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SPECIFICATIONS FOR A FULLY AUTOMATED, COMPUTER CONTROLLED RESILIENT MODULUS TESTING SYSTEM ON SOILS AND AGGREGATE MATERIALS

1. GENERAL SYSTEM, EQUIPMENT AND OPERATIONAL REQUIREMENTS

Equipment must consist of a fully operational and functional system (including all necessary sample preparation and testing components) meeting the following requirements:

1.1 One (1) new and complete computer controlled, fully automated Resilient Modulus Soil Testing System, ready for immediate operation with all hardware and software components (i.e. load frame, control and data acquisition software, and related computer interface hardware and manuals, editing and reporting software and manuals, sensors, connection cabling, etc.). The apparatus and software must be configured such that, at a minimum, it is capable of testing undisturbed and disturbed compacted samples of subgrade soils, and untreated base/subbase compacted to various diameters not to exceed 6.0 in. (152 mm), and with a height to diameter ratio of at least 2-2.5:1 including the following standard sizes:

a. Standard "thin wall type" (2.875 in [71 mm] diameter), height to diameter ratio of 2V:1H to 2.5V:1H specimen.

b. Standard recompacted sample (6.00 in [152 mm] diameter) height to diameter ratio of 2V:1H to 2.5V:1H, specimen.

1.2 Confining pressure application, to be done automatically through an electro-hydraulic system, according to default, preset or operator defined pressures and pressure application rates and durations for Resilient Modulus testing.

At the operator’s option, the confining pressure must either be applied automatically according to preset standard or standard default settings according to operator defined pressures and application rates and durations. Confining pressure must be fully controlled and maintained by system hardware and software.

1.3 Include comprehensive manuals for Resilient Modulus editing and reporting software, equipment operation and maintenance. Manuals must thoroughly describe the capabilities, function, set-up, calibration and control of all equipment and software, including troubleshooting and maintenance of all systems (equipment and software).

1.4 Software is to be coded onto a separate computer, not into the testing system. Software must be compatible with Windows 7 Pro (64 bit) and Windows 10 Pro (64 bit) operating systems.

1.5 All sensors and instrumentation required to perform, monitor and acquire data for the test method specified in Section 2.1.1 of this document.

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1.6 Related data acquisition equipment, computer interfaces, and connection cabling.

1.7 All equipment necessary for preparing each sample for the test method specified in Section 2.1.1 of this document (at a minimum for 71 mm and 152 mm diameter samples) for testing.

1.8 The system must be in place, calibrated and operating per FHWA startup procedures (FHWA-RD-02-034), with operators able to manufacture a sample, perform resilient modulus tests and generate reports [as specified in AASHTO T 307-99 (2012)] before the vendor leaves the site.

1.9 The equipment must be self-monitoring (automatic gain adjustment to keep loading and response curves within tolerance.

1.10 As illustrated in Figure 1 below, this specification requires a top loading closed loop, electrohydraulic testing machine with a function generator which can apply repeated cycles of haversine-shaped load pulses of the following definitions (0.1 sec pulse followed by 0.9 sec rest period.) The function generator must be fully integrated into the system software and electronics with the capability to stop and start tests in an automated mode through a computer. The function generator must be capable of generating sine, haversine, triangle, square, ramp, and any user defined waveform. The system must be capable of generating and controlling wave shapes that are defined by specific applications programs. The function generator will have a built-in cycle and a preset cycle count used to terminate the test. The operator must not have to set count at any time for resilient modulus testing; the system must automatically determine the number of cycles. The software must automatically eliminate AASHTO T 307-99 (2012) Table 1 steps 14 and 15 for Type I Subgrade. The function generator will include mean, amplitude, and frequency adjustment. Mean and amplitude controls for ensuring that the system operates to the desired mean and amplitude will be included. During the resilient modulus testing the operator shall not have to adjust any test levels, all settings must be automatic.

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Fig 1. Haversine LTPP Protocol on loading

1.11 The system must shear a sample keeping a constant rate of strain perAASHTO T 307-99 (2012) using an electro-hydraulic controller. Vertical cyclic loading must be done through a hydraulic load actuator.

1.12 The system must have the capability for expansion to run additional fully automated materials testing when provided with the necessary hardware and software. Future testing applications may include fully automated CU Tri-Axial testing or any other Tri-Axial test that would lend itself to a closed loop testing process.

1.13 On-site training, installation, documentation, and comprehensive minimum one year (after date of system acceptance – installation, set-up and calibration complete, training complete, and all systems demonstrated to be in full properly working order) hardware and software systems parts and repair warranties are to be included as part of this package. Refer to these sections in this document for further description.

1.14 One (1) computer running Windows 7 Pro (64 Bit) operating system that automatically controls and acquires data for the test method listed in Section 2.1.1 of this document, as well as perform a l l data reduction and reporting operations. Data must be stored in a format that is operator editable in the event of run-time test problems that result in invalid data.

2. SYSTEM REQUIREMENTS

The computer processor, monitor and computer peripherals (i.e. pointing devices, keyboard, display, printers, uninterruptable power supplies must be supplied by the successful bidder. The successful bidder must provide appropriate data acquisition (D/A) cards/devices and software.

Any necessary I/O cards to accept or transmit information from/to data acquisition systems, signal processors, control devices, etc. must be included as must all relevant sensors, controllers, load frames, related attachments and fittings, wiring, tubing, valves, and related computer software to control test function, acquire data, perform test calculations (with the exception of those requiring significant engineering judgment), and output data and graphical displays both to the screen and printed output.

The computer processor must be provided by the successful bidder, and must run under Windows 7 Pro (64 bit) and Windows 10 Pro (64 bit) operating systems. Hardware and software must be compatible with this environment.

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2.1 Equipment Requirements

2.1.1 Equipment for the testing system must be consistent with standard sizes and methodologies used in performing the following test method:

a. "Determining the Resilient Modulus of Soils and Aggregate Materials", AASHTO Designation: T 307-99(2012) and SHRP Protocol P46.

2.1.2 The system must operate on standard 120 V, 220V or 460V 60Hz power.

Note: Requirements to operate all system components must be indicated in the Vendor’s bid proposal.

2.1.3 The system must be appropriately rugged to withstand a standard laboratory testing environment with a projected service life of 10 to 15 years.

2.1.4 The system must be designed to operate at a standard room temperature environment of 10⁰C to 32⁰C (50⁰F to 90⁰F). The equipment must be able to withstand temperatures of -12⁰C to 49⁰C (10⁰F to 120⁰F) for shipping and storage.

2.1.5 Signal excitation, conditioning, and recording equipment are required for simultaneous recording of axial load and deformations. The signal must be clean of noise levels sufficiently low as to have no effect on test results as discussed in FHWA-RD-02-034. Use shielded cables for connections. If a filter is used, it must have a frequency which cannot attenuate the signal. The LVDT’s must be wired separately so each LVDT signal can be monitored independently. To provide a well-defined load amplitude, a minimum of 500 data points for the load cell and each LVDT must be recorded per load cycle.

2.1.6 The unit must come equipped with all standard equipment pertinent to the test method listed in Section 2.1.1 of this document including, but not limited to, triaxial pressure chambers with pushrods that can tolerate loads up to 1500 lbs. while generating less than the equivalent of 0.5 lbs seal drag for the 2.8 inch sample, and 2.5 lbs seal drag for the 6.0 inch sample, platens, gaskets, locking screws, fittings, valves, tubing, sensors, membranes and "O" type rings, and sensor mounting assemblies.

2.1.7 The system must include all standard equipment required to prepare test specimens for the test method listed in Section 2.1.1 of these specifications, and of the size and dimensions as indicated in Section 1 of these specifications. This includes but is not limited to all the equipment listed in AASHTO T 307-99 (2012) Annex B – Vibratory Compaction of Type 1 and Type 2 Soils and Annex C – Compaction of Type 2 Soils.

2.1.8 The top-loading closed loop, electrohydraulic loading device must include the following:

a. One (1) A u t o m a t e d 5 0 , 0 0 0 l b . load frame with at least a 10-inch stroke designed for static and dynamic testing with the following technical specifications:

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Fatigue force rating of at least 10,000 lbs and not more than 22,000 lbs. in both tension and compression

Vertical specimen and fixture height clearance sufficient for the required test accessories

500 lbf (2.22 kN), 2000 lbf (8.90 kN) and 5000 lbf (22.2 kN) external load cells. Other load cell capacities up to 10,000 lbf (4.45 kN) must be easily interchangeable.

Embedded controller Dedicated channels with signal conditioning and power supplies built-in.

Sufficient dedicated channels must be provided to run all tests indicated in these specifications.

Built-in Data Acquisition and Control Variable Speed range to run the test indicated in these specifications to the

requirements of the test method indicated. Accommodates test cell up to a max. Diameter of 6.00 in. (152 mm) Platen travel = min distance required to perform the test in Section 2.1.1 Upper and lower software limits to prevent ram over travel Built-in software safety shut-off when sensors max out Uprights with quick release/removal for easy and fast movement of cross

head Sensors set-up and configuration via software Integrated control and data acquisition board

b. A hydraulic actuator having a tension-compression fatigue force rating of up to

22,000 lbs must be mounted to the load frame on the crosshead such that all applied forces are downward and applied to the top of the test specimen. The actuator must have the internally mounted LVDT type displacement transducer for measuring actuator displacement. Minimum resolution of the actuator position measurement must be 0.0002 inches. The actuator must be capable of applying load pulses meeting the requirements in AASHTO T 307-99 (2012) and as indicated in Section 1.10 of this document.

c. A Hydraulic Subsystem with the following requirements:

● Fixed volume unit with a pressure-reducing valve for operating the HPS at selectable pressures

● Either a self-contained air cooling radiator (i.e. a closed recycling water cooling system that recycles water through the heat exchanger) or a water-flow heat-exchanger (i.e. a water source inflow and effluent waste into a floor drain) with sufficient capacity to cool the hydraulic fluid to the required operating temperature. Note: Minimum water hook-up and flow requirements must be indicated in the Vendor’s bid proposal.

● Failure mechanisms must be included with the HPS to prevent operation when either over temperature or low oil level conditions exists

● A sufficient reservoir capacity to ensure ample residence time of the fluid in the

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reservoir to remove trapped air and allow adequate cooling ● The HPS must be shipped with its normal fill of hydraulic fluid ● Flexible hoses (pressure, return and drain) of adequate length must be included

for the hydraulic power supply to the actuator manifold for operation of the system

d. Cell Pressure Controller including mounting bracket, all necessary equipment and accessories, fittings and built-in pressure sensor and software digital display of cell pressures. All pressures must be fully controlled and monitored by the system software.

2.2 Test Control Requirements

2.2.1 The hardware and software components, together described as the system, must provide fully automated operation and control to perform the test method indicated in Section 2.1.1. The hardware and software components must allow full operation and control of the testing system, including permitting fully automated operation of the equipment, while permitting alternate manual input and control of all loads, load rates and durations. Alternate manual control is permitted by editing of load software load sequence tables with text editor.

The hardware and software must provide both fully automated and operator defined modes of observation, recording and transfer all of test parameters and data, and instrument/sensor recordings. The test apparatus must be configured to be computer controlled, allowing operation both with the built in resilient modulus application, and permitting system control and customization through the computer outside of the resilient modulus application. The load frame must be able to have loads applied and removed, at the rates, magnitudes and shapes required, by the computer control system. Loading rates must have the option of being specified and controlled by the computer. The computer interface must allow the operator to adjust PID loop tuning values as well as the rate of data acquisition.

The system must be capable of fully automated control of the resilient modulus test, while allowing the capability of manual override should it become necessary to pause or terminate a test in progress. The computer control must acquire and display real time test functions and sensor data, and include or permit post processing and display of test results in both tabular and graphic form.

The apparatus must have necessary control functions to allow the operator to manipulate the location of the load platen for functions such as resetting the apparatus for a new test.

2.2.2 Vertical forces/displacements must be applied with high precision hydraulic load actuators for the test specified in Section 2.1.1 of this document at appropriate rates

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and within specified tolerances, consistent with those indicated in the relevant AASTHO specification.

Vertical loads and displacements must be monitored by appropriate sensors that transmit the information to the data acquisition system for use in engineering calculations and real time display and recording of load, displacement, and applied stresses/strains.

2.2.3 Test control parameters (applied loads and/or displacement rates and end of test criteria) must be adjustable during the testing sequence. The test control software must allow the test to be aborted at any time without the loss of existing data. Sensors must be included to detect an overload or ‘out-of-range’ condition and system controls must terminate the test if such conditions occur to protect the test system.

2.2.4 Readings, in operator defined or selected units, must be displayed in real time from test sensors to monitor the test and computer control system.

2.2.5 Sensor readings must be able to be electronically "zeroed" in the test control program.

2.3 Tolerance Requirements

2.3.1 Vertical displacements must be able to be determined to a minimum precision as indicated for the LVDT requirements indicated in Section 2.4.2 of this document, and as required by the test method indicated in Section 2.1.1 of this document. The Resilient Modulus System measuring device(s) for axial deformation must have a minimum range of:

Specimen Diameter Range(mm) (mm) (inch)

71 1 0.04100 2.5 0.1152 6 0.236

The requirements in the above table for range are approximately linear when plotted versus specimen cross-sectional area. Requirements for the measuring devices for axial deformation used with other specimen diameters must be approximated linearly.

The Vertical displacements must be able to be determined to the minimum range and precision requirements in the test method specified in Section 2.1.1 of this document.

2.3.2 Vertical loading must be controlled by an electronic load cell between the actuator and the chamber piston rod and must be maintained for the duration of appropriate testing periods (at each increment). The following capacities and accuracies are required for the axial load-measuring devices for the Resilient Modulus Test:

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Specimen Diameter Max Load Capacity Required Accuracy(mm) (kN) (N)

71 2.2 4.5100 8.0 10.0152 22.24 22.24

The above requirements for load capacity and accuracy are approximately linear when plotted versus specimen cross-sectional area. After being used to monitor loads during the resilient modulus testing sequences the load cell must be capable of completing the quick shear test as specified in AASHTO T 307-99 (2012) WITHOUT switching to a new load cell. The control electronics must remove load at 150% of full capacity of load cell automatically, without need for operator to preset any limits. Requirements for load cells used with other specimen diameters must be approximated linearly. The accuracies are to be over the range of the applied load.

2.3.3 The Axial Stress must be maintained within plus or minus 5% of the Target Axial Stress automatically throughout the duration of the testing sequences in Table 1 and Table 2 of AASHTO T 307-99 (2012).

2.3.4 Time must be recorded to the nearest second or less.

2.4 Data Acquisition Sensors

2.4.1 Applied vertical loads must be continuously monitored and must be measured with self-contained electronic load cells or similar high precision measuring systems which read loads directly. Instrumentation for measuring and monitoring load must perform at the loads and within the accuracies as indicated in the table in Section 2.3.2 of these specifications. Calibrated proving rings or mechanical spring systems coupled with digital dial gauges are not acceptable.

2.4.2 Displacements must be measured externally with 2 linear variable displacement transducers (LVDT’s) fixed to opposite sides of the piston rod outside the test chamber. These two transducers must be located equidistant from the piston rod and must bear on hard, fixed surfaces which are perpendicular to the LVDT axis. LVDT’s are required with a range of +/- 0.1 inches for the Resilient Modulus test. The LVDT’s must be long stroke units capable of being adjusted while the test is running with software automatically compensating, so that the LVDT’s do not have to be installed at the zero position. During each test interval, the two LVDT’s must be constantly monitored by the system software. A warning will be provided if the deflection variation is 10-30%, and again if it exceeds 30%. This warning must be provided automatically by the Resilient Modulus software without operator input. The software must have a pause

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feature to allow the operator additional time to make alignment adjustments, if necessary, and then continue the test from the point in which the pause was made. The two LVDT’s must be wired so that each transducer can be read and reviewed independently while the test is running and the results averaged for calculation purposes. The display of both LVDT waveforms must be overlaid and available continuously while the test is running. The display must also provide readouts of each LVDT span. These readouts shall be in addition to the system digital displays, and cannot be closed or modified by the operator. The LVDT’s must meet the following minimum specifications:

a. Linearity: 0.25 % of full scaleb. Repeatability: 1 % of full scalec. Minimum Sensitivity: 2 mv/v (AC) or 5 mv/v (DC)

2.4.3 Cell pressure must be measured by a pressure transducer with a minimum range of 0 psi to 70 psi (0 kPa to 483 kPa) and accurate to 0.1 psi (0.7 kPa) for the Resilient Modulus test. The pressure may be monitored internally in the pressure controller, if the triaxial cell is at the required pressure and tolerance. Verification of pressure inside the triaxial cell must be performed as part of installation, regardless of the transducer location. The chamber pressure must be adjusted automatically. The test must be automatically paused if the pressure feedback is not maintained within a +/- 0.1 psi tolerance of the pressure target. Therefore, an automatic pressurization unit must be included.

2.5 Calibration

2.5.1 Applicable calibration information must be provided with all sensors including instructions for use, and calibration factors as well as any additional instructions relating to their inclusion in the data acquisition system.

2.5.2 Computer software must be configured to perform relevant corrections for the system (i.e. no post-processing must be required).

2.5.3 Sensors and data acquisition equipment must be of appropriate quality, construction, and durability to maintain their precision such that calibration of the apparatus be required no more frequently than on an annual basis (assuming daily equipment use and with all manufacturer indicated maintenance and system checks performed as required).

2.5.4 The successful bidder must provide all equipment necessary to verify all system measuring components are in proper calibration. At a minimum, the equipment must include a separate calibrated proving ring to check and calibrate the system load cell, and a micrometer with compatible resolution or a set of specifically machined gauge blocks to check the accuracy of the LVDT’s.

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2.5.5 The system must have an internal process for calibrating sensors and provide results and data capable of indicating all sensors current state of function and calibration.

2.6 Data Input

2.6.1 Data and operating parameters relevant to the tests (i.e. sensor reading intervals, test specimen dimensions, etc.) must have the option to follow preset standard default settings or be manually specified by the operator. The system must be configured to permit manual override of data and operating parameters to be entered into the computer via the standard keyboard/numeric keypad interface.

2.6.2 The computer control program must provide a method for correcting input errors (i.e. use of delete, backspace, etc.). The control program must be of such a design where an error in the input process does not require the test to be aborted and re-started from the beginning.

2.7 Computer Environment (Hardware)

2.7.1 See Annex 1 (attached)

2.8 Computer Program Environment (Software)

2.8.1 Computer test control, data input, and reporting software must be applications that operate on a standard personal computer with Windows 7 Pro (64 bit) and Windows 10 Pro (64 bit) operating systems.

2.8.2 The software controlling the test indicated in Section 2.1.1 must continue to operate as hardware and computer operating systems are updated.

2.8.3 The software user interface must incorporate standard MS Windows conventions (i.e. use of mouse, use of minimize and maximize window functions, 'tab' and 'arrow' keys [to move between fields], 'enter' key [to accept information], function keys, numeric keypad, standard Windows tools such as cut, copy, paste, etc.) where relevant.

2.8.4 The computer test control data input and reporting software program must be able to present reports graphically on the computer screen as well as print reports (including tables and graphs) to both local and network printers and plotters.

2.8.5 The software must use nomenclature of input variables and output information

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consistent with that used for the test method indicated in Section 2.1.1.

The system editing and reporting software may run separately from the control and acquisition software. If the programs are separate, they must be integrated (i.e. using the same data storage and retrieval and naming conventions) and fully compatible with one another. Graphical user interfaces must be consistent such that naming of data items in the input is consistent with naming in the output. Units of measure, significant figures, etc., must be consistent among all programs or program components.

2.8.6 The computer software must be capable of capturing data from any installed AC or DC transducer, or externally conditioned transducer. The software must automatically recognize installed transducers. If a transducer is changed the system must know the transducer’s full scale and other information without operator intervention. The software must display real time sensor readings, in engineering units. Display of readings must be automatically updated without operator action.

2.8.7 The servo loop closure and data acquisition rate must be 10khz with all channels synchronized. The data acquisition rate must be independent of the computer. This loop closure and data acquisition rate must not be reduced regardless of the controller functions enabled. The controller must perform all data acquisition providing nonvolatile storage of information until processed by the application software.

2.8.8 The application software must utilize detectors for monitoring changes in peak / valley readings. This process can be used to trigger data collection or other definable test system processes either by means of the application software or directly by the controller.

2.8.9 The application software must allow the operator to selectively acquire data periodically as defined by logarithms, linear intervals or user selected intervals. This data must be collected in time, level crossing or peak and valley samples.

2.8.10 The application software must allow a virtually unlimited number of test procedures to be set up and stored.

2.8.11 The software must have the ability to control all functions available within the controller, including waveform generation, auto tuning, data acquisition, limits, PID, digital and analogue outputs.

2.8.12 The software must have the ability to define wave shapes, end levels, frequency, number of cycles, elapsed cycle count and also be able to output blocks of cycles.

2.8.13 Software must produce appropriate labeling of data, graphs, and displays. Graphs and

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tables must have the test title and filename clearly associated with them such that they can be readily identified if multiple windows are open. Additionally, graphs and tables must have appropriate headings, axes labels, column labels, etc. Values must be accompanied by appropriate engineering units (i.e. pressure values accompanied by the engineering units, in psi [or kPa]. Units of measure for the test method indicted in these specifications can be found in the applicable AASHTO specification. Software must be configured to provide an operator defined sample identification on all real-time data displays, and all printed results reports, data summaries and graphs.

2.8.14 The software must record and display simultaneously, real time axial load and deformations, load rates, and other pertinent test parameters depending upon the specific test being conducted (e.g. confining pressure). The system must be configured and be capable of providing a minimum of 500 data points from each LVDT and load cell per load cycle for Resilient Modulus testing.

2.8.15 The software must keep track of the overall non-recoverable deformation, and record this measurement in a file after each interval. If non-recoverable deflection reaches the 5% limit, a warning must be issued and a note must be automatically entered into the test report. Operators will have the option to end or continue the test. This measurement must automatically and accurately function even if the operators adjust the tri-axial cell mounted LVDT’s or remove and reinstall the tri-axial cell during the test. Resolution of the measurement must be 0.0002 inches or better.

2.8.16 The software must either provide user access levels or hidden system setting panels to prevent inadvertent changes to tuning and calibration files

2.8.17 The software must provide the capability to set up simple tests in any control mode with constant amplitude cyclic or ramp waveforms. These simple tests must also be able to acquire and store data from any defined transducer signal. In addition counter functions must be available from the simple test to present current and total counts as well as provide a present count for the test. The software must make it possible to save all the simple test settings and recall them for future use. Included in these simple tests are waveforms controlled by actuator position, load, either LVDT, and combinations of these channels such as cycling from a position to a load.

2.8.18 The software must have the capability to be programmed by the operator using a standard library of procedure calls designed specifically for real-time control of the system. The system must run the resilient modulus test without the need for any programming or operator control or input once the test is initiated and running. The system must start and run the test at the correct levels automatically. If specifications change, test levels must be changeable by the operator using simple human readable forms, such as text inputs or pulldown menus. Programming of new levels must be accomplished by copying the stress requirements directly form the procedure, without the need for calculations.

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2.8.19 The software must come equipped with a preprogrammed “template file” with the testing sequences in Table 1 and Table 2 of AASHTO T 307-99 (2012) so that the user does not have to enter them into the software for every test. The test loads must adjust automatically based on the specimen dimensions and material type. The operator must be prompted to enter pertinent data.

2.9 General Test Process Function

2.9.1 The test system must be controllable by the operator so that displacement and load rates can be automatically applied per preset standard default values, or as defined by the operator. The system must be configured to permit the operator to select from a menu of preprogrammed displacement and load rates, or permit the operator to program new standard default displacement and load rates.

The control program must record the vertical displacements and vertical load and stresses applied to the sample. Data sampling must be able to be specified by either time rate (minimum specified rate no greater than 0.1 minute) or strain rate (minimum specified rate no greater than 0.01%).

2.9.2 The system must automatically record time, vertical displacements, cell pressures, vertical forces and any other information required by the test method listed in Section 2.1.1 of this document at preset standard default intervals (these reading intervals must be consistent with the AASHTO test method requirements indicated for the test listed in Section 2.1.1 of these specifications), or intervals determined by the operator.

2.10 Manual Override

2.10.1 The system must include a manual override to allow the operator to terminate the test at any point.

2.11 Test Termination

2.11.1 The test must be automatically terminated once the system determines that it has reached final parameters for the input control values (i.e. maximum applied vertical stress or maximum % strain, etc.). The operator must be able to terminate the test prior to reaching system determined final parameters, however, the operator must not be able to override safeties designed to protect the equipment or system.

2.11.2 The computer software must have a status indicator, dialogue box, or other method to allow the operator to know that a test is complete (or in process).

2.12 Data Acquisition & Reduction

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2.12.1 The system must perform required conversions from electrical sensor output voltages to engineering units automatically (in the program background) with no operator input or direction required (i.e. operator does not need to enter conditioner information, sensitivities, conversion factors, multipliers, etc.).

2.12.2 Calculations used in the tests (i.e. determinations of stresses from loads and areas, etc.) must be performed by the system automatically.

2.12.3 The digital controller must provide for a closed loop control of the system. Loop times must have a 10 khz loop closure rate, regardless of options enabled.

2.12.4 The digital controller must have the capability to perform automated dynamic control mode switching between any connected transducer. The controller must condition all transducers used during resilient modulus testing. Any transducer, whether conditioned by the controller or not, can be selected for control. Control modes will include load control through a load cell, strain control through an extensometer, displacement control through an LVDT, control through any other installed transducer that provides a +/- 10 voltage input, and calculated control modes.

2.12.5 The controller must have a minimum of four channels installed at time of delivery, with future expansion capability available. The control system must possess the capacity for computer control of transducer zero, transducer excitation and linearization.

2.13 Error Correction

2.13.1 The system must store data in such a manner that it can be edited after completion of the test to correct errors found in the initial inputs (i.e. date, sample height, etc.) so that the test is not invalidated if these errors are discovered after the test has been completed.

The editing method does not have to be internal to the provided software (i.e. could be a standard text editor), but must at least be able to be edited using a standard Windows® text editor. The procedure must be documented in the relevant sections of the documentation.

2.13.2 Data must be stored in (or be downloadable in) a standard file convention (ASCII text or similar) that allows input, viewing, and/or content manipulation by standard text editors or spreadsheets.

2.14 Screen Display of Information

2.14.1 Real time test monitoring is required.

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2.14.2 Information must be displayed on a computer using Windows 7 Pro (64 bit) and Windows 10 Pro (64 bit) operating system. The system must be able to graphically display vertical force, vertical displacement, cell pressure and any other information required to be graphically presented for the test method listed in Section 2.1.1 of this document.

2.14.3 Editing functions must be available in the reporting software to adjust and refine graphical information (i.e. graph axes must allow automatic or "operator defined" values so specific portions of the graph can be enlarged/examined, or units of measure changed so graphical results of different tests can be compared on similar scales).

2.14.4 Previously run tests must be able to be recalled for display by the software from archived data files.

2.14.5 Test results must be able to be presented in both graphical and tabular format.

2.15 Printed Reporting & Data File Production

2.15.1 Printed tables of test data must be available as output. In addition, printed graphs showing typical Resilient Modulus test results must be provided by the program software. The test report must include constitutive relationships from: Design Pamphlet for the determination of design Subgrade per FHWA-RD-97-083 publication

2.15.2 The report must be in a standard format, as shown in AASHTO T 307-99 (2012). The report must be both printable and appear on the monitor (allowing the operator to check results immediately after completing a test).

2.15.3 Plotting to monitor, printer, or file must be provided as well.

2.15.4 Graphical units (i.e. x-y axes extent/scale) must have the option of being operator adjustable for presentation on printed output. A data file suitable for import into a standard spreadsheet (i.e. text file, ASCII file, or comma/tab delimited data file) must be available as a standard test output.

2.15.5 Output must be labeled such that test name, applied stresses/loads, displacement values, etc., and other sample or test identifying information is presented for identification of the output.

2.15.6 Previously run tests must be able to be recalled for display by the software from archived data files and printed (both tables and graphs).

2.15.7 Standard printed output must be compatible with either portrait or landscape orientation.

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2.15.8 Any internal printer drivers must be compatible with standard printers; the system must allow the use of standard Windows 7 Pro (64 bit) and Windows 10 Pro (64 bit) operating systems.

2.16 Units of Measure

2.16.1 The system must be capable of accepting input and providing output in either U. S. Customary units (English) or SI units.

2.16.2 A test conducted in one system of units, or mixed units system, must be able to be reported in either of the two unit systems.

2.16.3 Units and presentation of units must be consistent with NIST (National Institute of Standards and Technology) guidelines.

2.16.4 Available reporting units must be consistent with the AASHTO test method requirements indicated in Section 2.1.1 of these specifications and commonly used forms associated with the test and found in related engineering or lab procedure references (e.g. square inches and square millimeters; pound force/square inch and kilopascal).

3. DOCUMENTATION

3.1 Operator’s manuals must be provided with the system. Topics must include appropriate installation overview, detailed set-up instructions for first time installation, general operation, calibration, manual operator controls and troubleshooting.

3.2 An online "help" function must be associated with the software. This function must, at a minimum, indicate where further information can be found in accompanying manuals. The help function must include test methodology (how to run the test) for the indicated AASHTO test method specified in Section 2.1.1 of this document in addition to a description of relevant function keys and software controls. This requirement may be waived at the discretion of the Department if a thorough and adequate user manual covering all system operations is provided with the test system.

3.3 Any manuals relevant to components of the system (i.e. computer cards, sensors, D/A converters/conditioners, the computer, etc.) must be included with the system.

3.4 Sensor and instrument calibration information must be provided.

3.5 System documentation must clearly indicate all tolerances, maximum pressure or load ratings, etc., for the included components.

3.6 All warrantee or calibration documentation must be provided upon delivery.

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4. TECHNICAL SUPPORT

4.1 General

4.1.1 The successful bidder must provide reasonable technical support by staff that has familiarity with the equipment and its operation by telephone, fax, or e-mail during regular business hours (i.e. 8 AM - 4 PM EST). Requests for technical support must be answered within 24 business hours.

4.1.2 Mechanical problems must be addressed in a timely manner either by replacement of the equipment or by replacement of the component in the most practical method as determined by mutual agreement between the agency and the successful bidder (refer to Section 4.3, below).

4.1.3 Software problems (affecting system accuracy, precision, or ability of equipment to perform or meet the AASHTO test method specified in Section 2.1.1 of this document) must be corrected, and new software issued within 21 calendar days of the notice of malfunction.

4.2 Assembly

4.2.1 The successful bidder must pre-assemble all components. Hardware, software (if pre-installed on computer), sensors, cables, etc. must be verified for proper functionality prior to distribution of the system.

4.2.2 The system must be complete upon delivery, including all relevant connections, computer components, software, cables, power cords, electrical, electronic and mechanical fittings, calibration blocks, sensors, load frame parts, mounting assemblies, tubing, etc.

4.3 Warranty

4.3.1 If system defects, including software or hardware, are discovered or occur where the system fails to function properly, the successful bidder, at the bidder's expense must provide appropriate replacement components, software modifications and re-issues, or other applicable corrections or repairs at their expense for the 12 months (1 year) of system operation by the owner. One year of system operation is considered a cumulative period 12 months after date of system acceptance during which the system is fully operational. The date of system acceptance is defined as completion of system installation, set-up and calibration, training, and all systems demonstrated to be in full properly working order by the vendor. Periods of down time (i.e. the system is inoperable) due to component or system defects, malfunction or required adjustments and/or repairs, will not be included within the cumulative total twelve-

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month warranty. As an example, if the system is inoperable due to system malfunction or breakdown for a period of two months until the vendor can affect repairs, the two-month period is not included within the total twelve-month warranty. Any down time resulting from owner damage or misuse during the warranty period, will not result in warranty extension.

4.3.2 All parts must be completely functional and free of defects upon arrival.

4.3.3 Failed components must be replaced in a reasonable amount of time. This time must not exceed 30 days. The vendor will make any repairs or adjustments necessary to bring the system back to full operational capability and specification compliance when service, adjustments, or component/part replacement is required.

4.3.4 All warranty repairs must be done either off-site or on-site at the location of installation where practical. If comprehensive system diagnostics, major component cleaning or replacement, or other major operations requiring specialty work-benches, additional computer equipment, or several staff members are required, the system must be returned to the manufacturer for work of this nature. When any system or component needs to be repaired at another location all packaging and shipping costs are the responsibility of the successful bidder.

5. MANDATORY ON-SITE INSTALLATION AND TRAINING

1.2.3.4.5.5.1 Installation

5.1.1 The successful bidder must provide onsite installation of the system within 7 days of delivery of the equipment (set-up, assembly, calibration, computer program testing) by a qualified technician or engineer. The successful bidder must demonstrate full functionality of the equipment and systems for the test method listed in Section 2.1.1 of this document to the Department as part of the system setup.

5.1.2 The successful bidder must have the Fully Automated, Computer Controlled Resilient Modulus Testing System verified as meeting FHWA-RD-02-034 protocol including triaxial chamber piston seal drag force verification by a qualified individual of the Departments choosing onsite at the PennDOT Materials Testing Laboratory.

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5.1.3 The vendor must qualify each triaxial cell by documenting its static and dynamic seal drag as part of the system installation. The process for documenting seal drag must be as follows:

Test to be performed with components to be used in actual testing. Connect triaxial cell pushrod to load cell. With no specimen installed, pressurize triaxial cell to pressures used in testing. At each confining pressure, input position controlled haversine waveform at amplitudes

simulating an actual test (0.0005, 0.001, 0.002 through 0.010 inch) and record force measured by load cell.

Verify force is less than the maximum allowable value. (If this value is exceeded then during installation, the equipment must be modified to reduce drag.)

Air must be used in the triaxial chamber as the confining fluid. The cell’s confining pressure rating must be at least 150 psi. The triaxial pressure chamber will consist of the components outlined in AASHTO T 307-99 (2012)

5.2 Training

23455.25.2.1 Training must not be initiated or proceed until installation of all system components

and software are complete and full functionality of the equipment and systems for the test method listed in Section 2.1.1 of this document have been demonstrated to the satisfaction of the Department.

5.2.2 Training must be provided for the test method listed in Section 2.1.1 of this document. (Note: This includes ALL aspects of AASHTO T 307-99 (2012), including sample preparation/molding procedures)

5.2.3 The successful bidder must provide a minimum three (3) business-days of equipment test training sessions for an unlimited number of employees by a qualified technician or engineer who is familiar with the installation and operation of the equipment. This training is to be included with the purchase price of the RM test system. The Department will video all training sessions for internal future use.

5.2.4 Training must include the following:

a. Set up of equipment, connections, etc.b. Check of sensor calibration

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c. Calibration of sensorsd. Operation of load framee. Operation of test control software including:

Changing units, Control modes and data entry Standard test set-up and operation Specimen set-up Zeroing sensors Standard testing Specimen break-down

f. Operation of test reporting software (Test result download, presentation, reporting, error correction, graphing and output manipulation)

g. Frame and cell care and maintenanceh. General program and hardware troubleshootingi. Development of 'set-up' files for common tests including:

develop data sampling rates develop input parameters

i.ii.

iii.iv.v.

vi.vii.

viii.j. Review of hardware and softwarek. Sample preparation/molding of specimens

5.2.5 Trainings must take place at the Department’s Material Testing Lab in Harrisburg, PA, USA.

5.2.6 Training must take place immediately after setup and proper operational demonstration and verification is complete.

5.2.7 Training must be directed towards an audience of operators who will be operating the apparatus and will be using the data generated from testing.

5.2.8 The vendor must complete a minimum of three Resilient Modulus tests on a soil material following the sequence schedule listed in Table 1 of AASHTO T 307-99 (2012) and three Resilient Modulus tests on an aggregate material following the sequence schedule listed in Table 2 of AASHTO T 307-99 (2012) on each newly installed testing system. The soil sample and aggregate sample will be reference materials provided by the Department and the results must meet the following acceptance criteria:

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Soil Sample:

● Average Max/Min Mr ratio for the fifteen load sequences = maximum of 1.010. This value is determined by calculating the Max/Min Mr ratio (ratio of the maximum to minimum resilient modulus) for the last five load cycles of each load sequence and then calculating the average Max/Min Mr ratio for the fifteen load sequences.

● The ratio of the Mr (resilient modulus) value for the 4 psi confining/6 psi axial stress load sequence to the average Mr value for all 15 load sequences must be between 0.900 and 1.050 (between 90 and 105 percent).

Aggregate Sample:

● Average Max/Min Mr ratio for the fifteen load sequences = maximum of 1.005. This value is determined by calculating the Max/Min Mr ratio (ratio of the maximum to minimum resilient modulus) for the last five load cycles of each load sequence and then calculating the average Max/Min Mr ratio for the fifteen load sequences.

● The ratio of the Mr (resilient modulus) value for the 10 psi confining/10 psi axial stress load sequence to the average Mr value for all 15 load sequences must be between 0.900 and 1.050 (between 90 and 105 percent).

5.2.9 PennDOT lab technicians must be able to perform the entire test from making the sample to printing the report supervised by the vendor.

6. UPGRADES

6.1 The Department must be notified of software upgrades/updates through functional life of the product. Software upgrades developed within one year of the date of delivery must be made available to the Department without charge.

7. NOTICE TO BIDDERS

1.1.12.1.13.1.14.1.15.1.16.1.17.1.1

7.1 Bidders must provide with the bid sufficient documentation, specifications, drawings, etc. to allow the agency to evaluate the offered apparatus and all components for conformance to these specifications and requirements. This documentation must include:

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a. Evidence that the system has been tested and verified as meeting FHWA RD-02-034 protocol.

b. Examples of generated reports, preferably reports based on replicates of soil samples tested over time.

c. Results from tests completed on their resilient modulus testing system. The results must be from a minimum of two replicates of a soil sample tested at approximately 1 month intervals over a minimum of six months. Each replicate’s results must not vary within +/- 5%. A minimum of 12 specimens must be included. The Department will work with the vendor in determining what meets this requirement.

d. Reference lists, showing a significant installed base of similar equipment and a history of satisfactory delivery performance.

e. Inventoried standard product parts lists. 7.2 Equipment delivery deadline (Maximum 100 Days) after award of bid (includes all test

equipment, sample preparation equipment, standard reference samples or standardization/verification device(s) – i.e. all deliverables). Responding vendors must include a list of utility and service requirements that are necessary prior to installation of the system.

7.3 Bidders must include a list of site preparation requirements necessary for the installation and operation of the offered equipment including all utility requirements.

7.4 Failure to provide said documentation may result in that bid being rejected. If such documentation is deemed necessary by the Department to evaluate portions of the system and/or equipment, and the documentation is not provided upon subsequent request, the Department can reject the bid.

7.5 Bidders must include with their response, certification (signed by a responsible

vendor official) that the bid meets all requirements indicated in this document and any attachments to the bid package.

7.6 If any of the requirements indicated in these bid specifications are not clearly understood or cannot be met, the bidder must contact the Department prior to submission of the bid for clarification and/or determination if the requirement must be modified or can be waived. Any discrepancies or clarifications that many be necessary after award of the bid will be resolved at the discretion of the Department (Pennsylvania Department of Transportation), whose decision will be final. Any changes or modifications required because of discrepancies or clarifications not identified and/or communicated prior to award of the bid, must be done at no additional cost to the Department.

8. PERFORMANCE VERIFICATION AND CALIBRATION CHECK REQUIREMENTS

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● These requirements are in addition to those previously indicated in these specifications

● Any equipment (hardware, software, data acquisition or processing) or materials necessary to perform the complete dynamic test system evaluation and verification, but not included with the resilient modulus and unconfined compression testing equipment (including hardware and software, standardization/verification sample or device, and sample preparation equipment), must be provided as necessary to complete the system evaluation and verification.

● Follow and meet the requirements of FHWA-RD-02-034, "Long-Term Pavement Performance Materials Characterization Program: Verification of Dynamic Test Systems With Emphasis on Resilient Modulus" (including but not limited to those specifically referenced below), except as noted, revised or specified in all following sections of these specifications.

● Elements of the overall test setup must first be checked/tested to verify they are operating properly and produce required/appropriate responses and performance.

● Each of the Individual test system components, including but not limited to those listed on page 25 of FHWA-RD-02-034, must be checked for proper calibration and performance, prior to overall system calibration and performance verification.

8.1 Performance Verification of Electronic System

8.1.1 All verification tests must be performed "in-system

8.1.2 All LVDT's must be actuated mechanically (no electrical simulations permitted).

8.1.3 All load cells must be physically actuated with hydraulic loading systems no electrical simulations permitted).

8.1.4 Separate test systems must be used for testing the AC LVDT system and the DC load cell system.

8.1.5 Provide and use suitable, stable LVDT holders for verification testing and production testing.

8.1.6 Provide and use test systems for the verification process and during production testing, as necessary to provide accurate verification and production test results, with the necessary and/or required resolution and sensitivity.

8.1.7 Provide and use all components required and/or necessary for the verification process and testing and for production testing, of the necessary and/or required accuracy, sensitivity and/or resolution.

8.1.8 Collect all verification test data electronically, and provide a user friendly annotated electronic record of all verification test data and results.

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8.1.9 During LVDT performance verification, do not collect and use less than 20 points per complete sine wave (from the moment of the load initiation cycle, through the sine wave peak and the zero-crossing point).

8.1.10 Acceptance Criteria:

All channels must have matched input delays. Delays derived from digital data must indicate input-to-output delays within +/- 0.000400 seconds at 50 Hz.

The maximum deviation in amplitude (signal attenuation) from 2 Hz to 10 Hz for a single channel must be less than 0.5 percent as determined from the digitized data.

8.2 Deformation Measurement Devices

8.2.1 Full scale range and travel for deformation measurement devices must not exceed 2.54 mm.

8.2.2 Deformation Measurement Device Acceptance Criteria:

The best fit curve must have a zero intercept (+/- 0.0254 mm) and an R2 value of at least 0.99.

The maximum difference in the readings between the micrometer and the deformation device cannot exceed 1 percent of the device's full-scale travel.

Deformation device(s) must be free of visual defects and must operate in an acceptable manner (e.g., no visible damage and no sticking).

8.3 Load Cell Zeroing

8.3.1 The load cell is removed from the test apparatus for this procedure.

8.3.2 No load is applied to the cell during this procedure.

8.3.3 Acceptance Criteria: the load cell zero reading cannot exceed 1.5 percent of its full-scale, factory-indicated sensitivity.

8.4 Load Cell Calibration

8.4.1 Calibration must be conducted per the latest version of the ASTM E4 standard.

8.4.2 The dynamic test system is not used for this procedure.

8.4.3 Acceptance Criteria: The load cell must be calibrated prior to overall system calibration and performance verification, but within 120 days of the overall system calibration and performance verification. Certification of calibration must be provided.

8.5 Verification of Load Cell Calibration (Static)

8.5.1 Verification of load cell calibration must be conducted with the system fully assembled as if a production test were going to be performed.

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8.5.2 A calibrated proving ring of necessary range and sensitivity must be used for this procedure.

8.5.3 The procedure does not take the place of the NIST traceable calibration.

8.5.4 All test systems must be turned on a warmed up per manufacturer’s specifications, requirements or recommendations.

8.5.5 Follow the approach outlined on pages 33 through 35 of FHWA-RD-02-034 for this procedure.

8.5.6 Acceptance Criteria:

The test system load must be within +/- 5 percent of the proving ring load. The test system deformation must be within +/- 5 percent of the proving ring

deformation.

8.6 Load Versus Deformation Response Check (Dynamic)

8.6.1 All test systems must be turned on and warmed up per manufacturer’s specifications, requirements or recommendations.

8.6.2 Follow the approach outlined on pages 40 through 47 of FHWA-RD-02-034 for this procedure.

8.6.3 Acceptance Criteria:

The generated haversine wave form conforms to the ideal haversine wave form. Load and deformation consists of a minimum of 500 points per cycle. The generated deformation output conforms to the ideal haversine waveform. Time lag between load peak and deformation peak is less than 0.008 second and

deformation is occurring after load. Maximum and cyclic loads must be within 5 percent of target. Contact load must be

within 10 percent of target. Deformation devices must measure within 10 percent of each other. Mean deformation values versus mean applied load must be within +/- of the 5 percent

band lines. The R2 value of the best fit line must be greater than 0.99.

8.7 System Dynamic Response Check

8.7.1 All test systems must be turned on and warmed up per manufacturer’s specifications, requirements or recommendations.

8.7.2 Follow the approach outlined on pages 55 and 56 of FHWA-RD-02-034 for this procedure.

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8.7.3 Acceptance Criteria:

The phase angle measurement must remain consistent for all five periods at a given frequency (within +/- 0.5 degree).

The phase angle measurement must be less than 2.8 degrees.

8.8 Tri-Axial Pressure Chamber

8.8.1 All test systems must be turned on and warmed up per manufacturer’s specifications, requirements or recommendations.

8.8.2 Follow the approach outlined on page 59 of FHWA-RD-02-034 for this procedure.8.8.3 Acceptance Criteria:

All system pressure readings must be within +/- 2.5 percent of the target values for the duration of the test procedure.

All NIST gauge pressure readings must be within +/- 2.5 percent of the target values for the duration of the test procedure.

All system and gauge readings must be within +/- 2.5 percent of each other for the duration of the test procedure.

The target pressure must be achieved within 30 seconds.

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Annex 1

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Computer Requirements with Monitor