properly sourced by the project engineer

Chapter 1 — Material Inspection Guide Section 54 — Reinforcing Steel




Sampling and testing are not required unless material is of questionable quality. The project engineer samples uncoated reinforcing steel according to “Tex-709-I, Sampling Reinforcing Steel” and epoxy coated reinforcing steel according to “Tex-739-I, Sampling and Testing Epoxy Coated Reinforcing Steel.”

Chapter 1 — Material Inspection Guide Section 55 — Right of Way Markers


Section 55 Right of Way Markers

Overview

Right of way markers may be either precast or cast-in-place concrete.

Reference


♦ “Item 538, Right of Way Markers.”



♦ inspects precast concrete right of way markers for cracks or other damage

♦ verifies the shape and dimensions for right of way markers according to the plans.





Remarks

When bronze disks are required by the plans, they will be furnished by TxDOT to the contractor at no cost.

Chapter 1 — Material Inspection Guide Section 56 — Roadside Sign Supports


Section 56 Roadside Sign Supports

References


♦ “Item 646, Small Roadside Sign Supports”

♦ “Item 647, Large Roadside Sign Supports.”



♦ verifies sign mounts furnished are the mounts required for the project

♦ inspects small roadside sign supports for the following: • rusting, coating damage, or shipping damage (i.e., bent, twisted, etc.) • that driveable supports furnished are preapproved as shown on the plans • that fiberglass reinforced plastic (FRP) supports furnished are from the approved

list maintained by the Traffic Operations Division • certification from the sign support manufacturer stating the mounts were

manufactured in compliance with the specifications.

♦ inspects large roadside sign supports for the following: • rusting, coating damage, or shipping damage (i.e., bent, twisted, etc.) • TxDOT monogram for large roadside sign supports inspected by CST/M&P

♦ advises CST/M&P when supports appear questionable.



♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected large roadside sign supports

♦ inspects and stamps, with the TxDOT monogram, all large roadside sign supports fabricated at locations where CST/M&P performs inspection



Chapter 1 — Material Inspection Guide Section 56 — Roadside Sign Supports




Chapter 1 — Material Inspection Guide Section 57 — Roadway Illumination and Traffic

Signal Pole Assemblies


Section 57 Roadway Illumination and Traffic Signal Pole Assemblies

References

Refer to Spec Book for information on the following:

♦ “Item 610, Roadway Illumination Assemblies

♦ “Item 686, Traffic Signal Pole Assemblies.”



♦ inspects roadway illumination assemblies and traffic signal pole assemblies for the following: • TxDOT monogram for assemblies inspected by CST/M&P • proper dimensions and general fabrication • visual defects in the welds • damage or defects in the galvanized or paint coatings (bare spots, peeling, flaking,

etc.).

♦ advises CST/M&P of any unacceptable material received at the job-site.

NOTE: Sample luminaires, lamps and ballasts according to “Tex-1110-T, Sampling Lighting Assemblies” (also see “Lighting Assemblies” ).



♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected roadway illumination and traffic signal poles, mast arms, luminaire arms, and transformer bases

♦ inspects and stamps, with the TxDOT monogram, roadway illumination and traffic signal poles, mast arms, luminaire arms, and transformer bases fabricated at locations where CST/M&P performs inspection



Chapter 1 — Material Inspection Guide Section 57 — Roadway Illumination and Traffic

Signal Pole Assemblies



Sampling and testing are required for luminaires, lamps and ballasts (see “Lighting Assemblies” ).

Remarks

Pedestal poles are not inspected and tested by CST/M&P and should be inspected by the project engineer.

Chapter 1 — Material Inspection Guide Section 58 — Sealed Expansion Joint


Section 58 Sealed Expansion Joint

Reference


♦ “Item 454, Sealed Expansion Joints.”



♦ inspects sealed expansion joint seals and extrusions for the following: • TxDOT monogram on extrusions inspected by CST/M&P • damage or distortions to the seals and extrusions • sealed expansion joint system furnished is preapproved as shown on the plans.



♦ performs tests for preapproval of sealed expansion joint systems

♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications for all inspected sealed expansion joints extrusions

♦ inspects and stamps, with the TxDOT monogram, sealed expansion joint extrusions fabricated at locations where CST/M&P performs inspection





Chapter 1 — Material Inspection Guide Section 59 — Sign Walkways


Section 59 Sign Walkways

Reference


♦ “Item 654, Sign Walkways.”



♦ inspects sign walkways for the following: • TxDOT monogram for sign walkways inspected by CST/M&P • shipping damage and proper assembly

♦ advises CST/M&P of any unacceptable materials received at the job-site.



♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected sign walkways

♦ inspects and stamps, with the TxDOT monogram, sign walkways fabricated at locations where CST/M&P performs inspection





Chapter 1 — Material Inspection Guide Section 60 — Signs


Section 60 Signs



♦ inspects signs for the following: • TxDOT monogram for signs inspected by CST/M&P • shipping damage and proper assembly • proper completion of the sign identification decals located on the back side lower

left hand corner of the signs (refer to “Item 643, Sign Identification Decals”).



♦ inspects signs and stamps, with the TxDOT monogram, signs fabricated at locations where CST/M&P performs inspection





Remarks

Construction signs are not inspected by CST/M&P.

Chapter 1 — Material Inspection Guide Section 61 — Soil Retention Blanket


Section 61 Soil Retention Blanket



♦ inspects rolls for damage

♦ checks to ensure that the brand name furnished by the contractor is listed on the approved material list for soil retention blankets, of the class and type specified on the plans

♦ samples rolls furnished on a random basis only • samples are not required for each project which specifies soil retention blankets • samples, if taken, shall be 2.7 m (3 yds.) minimum and shall be submitted to the

TxDOT Maintenance Division • a full set of manufacturer’s literature for the sample shall be included with the

sample

♦ ensures that the soil retention blanket is installed according to the manufacturer’s literature or the Standard Plan Sheets “Soil Retention Blanket” for the class and type specified and for the specific product trade name utilized.

NOTE: Test reports on soil retention blankets are not required from CST/M&P before the project can be finalized. Test reports as generated from any random sampling performed will be used only as a subsequent verification of quality control of products currently on the approved material list.

Remarks

Prequalification procedures and a list of prequalified materials may be obtained by writing to: Texas Department of Transportation; Maintenance Division Director; Vegetation Management Section; 125 East 11th Street, Austin, TX, 78701-2483, or call (512) 416-3091.

Chapter 1 — Material Inspection Guide Section 62 — Structural Steel


Section 62 Structural Steel

References


♦ “Item 441, Steel Structures

♦ “Item 447, Structural Bolting.”



♦ inspects structural steel rolled beams, welded I-section plate girders, box girders, bent caps, diaphragms, shoes, armor joints, and finger joints for the following: • TxDOT monogram for structural steel inspected by CST/M&P • damage such as dents, bends or twists and missing studs • damage or deterioration to the paint • markings that would affect uniform weathering on weathering steel • match marks, according to erection plans, for bolted connections • proper fit during and after erection.



♦ obtains Form D-9-USA-1, Material Statement, MTRs, and certifications on all inspected structural steel

♦ inspects and stamps, with the TxDOT monogram, structural steel fabricated at locations where CST/M&P performs inspection




Sampling and testing are not required for structural steel.

Bolts, nuts, and washers for bridge members may be sampled, at the discretion of the project engineer, according to “Tex-719-I, Sampling High Strength Bolts, Nuts and Washers.”

Chapter 1 — Material Inspection Guide Section 62 — Structural Steel


Rotational Capacity (RC) testing of fasteners for bridge member connections shall be performed at the project site according to “Item 447, Structural Bolting.”

Chapter 1 — Material Inspection Guide Section 63 — Thermoplastic Pavement Markings


Section 63 Thermoplastic Pavement Markings


The project engineer samples thermoplastic pavement marking material at the job-site, unless prior arrangements have been made

NOTE: This material is furnished in either 50 lb. bags (bulk) or 50 lb. boxes (block).




♦ samples thermoplastic pavement marking materials at origin or a warehouse and issues test reports, when prior arrangements have been made.



♦ Sample size • Granular Materials – 1.36 to 2.27 kg (3 to 5 lbs.) per sample • Block Material – 1.36 to 2.27 kg (3 to 5 lbs.) per sample

♦ Number of samples • Job quantity 6810 kg (15,000 lbs.) or less – select two samples of each color. • Job quantity over 6810 kg (15,000 lbs.) (each color) – select one sample per 6810

kg (15,000 lbs.) or fraction thereof, per load.

♦ Refer to “Tex-862-B, Sampling Thermoplastic Pavement Marking Material.”

Remarks

Show the following information on TxDOT Form 202, “Identification of Material Samples”:

♦ net weight received per load

♦ batch or lot numbers of bags or boxes sampled.

Chapter 1 — Material Inspection Guide Section 64 — Traffic Beads


Section 64 Traffic Beads



♦ samples traffic beads at the job-site, unless prior arrangements have been made to sample at origin

♦ advises CST/M&P if material of questionable quality is received at the job-site.





♦ samples traffic beads at origin or an approved warehouse when prior arrangements have been made

♦ issues test reports



Three bags of beads shall be selected at random from each shipment at destination by the project engineer according to “Tex-830-B, Sampling Traffic Beads.”

Remarks

The project engineer shows the net weight received per load and batch or lot numbers of bags sampled on TxDOT Form 202, “Identification of Material Samples.”

Chapter 1 — Material Inspection Guide Section 65 — Traffic Signal Controllers


Section 65 Traffic Signal Controllers



♦ inspects controllers for conformance with the requirements of the plans and specifications

♦ performs five-day field test according to the plans and specifications

♦ samples controllers for environmental testing by the Traffic Operations Division (TRF) in Austin

♦ samples at the minimum rate of one sample per lot (a lot shall consist of ten or less of each model and type of controller).

Functions of TRF

TRF performs the following functions:

♦ environmental testing of samples submitted by the project engineer

♦ reports test results to the project engineer.


Refer to “Tex-1170-T, Sampling and Environmental Testing of Traffic Signal Controller Assemblies: Traffic Signal Controllers and Conflict Monitors” for sampling and testing of controllers.

Remarks

Ship samples, at TxDOT expense, prepaid, to the Traffic Operations Division, 4305 Bull Creek Rd., Bldg. No. 40, Austin, TX 78731, and upon completion of environmental testing samples will be returned to the project engineer collect.

Chapter 1 — Material Inspection Guide Section 66 — Treated Timber Products


Section 66 Treated Timber Products


The project engineer accepts treated timber products as follows:

Treated Timber Poles for Electrical Services

Performs inspection to verify compliance with “Item 627, Treated Timber Poles.”

♦ verifies receipt of a treatment certification indicating the preservative treatment type, and that the treatment values shown meet the required minimum net retention of preservative

♦ verifies compliance of the dimensional and quality requirements of the poles

♦ verifies poles are properly marked.

Treated Piling, Lumber, Posts, and Spacers

All treated piling, lumber, posts (MBGF and wire fence), and spacers (MBGF) proposed for TxDOT use shall be inspected at the treating plant by a commercial inspection agency authorized by CST/M&P. The project engineer verifies:

♦ that all material received is from a TxDOT approved treating plant (see Timber Treating Plants), then indicate the source in the Contract Information Segment (CIS)

♦ receipt of completed Form D9-MC-92, “Certificate of Compliance”

♦ receipt of shipping invoice for each shipment

♦ that the material is hammer-marked with one of the approved Commercial Inspection Agency’s identification mark and the Inspector’s number, as shown in the following examples:

Examples of Identification Marks and Numbers “SL” Southwest Timber Laboratories’ identification mark “34” Inspector Number (each inspector has a unique number) “TP” Timber Products Inspection’s identification mark “76” Inspector Number (each inspector has a unique number)

NOTE: The TxDOT monogram will not appear on these treated timber products.

♦ a legible brand mark or tag, with the name of the treater, the date of treatment or lot number, and the type of treatment, is included on all bundles of treated timber products

♦ compliance of the material dimensional and quality requirements

♦ Inform CST/M&P of any unacceptable treated timber products received.

Chapter 1 — Material Inspection Guide Section 66 — Treated Timber Products




♦ administers the inspection, by a commercial inspection agency, of the following treated timber products: • posts (MBGF and Wire Fence) • spacers (MBGF) • lumber • piling.

♦ issues a Quality Monitoring (QM) test report once the district representative has indicated the source in the CIS. A QM test report will be issued for each material type and material source

♦ maintains the list of TxDOT approved timber treating plants (see Timber Treating Plants)




Remarks

Untreated lumber is accepted based on visual inspection by the project engineer or other responsible district personnel.

Chapter 1 — Material Inspection Guide Section 67 — Water


Section 67 Water



♦ samples where required by specification.

NOTE: Water from municipal suppliers approved by the Texas Department of Health will not require testing.


Test samples of water submitted by the project engineer and issue test reports.


The project engineer submits a 6 L (3/4 gallon) sample of water in an 8 L (1 gallon) plastic container.

Remarks

Allow three (3) days for testing.

Material inspection guide

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