UDOT Construction Inspection Guide - Chap 4

Published November 2012

UDOT Construction Inspection GuideConstruction Inspection GuideCHAPTER 4: Drainage

Table of Contents

Drainage

Box Culverts 02646 Concrete Box Culverts Culverts channel water under roads, railways and embankments. When inspecting…. 02645 Precast Concrete Box & 3 Sided Culvert Structures Precast unit inspection requires materials approval and installation inspection….

4.2

Drainage Structures 02633 – Concrete Drainage Structures This section includes the inspection of catch basins, drop inlets, inlets, and manholes…. 02635 – Grates, Solid Covers, Frames & Manhole Steps Inspection Checklist… 02643 – Concrete Lined Ditch Inspecting concrete lined ditches requires an understanding of pervious chapters, particularly…. 02611– Diversion Box Gate and Frame Inspectors must ensure the contractor has properly installed and used the correct materials…. 02624 – Approach Slab Catch Basin This section covers the inspection of the construction of a drainage catch basin in the approach slab …. 02625 – Approach Slab Drain Frame Modification This section covers the inspection of providing a frame riser to raise the existing drain grate …. 02626 – Deck Drain Modification or Closure The contractor must modify or close existing drains and install new drains at locations specified…. 02622 – Underdrain This section covers inspection procedures for placing pipe underdrains. Inspectors should be familiar….

4.3

Rip Rap 02372 – Wire Enclosed Riprap This section covers the inspection and procedures for wire enclosed riprap which is constructed by …. 02373 - Riprap This section covers the inspection and procedures for loose riprap, hand placed riprap and plated… 02374 – Grouted Riprap This section covers the material requirements and procedures for grouted riprap ….. 02376- Erosion Control Blankets/Channel Liners This section covers the inspection procedures for erosion control blankets and fabrics. These materials.. ….

4.4

Pipe Culverts - Introduction Well designed and constructed drainage systems are a critical component of ….. 02610 – Pipe, Pipe-Arch, Structural Plate Pipe and Structural Pipe Arch

This section covers the inspection of the materials and procedures used for installing…. 02613 – Culvert End Sections The contractor should use culvert end sections made of the same materials as the pipe…

4.1

CHAPTER 4: DRAINAGE

Page | 1UTAH DEPARTMENT OF TRANSPORTATION

CHAPTER 4: DRAINAGE

4.0 INTRODUCTIONWell designed and constructed drainage systems are a criti cal component of ensuring the

longevity of a highway. Roadway drainage involves collecti ng surface runoff and other water

sources to convey water to designated areas, ensuring traffi c safety and protecti ng the

roadway itself from damage. Water quality is an increasingly important concern, as roadway

runoff contributes to non-point source polluti on, so inspectors must adhere to applicable

environmental controls.

Many sections in this chapter closely follow a corresponding section in the Standard

Specifications. However, the intent of this chapter is not to repeat the specifications, but

to offer guidelines for inspectors to ensure compliance and to measure work done. All

section numbers refer to the Standard Specifi cati ons 2012 edition.

As explained in Chapter 1, the fi rst duty of an inspector is to become thoroughly familiar with

the contact plans, standard plans, special provisions, standard specifi cati ons, and any right-of-

way agreements that apply to the parti cular project. This guide is not a substi tute for a good

understanding of the project plans and standard specifi cati ons.

The secti ons of this chapter are further divided into the following subparts for most secti ons:

• General briefl y familiarizes the inspector with the secti on and describes the work coveredin the secti on.

• Before and During Constructi on describes tasks the inspector should perform duringthose phases of constructi on.

• Submitt al Requirements ensures the inspector gathers all necessary documentati onduring each phase of work for submission to the Offi ce Manager or Project Engineer.

• Site Inspecti on details specifi c items to look for during constructi on.

• Common Issues Encountered familiarizes the inspector with common contractor mistakes.

Chapter 4

UDOT Construction Inspection GuideConstruction Inspection Guide

Page | 2 CHAPTER 4: DRAINAGE

• Inspecti on Checklist describes the acti ons the contractor must take before constructi onbegins and acti ons the inspector must take during the course of work. This checklist alsoincludes the measurements and payments the inspector must complete. This providesthe guidelines for measuring and paying for the work covered in the parti cular secti on.

4.1 PIPE CULVERTS – GENERAL INFORMATIONThe life of a roadway depends largely upon well-designed and constructed drainage systems. Pipe culverts are a key component of these systems and correct placement is criti cal for proper functi on. The inspector must therefore understand staking informati on and be able to check for correct placement and installati on of culverts and the other drainage features uti lized on the project. It is necessary to inspect the drainage faciliti es to ensure proper sizing and quality of constructi on. For additi onal informati on refer to Appendix C.

A) PIPE, PIPE-ARCH, STRUCTURAL PLATE PIPE, AND STRUCTURAL PIPE

ARCH – SECTION 02610

General

This secti on covers the inspecti on of the materials and procedures used for installing pipe. Inspectors should be familiar with the class, type, size, and thickness designati ons of pipe called for in the plans, as well as any asphalt coati ngs to be used. Pipe and pipe arch are identi fi ed according to diameter or by span and rise and according to corrosion classifi cati on. Refer to Secti on 02610 for defi niti ons of materials and procedures used. Keep in mind the Utah Occupati on Safety and Health Regulati ons that apply during this phase of constructi on.

Before Work Begins

The inspector should request copies of the contractor’s submitt als to the Department for approval. Refer to Secti on 02610 and the Minimum Sampling and Testing Guide (MS&TR) for detailed guidance on materials certi fication. The

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CHAPTER 4

UTAH DEPARTMENT OF TRANSPORTATION

contractor may perform the acceptance testing, or use the services of a UDOT approved third party testing company. The Department must not accept any damaged pipe, so inspectors should ensure that damaged pipe is never used. Pipes are accepted after verification that the materials meet the specification’s requirements. These elements include horizontal and vertical alignment deviations, barrel distortion, any damage to the pipe, joints, and coating integrity. Refer to Secti on 2.1 of 02610 for types of pipe and the DG Series Standard Drawings for pipe type selection.

During Constructi on

Refer to Section 1.6 of 02610 for acceptance criteria once pipe has been placed. Inspection of the cross culverts, storm drains, and irrigation pipes installation must be done prior to placing the roadway pavement. The Engineer should have selected 25% to be inspected in addition to any areas with defects. The Department will pay the cost of any requested additional tests that show the pipe tested being in compliance with the criteria in Section

02610.

The contractor should furnish pipes with joints that can sustain minimum pressures. Each pipe type must be tested according to the proper AASHTO and ASTM test requirements by an independent lab or witnessed by a UDOT representative. The contractor must comply with the manufacturer’s recommendations for connecting pipes and for connecting pipes to concrete headwalls, catch basins, and similar structures.

Proper placement of the pipe is critical to the drainage system operating correctly. The inspector must understand the information on the offset survey stakes and check for proper placement of drainage items. Be sure the system will drain the intended area. As excavation progresses, check line and grade. Refer to Chapter 3 of this guide, Section 02317, and the DG Series Standard Drawings.



Verify bedding material and placement is accepted in accordance with Section 02056 and the requirements shown in the Standard Drawings DG 5a, 5b and 5c. Placed bedding material should be smooth, free of protruding rocks and conform to the surveyed grade. If excavation violates OSHA safety standards by not using a trench box or shoring, notify the contractor and report the condition to the Senior Inspector or the Resident Engineer.

Refer to the standard drawing DG 5. The material should be properly moistened and compacted to the required density by means of a mechanical tamping device approved by the Resident Engineer. When the top of the pipe is exposed above the top of the trench, embankment material, the same material used for trench backfill, should be placed and compacted by mechanical tamping. The remainder of the adjacent side fill may be regular

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CHAPTER 4


embankment material and can be compacted with power equipment as long as is can be done with no damage to the pipe. The adjacent side fill shall be placed and compacted to a minimum width of two diameters of the pipe or 12’, whichever is less, prior to use by traffic or construction equipment.

All materials should be installed according to manufacturers’ instructions to conform to AASHTO Standard Specifications for Highway Bridges. The joints should be closed in accordance with the manufacturer’s recommendations.

Sampling and Testi ng

The unit sampled depends on the type of pipe being inspected. Inspect the enti re length of cross culverts and the enti re length of pipe between manholes or other juncti on structures when inspecti ng closed conduits, such as storm-drains and irrigati on pipes. Visually inspect all other pipes as needed and be sure to follow OSHA requirements when performing inspecti ons in confi ned spaces. Use a mobile video camera to inspect and record the conditi on inside of installed pipes.

Manual measurements of pipe deformati ons will always need to be completed and verifi ed with the Engineer to ensure requirements have been met. In some cases of pipe deformati on, the Engineer could require a Mandrel Test to verify that the installed pipes meet specifi cati on requirements. All pipes that fail the Mandrel Test and that do not exceed 10% defl ecti ons, the contractor must provide engineering analysis certi fying the structural and hydraulic integrity of the pipe to the Resident Engineer and Central Hydraulics, signed and sealed by a professional engineer licensed in the State of Utah, for pipe acceptance to take place. The inspector should request a copy of this submitt al. If engineering analysis does not take place, inspectors must apply the pay reducti on schedule to sample units left in place that have pipes that do not meet Mandrel Test requirements. The contractor must remove and replace all pipes that exceed 10% defl ecti ons. This pay reducti on schedule is outlined in the table below.

PIPE DEFLECTION PAYMENT REDUCTIONS

Amount of Deflection (%) Payment

0.0 to 5 100% of the Unit Bid Price

5.1 to 9.9 75% of the Unit Bid Price

10 or greater Remove and Replace



In additi on to the inspecti on requirements in Secti on 02610, Arti cle 1.6 paragraph C, test the joints of all storm drains and irrigati on pipes with diameters equal to or less than 42” when visual inspecti on indicates noncompliance with the criteria. Test all pipes that have joints showing visible gaps, defects, or any other problem with an air or exfi ltrati on testi ng method. The contractor must repair all areas of damage that do not pass tests at no cost to the Department. See Secti on

02610 for leakage allowances. Repaired areas must be retested and replaced unti l these areas pass leakage tests. The table below will assist in the inspecti on process.

Before applying any coati ngs, the contractor should remove moisture, dirt, oil, un-bonded or incompati ble paint, grease residual oil, alkalis, or other foreign matt er from the surface to be coated. To conduct verifi cati on tests of the coati ngs, the Department will take a representati ve sample from each lot furnished by the contractor. The contractor should repair or replace any damaged materials. Asphalt coati ngs are not allowed on structural plat pipe and plate pipe arch.

Generally, the inspector should ensure the contractor has provided adequate cover or protecti on for all pipe during project constructi on. The contractor must replace all damaged pipe before acceptance by the Department. Some causes for rejecti on are irregular or distorted shape, dents, bends, damaged, broken, delaminated, scaled coati ngs, loose bolts or nuts, uneven laps, improper fi tti ng joints, or any damage that compromises the functi onality and design life of the pipe.

PIPE TESTING REQUIREMENTS ACCORDING TO PIPE FUNCTION OF CRITERIA IN SECTION

Pipe Category & Size Visual:Sight

Physical:Video Recording

Leakage:Manual Measure

Mandrel (See Article 1.6.C6)

Airor Water Test

Cross Culverts ≤ 48” Diameter X* X* When visual test

shows non-compliance

Cross Culverts > 48” Diameter X X

Storm Drains/Irrigation Pipes ≤ 48” Diameter X* X* When visual test

shows non-complianceWhen visual test


Storm Drains/Irrigation Pipes > 48” Diameter X X When visual test


* Both methods are acceptable for pipes with diameters larger than 30”.

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CHAPTER 4


Inspectors should document equipment and manpower uti lized, as well as damage, re- pairs, density tests, pay quanti ti es, and pay adjustments.

Submitt al Requirements

Prior to performing inspecti on, request copies of the following documents:

1. Uti lity Locati on and Protecti on (Blue Stakes receipt form)

2. Documentati on of Density Testi ng

3. Documentati on of Lift Thickness

4. Documentati on of Random Sample and Test Locati on or Interval

5. Material Approval and Inspecti on

6. Acceptance Criteria Documentati on

Site Inspecti on

Inspect the site for proper constructi on:

1.

Material is properly placed2.

Material is certi fi ed per UDOT standards3.

Material was tested and reports received approval

Common Issues Encountered Document these common contractor mistakes:

1. Existing Drainage feature is not maintained

2. Site isn’t properly prepared before installati on

4. Damage occurs and isn’t repaired

5. Quanti ti es are incorrectly measured

4.

Trenching & Excavation meets OSHA Guidelings

3. Pipe inspection is not performed and accepted prior to placement of Pavement



Pre-Inspection Items Contractor has located and protected utilities within the affected area by contacting Blue Stakes

before disturbance. Refer to Sections 00820 and 01571.

Inspector has cross referenced the plan summary sheets.

Site preparation, including pre-compaction, is complete.

Correct pipe was used according to the plan specifi cations, including material, size and class.

All manufactured materials are certifi ed as per UDOT standards.

Contractor has provided the manufacturer’s Certifi cate of Compliance (COC) or product dataindicating the materials furnished meets specifi cation requirements.

Contractor has provided the manufacturer’s Certifi cate of Compliance (COC) certifying thecoating thickness and that the pipe joints meet or exceed the specifi ed pressure requirement forthe application.

Contractor has completed all required UDOT Test Reports.

Field Documentation Items Visually inspect materials and site before placement to ensure; pipe fi ts drainage, tight joints,

horizontal and vertical alignment for bellies or bends, camber if required, proper coating, andbolt tightness.

Inspector then completed Form 150, Culvert Inspection.

Verify proper slope, invert and outlet elevations, proper fl ow direction, and inlet and outlet survey.

Visual inspection for damage to pipe structure including dents, holes, abrasions, or cracks.

Bedding, backfi ll, and compaction requirements have been met, specifi ed depth and lift thickness,test reports and testing frequency per MS&TR. Ensure excavation and bedding are executedproperly and according to standards. Ensure bedding and backfi ll are compacted to 96%maximum laboratory density and placed in 6” lifts.

Document all activities in daily diary or electronic fi eld book.

Inspector has witnessed contractor’s testing per acceptance criteria specifi ed in Section 02610.

Video or visual inspections have been performed. Ensure pipe and other components are placedin correct locations. Check placement locations against survey stake information and documentresults.

Mandrel pressure testing if necessary.

Document equipment and manpower utilized.

Document density results with random locations.

Determine pay quantities by measuring and documenting the length of pipe placed and placedquantity of related items. Payment adjustments for pipe defl ections have been made.

Ensure conditions of Section 1.6 of 02610 are met and documented as required.

02610: PIPE, PIPE-ARCH, STRUCTURAL PLATE PIPE, AND STRUCTURAL PIPE ARCH

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B) CULVERT END SECTIONS –SECTION 02613

General

The contractor should use culvert endsecti ons made of the same materials asthe pipe or pipe arch to which they areconnected. The only excepti on would bewhen the contractor should use a metalend secti on with HDPE with concrete pipeaccording to AASHTO M294. The coati ngapplied to the metal end secti on shouldbe identi cal to the coati ng applied to thepipe material.

The end secti on should be placed according to the constructi on methods specifi ed for the type and class of pipe to which they connect. Refer to DG Series Standard Drawings and Secti on 02610 for more informati on.



1. Material Certi fi cati on

Site Inspecti on


1. Material is properly placed

2. Material is certi fi ed per UDOT standards

3. Compacti on is correct



Common Issues Encountered

Document these common contractor mistakes:


2. Missing Hardware

Pre-Inspection Items Utilities have been located and protected.


Field Documentation Items The contractor has used the correct size, type, material, coating

or fi nishing.

There is a tight connection to pipe, and no damage to the pipe.

Grading allows proper drainage.

Backfi ll and compaction are correct.

02613: CULVERT END SECTIONS


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4.2 BOX CULVERTS

A) CONCRETE BOX CULVERTS – SECTION 02646

General

Culverts channel water under roads, railways and embankments. When inspecti ng concrete boxculverts, inspectors should ensure the contractor has provided waterstops as shown inthe plans, and adhered to all other requirements as specifi ed in the plans and standardspecifi cati ons. Contractors should noti fy the Department in writi ng at or before thepreconstructi on conference about which concrete box culvert type will be used at eachlocati on. Substi tuti ons may be made. For example, precast reinforced concrete box culvertsmay be substi tuted for cast-in-place reinforced concrete box culverts as shown in the plansunless specifi ed otherwise in the contract. This substi tuti on requires contractors to meet allrequirements and submitt als of Secti on 02645, Precast Concrete Box and Three-Sided CulvertStructures, detailed in the following secti on of this chapter.

Concrete box culverts may be accepted at a reduced price when the concrete strength is below that specifi ed. Reference Secti on 03310 for price adjustments. If cast-in-place culverts are used, inspectors should ensure that contractors do not backfi ll unti l the concrete has been in place at least 7 days and has att ained the specifi ed strength.



1. Signed and Sealed Drawings and Calculati ons

2. Prequalifi ed Source Documentati on

3. Backfi ll Documentati on

Site Inspecti on




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CHAPTER 4






3. Material is installed incorrectly

B) PRECAST CONCRETE BOX AND THREE-SIDED CULVERT STRUCTURES –SECTION 02645

General

Precast unit inspecti on requires materials approvaland installati on inspecti on. The contractor mustfurnish to the Engineer all shop drawings and designcalculati ons, and keep in mind that the Departmentwill reject any units fabricated before writt enapproval of the fabricator’s shop drawings wasreceived. Ensure any precast units are stamped withthe date of casti ng and supplier identi fi cati on. Thecontractor must replace any cracked or damagedunits at no additi onal cost to the Department.

Pre-Inspection Items Shop drawings and design calculations signed and sealed by Utah

licensed professional engineer.

Contractor has used a prequalifi ed source for precast structures.

Field Inspection Items Site is excavated to the required depth and elevation.

Contractor has used suitable materials for backfi ll, depth of lift,optimum moisture and compaction. Refer to Chapter 3 of this guide.

Contractor has provided the test reports from the UDOT MaterialsDivision for precast structures.

Compaction and fi ll requirements have been met. Backfi lldocumentation per MS&TR Section 02056.

02646: CONCRETE BOX CULVERTS



During site inspecti on, ensure the area is properly excavated, trenched and backfi lled, and that minimum bedding requirements have been met. The contractor must over-excavate as directed by the Engineer.





3. Test Reports for Precast Structures Submitt ed


Site Inspecti on







2. Required compacti on is not achieved

3. Damaged units are not replaced

Pre-Inspection Items Inspector has cross referenced the plan summary sheets. Shop drawings and design calculations are signed and sealed by Utah licensed professional engineer. Contractor has provided the test reports from the UDOT Materials Division for precast structures. Contractor has used a prequalifi ed source for precast structures.

Field Inspection Items Contractor has excavated the site to the required depth and elevation. Contractor has used suitable materials for backfi ll, depth of lift, optimum moisture and compaction.

Refer to Chapter 3 of this manual. Backfi ll documentation per MS&TR Section 02056.

02645: PRECAST CONCRETE BOX AND THREE-SIDED CULVERT STRUCTURES

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4.3 DRAINAGE STRUCTURES

A) CONCRETE DRAINAGE STRUCTURES – SECTION 02633

General

This secti on includes the inspecti on of catch basins, drop inlets, inlets, and manholes. Contractors must construct cast-in-place or install precast drainage structures to meet all requirements of the Secti on. The Engineer must be noti fi ed in writi ng on the selecti on of the method of constructi on, and the contractor may not change constructi on methods thereaft er without writt en approval from the Engineer.


All pre-cast structures furnished must be in conformance with the CB Series Standard Drawings and the contractor should provide verifi cati on of UDOT prequalifi cati on for precast supplier, when applicable. All cast-in-place structures must have an approved mix design. Additi onally, ensure contractors have repaired or replaced any structures that have fractures, cracks, damage, honeycombing, or defects and submitt ed repair procedure to the Engineer for approval. Ensure the contractor has performed either the vacuum test or ex-fi ltrati on test to verify the drainage structures are waterti ght. The contractor must receive acceptance from the Engineer aft er installati on and before backfi lling.





1. Concrete Mix Design Approval


3. Certificate of Compliance



Site Inspecti on

Inspect the site for proper constructi on and document the contractor’s acti ons:

1. Excavati on meets OSHA requirements

2. Field verify the fit and function at structure location before construction or manufacturing.

3. Installed materials are at specifi ed elevati ons


5. Verify the connection of the pipe and drainage structure is properly sealed as per section 02633 3.1C

6. Installati on was inspected and accepted before backfi lling began

7. Verify reinforcing steel sizes, epoxy coati ng, and spacing





3. Damage is not repaired

1. Field verification of exisiting features where not verified.

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B) FURNISH AND INSTALL GRATES, SOLID COVERS, FRAMES, AND MANHOLE STEPS – SECTION 02635

Pre-Inspection Items Utilities have been located and protected.


Contractor has used an approved mix design for cast-in-place structures.

Inspector has verifi ed reinforcing steel sizes, epoxy coating, and spacingfor cast-in-place structures.

Contractor has used a prequalifi ed source for precast structures inaccordance with UDOT Quality Management Plan. The inspector must verifytype and structure I.D., and cross reference these to the plan summary sheets.

Structures are marked with date of casting and supplier identifi cation.

Contractor has provided the manufacturer’s Certifi cate of Compliance(COC) for reinforcing steel.

Contractor has provided manufacturer’s product data, specifi cations, andrecommended installation instructions for curing compounds, if applicable.

Field Inspection Items Engineer has approved installation before placing backfi ll.

Contractor has used suitable materials for backfi ll, depth of lift, optimummoisture and compaction. Refer to 3.3.

Compaction and fi ll requirements have been met. Backfi ll documentationper MS&TR Section 02056.

Contractor has excavated to the required depth and installed materials atthe required elevation.

Contractor used coated reinforcing steel and non-shrink grout, if applicable.

02633: CONCRETE DRAINAGE STRUCTURES

Contractor has used the correct type, foreign or domestic steel.

Contractor has used the correct step spacing.

Offset from curb or barrier is correct.

Contractor has used proper placement methods, including orientation, andinstalled according to plan specifi cations.

02635: GRATES, SOLID COVERS, FRAMES & MANHOLE STEPS

Contractor has verified the fit and function of the concrete drainagestructure.



C) CONCRETE LINED DITCH – SECTION 02643

General

Inspecti ng concrete lined ditches requires an understanding of previous Chapters, parti cularly embankment, borrow, backfi ll, and concrete secti ons.

If the fi nished concrete strength is below that specifi ed by the plans, the ditch may be accepted and paid at a reduced price. The inspector should follow the price adjustment pay factor in Secti on 03055.



1. Verifi ed plan dimensions


3. Concrete curing compound approval

Site Inspecti on




3. Concrete strength is tested






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D) DIVERSION BOX GATE AND FRAME – SECTION 02611

General

Inspectors must ensure the contractor has properly installed and used the correct materials for gates and frames.



1. Shop Drawings

2. Installati on Procedures

3. Fabricati on Methods

Site Inspecti on



2. Appropriate materials are used in constructi on

Pre-Inspection Items Inspector verifi ed plan dimensions and locations.

Contractor has properly compacted the ditch before concrete application.

Contractor has fi nished the ditch surface to remove projections and honeycomb.

Concrete mix design was submitted and received approval from the Engineer.

Field Inspection Items Contractor has documented concrete testing using MS&TR, if applicable.

Contractor has the manufacturer’s product data, specifi cations, and recommended application instructions for the concrete curing compound.

Concrete strength is tested and documented for payment.

Ensure the contractor has constructed contraction joints at 10’ intervals, and expansion joints at 30’ intervals. Refer to Section 03152.

02643: CONCRETE LINED DITCH





1. Materials are not properly installed

E) APPROACH SLAB CATCH BASIN – SECTION 02624

General

This secti on covers the inspecti on of the constructi on of a drainage catch basin in the approach slab of an existi ng structure. The contractor should properly remove existi ng concrete from marked work areas. The area must be properly excavated to the size and depth required by the plans. Reinforcing steel encountered during concrete removal should be cut so that the fi nished catch basin opening is not restricted. The catch basin should be ti ed to the existi ng approach slab and fi nished according to the plans. If necessary, the Engineer may adjust the locati on for bett er drainage.

Pre-Inspection Items Request a copy of the approved shop drawings from the contractor.

Contractor has documented concrete testing using MS&TR, if applicable.

Contractor has submitted the following to the Engineer for approval at least two weeks in advance of fabrication:

Diversion box screw gate and frame shop drawings Installation procedures Fabrication methods

Field Inspection Items Contractor has used the appropriate materials, such as zinc coated blades and metal frames for hand-slide grates.

Contractor has installed the screw gate and frame according to shop drawings so the gate opens and closes smoothly.

02611: DIVERSION BOX GATE & FRAME

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CHAPTER 4





2. COC


Site Inspecti on


1. Necessary removal of concrete is completed







Pre-Inspection Items Contractor has submitted and received approval from the Engineer for the concrete mix design.

Inspector should request a copy of the manufacturer’s Certifi cate of Compliance (COC) for both structural steel and reinforcing steel.

Field Inspection Items Contractor has completed concrete removal, if applicable, with the proper equipment and the correct exposure of reinforcing steel for installation.

Contractor has used proper materials placement including proper location, dimensions and elevation, and proper connection to pipe.

Contractor has used suitable materials for backfi ll, depth of lift, optimum moisture and compaction. Refer to Chapter 3 of this manual.

Compaction and fi ll requirements have been met. Backfi ll documentation per MS&TR Section 02056.

Ensure fi nished basin has proper drainage.

02624: APPROACH SLAB CATCH BASIN



F) APPROACH SLAB DRAIN FRAME MODIFICATION – SECTION 02625General

This secti on covers the inspecti on of providing a frame riser to raise the existi ng drain grate to match the grade of the asphalt surfacing. The inspector should verify the plan dimensions for the existi ng grate system before the contractor begins fabricati on of the new frame riser.




2. Buy America requirement compliance, if applicable

Site Inspecti on








Pre-Inspection Items Contractor has used a galvanized frame riser.

Plan dimensions for the existing grate system have been verifi ed.

Contractor has complied with the Buy America requirements, when applicable.

Field Inspection Items Contractor has galvanized the frame riser after fabrication, as specifi ed.

Materials are set to the proper elevation and direction.

Hot Mix Asphalt has been properly compacted.

Contractor has constructed and positioned the frame riser according to the plans.

Extended pipes are properly secured.

02625: APPROACH SLAB DRAIN FRAME MODIFICATION

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CHAPTER 4


G) DECK DRAIN MODIFICATION OR CLOSURE – SECTION 02626General

The contractor must modify or close existi ng drains and install new drains at locati ons specifi ed in the plans. Inspectors should verify the existi ng plan dimensions before work begins.




2. Buy America requirement compliance, if applicable

Site Inspecti on








Pre-Inspection Items Contractor has used a galvanized frame riser.

Plan dimensions for the existing grate system have been verifi ed.

Contractor has complied with the Buy America requirements, when applicable.

Field Inspection Items Contractor has galvanized the frame riser after fabrication, as specifi ed.

Materials are set to the proper elevation and direction.

Hot Mix Asphalt has been properly compacted.

Contractor closed the deck drains as shown in the plans prior to placing the new asphalt surfacing.

Contractor cleaned the grate ribs and drain basin after work was completed.

02626: DECK DRAIN MODIFICATION OR CLOSURE



H) UNDERDRAIN – SECTION 02622

General

This secti on covers inspecti on procedures for placing pipe underdrains. Inspectors should be familiar with site preparati on procedures such as embankment, and types of drainage pipes and drainage geotexti les.

The inspector should ensure the contractor has properly excavated the work area to the required width and depth as specifi ed in the plans. If geotexti les are called for in the plans they should be properly installed and product data and installati on informati on should be submitt ed before use. The inspector should request a copy of these submitt als.

Underdrain granular backfi ll should be properly compacted aft er correct placement in the prepared trench. Aggregates used should have approved source suitability. Ensure pipe is placed as called for in the plans. Generally, slots or perforati ons should face down and bell or grove end upstream. The spigot should be fully entered into the bell.



1. Material Source Approval

Site Inspecti on








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CHAPTER 4


4.4 RIPRAP

A) WIRE ENCLOSED RIPRAP – SECTION 02372

General

This secti on covers the inspecti on of the materials and procedures for wire enclosed riprap. Wire enclosed riprap is constructed by fi lling modular galvanized steel wire mesh box-shaped baskets with stone on site.

Before Work Begins

Before placement of the baskets, the contractor must properly prepare the subgrade by completi ng site-preparati on acti viti es including the removal of all brush, trees, stumps, and other objecti onable materials. Unacceptable material should be removed to a depth of 1’. Refer to Secti on 02316. The surface should then be fi nished with granular borrow to bring the grade to the base of the wire enclosed riprap structure. Refer to Secti on 02056. The foundati on must be fi rm and uniform to line and grade as shown in the plans. If required, the contractor should provide geotexti le separati on fabric.

The contractor must submit the manufacturer’s product data, including typical constructi on details and procedures. The inspector should request a copy of this submitt al and be familiar with the manufacturer’s recommendati ons.

Pre-Inspection Items Contractor has provided geotextile product data and installation instructions.

Contractor has used materials with approved source suitability for free draining granular backfi ll. Refer to Section 02056 and Chapter 3 of this Guide.

Field Inspection Items Inspector should ensure contractor excavated to the correct depth, and geotextiles have been properly installed, and slots are in the correct position.

Inspector should ensure the free draining granular backfi ll is properly compacted. Refer to Section 02056 and Chapter 3 of this Guide.

02622: UNDERDRAIN




The inspector should ensure the contractor has properly built the baskets. All perimeter edges should be secured with lacing wire and binding wire should be ti ghtly looped around every other mesh opening along the seams, alternati ng single and double loops.

To fi ll, the contractor should use a loading frame, if needed, to prevent damage to the wire baskets. It may also be necessary to hand place stone around the outer edges so as not to lose smaller gradati on of stones through the openings in the mesh. No stone should be greater than 10” in size. The individual baskets for all revetment designs should be assembled in such a manner that the failure and loss of stone fi ll from any single basket will not cause the failure and loss of stone fi ll in the adjoining baskets. The lids of the baskets should be secured in the same manner of tying as the assembly of the walls.

Visually inspect the placement of the baskets. The contractor should begin assembly and stone placement at the lowest layer and ti e each subsequent layer to the one below and the adjoining structure. Wire used in this process should be equal to that required for selvage wire. Anchors and other proprietary materials should be installed according to manufacturer’s recommendati ons.



1. Material Product Data and Installati on Instructi ons


3. Wear & Soundness

4. Basket Certi fi cati on

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Site Inspecti on







2. Drainage is not maintained


4. Baskets are not properly assembled

Pre-Inspection Items Contractor has provided material product data and the installation information and procedures for wire baskets.

Request copies of certifi cations for baskets from contractor.

Visually inspect and document the assembly and installation of baskets and quality of rock to ensure contractor’s compliance with the plan specifi cations.

Ensure that samples or submittals are in for rock source, Wear & Soundness tests. Check with the Regional Materials Lab.

Inspector should ensure the contractor has properly prepared the foundation, and properly located and graded the site..

Field Documentation Items Visually inspect and document the subgrade for fi rmness.

Other visual inspection items: basket placement to line, grade and proper order; suffi cient hog rings and lacing to secure baskets and prevent deformation; and correct rock size.

Visually inspect the rock to ensure it is angular, well graded, 10” minus in size, and free of seams or cracks.

02372: WIRE ENCLOSED RIPRAP



B) RIPRAP – SECTION 02373General

This secti on covers the inspecti on of the materials and procedures for loose riprap, hand placed riprap, compacted riprap, and plated riprap.

Riprap is a protecti ve layer of rock placed on earthen slopes to reduce the eff ects of erosion from runoff or stream scour. Materials vary from small, hand placed stones on slopes to large boulders in stream channels. The angular and irregular shape of riprap is important because it prevents the material from being carried away by runoff or scour. Inspectors should be familiar with the gradati on requirements as set forth in the plan specifi cati ons and Standard Specifi cati ons. Additi onally, the correct placement, layering and thickness of riprap are important to prevent water from getti ng into weak areas and causing erosion.

Before Work Begins

Inspectors should be aware of any environmental constraints involved in the placement of riprap. These could include permits for in-stream acti viti es, using clean equipment when working in or near streams, cleaning up any oils spills, and applicable provisions of the Nati onal Pollutant Discharge Eliminati on System (NPDES) permit program for storm- water discharges. Ensure the contractor has a valid SWPPP.

The contractor must submit data showing riprap source gradati on, Wear & Soundness, and placement technique 10 working days before use. The contractor must also submit samples for Quality Assurance testi ng before use of the riprap. Request copies of these submitt als from the contractor.

To prepare the subgrade, the contractor must properly complete site-preparati on acti viti es including the removal of all brush, trees, stumps, and other objecti onable materials. The foundati on must be fi rm and uniform to line and grade. If required, the contractor should provide geotexti le separati on fabric. The contractor may not over-excavate and disturb compacted foundati ons or undisturbed soils outside of the required lines and grades shown on the plans. Before backfi lling or installing geotexti les the contractor should secure approval from the Engineer. If geotexti les are used they should be installed following Secti on 02075 and plan specifi cati ons.

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Contractors using loose riprap should distribute and manipulate the stones in a manner that the larger rock fragments are uniformly distributed and that the smaller rock fragments fi ll the space between the larger fragments. Ensure that the toe of the slope is embedded to protect against undercutti ng. Contractors using hand-placed riprap should place and bed the stones to key them together and fi ll irregulariti es between the stones with suitable size stones. The fi nished surface should be ti ght and uniform when complete. The riprap should be imbedded below the ground. Loose riprap should be compacted so that it is free of any protrusions greater than 3” in height.

Visually inspect the riprap materials upon delivery. It should be durable, angular, hard, stone that is free from seams, cracks, or other structural defects.

If the contractor is using plated riprap, ensure it is properly placed loose riprap and compacti on is complete when a uniform surface, free of protrusions greater than 4”, is observed. As always, inspectors should measure, calculate and document the quanti ti es for payment.



1. SWPPP



4. Riprap Source Gradati on

5. Wear & Soundness

6. Quality Assurance Test

7. Placement Technique

Site Inspecti on




3. Compacti on is correct

4. Environmental controls are in place







3. Material used is not of required quality


Pre-Inspection Items Contractor has provided geotextile product data and installation information.

Ensure that samples or submittals are in for rock source and Wear & Soundness tests. Check with Regional Materials Lab.

Contractor has used materials with approved source suitability for riprap and the correct size (D50, Dmin and Dmax) and provided samples for quality assurance.

Request copies of contractor’s submittals for riprap source gradation, Wear & Soundness, placement technique, and Quality Assurance testing.

Request a copy of materials certifi cation from the contractor to ensure that all certifi cations are in for geotextile fabrics.

Visually inspect and document the subgrade for fi rmness.

Field Documentation Items Visually inspect and document the rock to ensure proper installation of rock and quality of rock.

Visually inspect geotextiles to ensure contractor has used the correct material size and correct placement with proper overlap.

Installation of riprap was done according to plans or detailed drawings, plan area and depth.

Proper installation around pipe end section, as applicable.

Proper distribution of rock to form a dense mass.

Visually inspect the rock to ensure it is angular, well graded, 10” minus in size, and free of seams or cracks.

02373: RIPRAP

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CHAPTER 4


C) GROUTED RIPRAP – SECTION 02374

General

This secti on covers the inspecti on of the materials requirements and procedures for grouted riprap. The inspector should keep in mind that the source of the riprap must be tested and approved. The riprap selected must meet the gradati on requirements for the intended use as specifi ed in the plans. Refer to the Standard Specifi cati ons for a table on the size, and keep in mind that the contractor should use gradati ons that allow full grout penetrati on around the rocks.

Before Work Begins

The contractor should set up a riprap source locati on inspecti on meeti ng with the Engineer and source material owner prior to delivering materials to project site. During this preconstructi on conference the contractor must provide the proposed source site, material test results, samples for quality assurance testi ng before use, a grouted riprap sample pan- el, the grout mix design, and a Quality Control Plan. The contractor should also identi fy a stockpiling procedure and locati on. Stockpile preventi on plans should be determined in the SWPPP. The contractor must provide writt en certi fi cati on verifying the quality of riprap existi ng at the industrial source. Many tests must be performed on the aggregate before certi fi cati on and the inspector should request copies of all these submitt als.

The contractor must certi fy that “reacti ve” stones are not found in the quarry pit by sending samples to the Materials Lab for testi ng, if required. Alkali-silica and alkali- arbon reacti ons are the most frequent of these reacti ons so the contractor must perform an alkalinity test and perform a petrographic analysis on representati ve aggregate samples to determine whether reacti ve stones are present, in the absence of a documented 10 year history of use of quarry aggregates in commercial concrete mix designs. If a documented history is present, the contractor should provide historic results on reacti vity of the rock. The contractor must also perform a percolati on test, sieve analysis, petroleum disti llates test, and a LA wear test.

The contractor must use grout that conforms to requirements of Secti on 02374 and has an approved mix design. Geotexti les and bedding materials must also conform to requirements and be installed according to manufacturer’s instructi ons or plans. Bedding aggregate under riprap must be at least 6” thick.



Site preparati on is important before placement of grouted riprap. This includes installing surface and ground water control measures to ensure dry conditi ons during constructi on and ensuring that natural drainage areas are not compromised. As is the case with all site preparati ons, the contractor must remove all topsoil, loose excavated materials, vegetati ve debris, concrete debris, and other objecti onable materials from beneath the areas where the grouted riprap is to be placed. The subgrade should be compacted to 95% maximum density, AASHTO T 99, or to a 70% relati ve maximum density, AASHTO T 180.

The contractor must perform surface and ground water control measures as needed to ensure dry work area conditi ons. Water control measures include, but are not limited to diversions, culverts, sumps with pumps or other means necessary to maintain the level of groundwater below subgrade elevati on and to divert surface water away from the work area. The contractor must not block natural drainage layers or horizons within the channel bott oms.


Aft er proper site preparati on, approved materials should be placed and compacted as specifi ed in the plans to the designated subgrade elevati on. The contractor should not backfi ll depressions with shatt ered shale materials. Fill materials should be spread uniformly to minimize segregati on. The graded areas should be smoothed to maintain the specifi ed slope with no more than 3” change, unless closer tolerances are specifi ed.

The contractor should place a free draining bedding layer around the weep drains and provide suffi cient cover to prevent crushing by riprap. The contractor must also place bedding materials prior to placement of riprap. The contractor should noti fy the Engineer before placing riprap elements over bedding layer because the Engineer must fi rst verify compacti on requirements have been met.

If geotexti les are used, they must be undamaged, properly overlapped, and have a minimum of 3” of bedding aggregate over the fabric. These materials should also be approved.

Then the riprap materials can be placed on the prepared site. The contractor should begin placing stones at the lowest point, and remove any stones protruding more than 10% of the stone layer thickness. Large stones should be distributed uniformly to provide adequate access for the grout to the lower porti ons of the stone to prevent voids from forming. Check for minimum thickness and height indicated in the plans, and ensure the fi nished outer edges are level with the adjacent ground.

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CHAPTER 4


Finally, the riprap can be grouted aft er it is properly in place. The contractor must not place the grout if the temperature is less than 40 F or on frozen surfaces. The temperature should be between 50 F and 90 F. during the placement and curing period. The grout must penetrate to the subgrade and fi ll all voids while leaving the top of the stones fully exposed.

To ensure proper curing and protecti on the contractor must keep all exposed surfaces conti nuously moist for 7 days and protect from becoming damaged.



1. SWPPP

2. Materials Lab Approval



5. Quality Control Plan

Site Inspecti on


1. Subgrade is prepared






2. Density requirements are not achieved

3. Moisture is not maintained




D) EROSION CONTROL BLANKETS/CHANNEL LINERS – SECTION 02376

General

This secti on includes inspecti on procedures for erosion control blankets and fabrics. These materials include fabrics applied on slopes to prevent soil erosion and protect the seed- bed. They are usually machine-produced fabrics consisti ng of elongated wood, coconut fi bers, or straw bonded together. A fl exible channel liner is a machine produced mat consisti ng of elongated materials that are bonded together and used to line channels.

As with geotexti les, the materials have to be approved before use and meet plan specifi cati ons. The contractor must submit a sample of the blanket or liner, staples and other materials used to the Engineer for approval. The manufacturer’s specifi cati ons and recommended installati on requirements need also be submitt ed. The inspector should request copies of these submitt als and be familiar with the recommended installati on procedures.

Pre-Inspection Items Contractor has used materials with approved source suitability for riprap and the correct size (D50, Dmin and Dmax) and provided samples for quality assurance.

Ensure that samples or submittals are in for rock source, Wear & Soundness tests, and grout mix design. Check with the Regional Materials Lab.

Petrographic analysis of the proposed materials is submitted, if required.

Request copies of certifi cations of all other materials from the contractor.

Field Inspection Items Rock is clean and free of clay or foreign material and thoroughly wetted to a saturated surface condition before grouting.

Contractor has properly placed bedding materials.

Contractor has used the proper placement and consolidation of grout.

Contractor has provided a compacted subgrade and gained approval from the Engineer. Ensure a density test has been performed and documented.

Contractor has used an approved grout mix design.

Installation of riprap is done according to plans or detailed drawings, plan area and depth.

Contractor kept all exposed surfaces continuously moist for 7 days and protected from becoming damaged to ensure proper curing.

Final visual inspection and documentation of proper installation of fabric, rock, and grout.

02374: GROUTED RIPRAP

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Site Inspecti on


1. Material is properly placed and installed






Pre-Inspection Items Contractor has provided manufacturer’s product data and installation instructions.

Contractor has submitted proper samples of materials to be used for approval.

Field Inspection Items Inspector should ensure contractor has removed all vegetation before placement, anchored the material as it is rolled out, used suffi cient anchors, properly buried the edges, and installed the materials according to the manufacturer’s recommendations.

02376: EROSION CONTROL BLANKETS/CHANNEL LINERS

Construction Inspection Guide Chapter Links

1-Preface & Introduction

2-Traffic Control

3-Demolition and Earthwork

4-Drainage

5-Pavement & Materials

6-Structures

7-Traffic Signals, Lighting, ATMS

8-Striping, Signing, Safety Features

9-Landscaping, Fencing, Incidental Const.

10-Utilities

11-PDBS

12-Crash Cushion & Barrier End Treatments

http://issuu.com/tlcs/docs/udot_ci_chapter_1f?mode=window&viewMode=doublePage










http://issuu.com/tlcs/docs/udot_ci_chapter_11plusapdxjf?mode=window&viewMode=doublePage

http://issuu.com/tlcs/docs/udot_ci_chapter_12_appgf?mode=window&viewMode=doublePage

Construction Inspection Guide

udot.utah.gov/go/construction

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UDOT Construction Inspection Guide - Chap 4

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Transcript of UDOT Construction Inspection Guide - Chap 4