student manual lesson 6- earthwork record system level 1/06 -2009...student manual lesson 6-...

Student Manual Lesson 6- Earthwork Record System

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Materials ManualSection 2.3- Earthwork Record System

2.3.1 PURPOSE

To describe the project Earthwork Records System and to provide a written procedurefor the assembly and use of samefor the assembly and use of same.

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2.3.2 SCOPE

This record system is to be used by all inspectors performing density tests on FDOTroadway earthwork construction. Quality control records certified by the Contractor,roadway earthwork construction. Quality control records certified by the Contractor,and Verification records properly maintained for each construction contract, andattested to by responsible District personnel, shall be used by the Department as thebasis for certifying the completed roadway earthwork.

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2.3.11 TRAINING

An Earthwork Records System training class is available The training includesAn Earthwork Records System training class is available. The training includesinformation concerning the Earthwork Records System assembly, computer coding togenerate earthwork graphs and the proper use of the completed Earthwork RecordsSystem. Requests for training should be processed through the District ConstructionTraining Administrator. Additional information is available from the State ConstructionTraining Manager. Training information is available at the State Materials Office websiteat:

http://materials.dot.state.fl.us/smo/Geotechnical/Earthwork/earthwork.htm

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M t i l ManualMaterials ManualSection 2.3- Earthwork Record System

2.3.5 INSTRUCTIONS

Construction contracts with roadway earthwork items shall have an EarthworkRecords System. The Earthwork Records System shall be assembled, available foruse and have all pertinent information entered on each Density Report. Each contractshall have an Earthwork Records System consisting of a Quality Control record withnumbered pages and a separate Verification record. For convenience, a completelyassembled Earthwork Records System may be temporarily separated by roadway,structure, staged construction, multiple numbered projects, or among DensityInspectors. The District Materials Engineer shall approve exceptions. An EarthworkDensity Report shall be used to record all test dataDensity Report shall be used to record all test data.

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2.3.6 EARTHWORK RECORDS SYSTEM PREPARATION

Prior to earthwork construction commencing, properly trained Department projectinspection personnel shall be responsible, when necessary, for guiding the Contractorin the Earthwork Records System preparation and organization All Earthwork Recordsin the Earthwork Records System preparation and organization. All Earthwork RecordsSystem graphs shall be computer plotted and page numbered. The Log Book plotprogram, pipe backfill and roadway earthwork computer coding forms, (675-020-05)for Pipe Backfill and (675-020-06) for Embankment, Subgrade, and Base, areavailable from the Department’s Form Library. Embankment graphs are not requiredin areas where no embankment is placed or disturbed. The Pavement Plot sheet maybe added to the record system in these situations. This form is a part of the EarthworkDensity Report form. When electronic design files are available, computer plots for theEarthwork Records System may be prepared utilizing the automated system. Thecomputer-plotted graphs shall accurately illustrate the required testing (the first to thelast lifted placed). Verification plots may be used at the option of the ProjectAdministrator. Any subsequent changes or replots that reflects a change from the plancross sections shall have a detailed note written on appropriate pages.

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Materials ManualMaterials ManualSection 2.3- Earthwork Record System

2.3.7 Plots

Regular roadway earthwork construction may consist of embankment, subgrade andbase. Attach computer plotted graphs to the Density Report sheets for the sections withE b k L h f h l h ld b h h l i b id ifi dEmbankment. Length of the plots should be such that test locations can be identifiedadequately. For the sections with no Embankment, the Pavement Plot sheet may beused.

Account for all drainage structures and connecting pipe, inside and outside the 1:2 (V:H)slope. Attach plots for all Drainage structures that require testing.

A shorter section roadway graph, less than 500 feet (150 meters), may be used to plotsections of MSE wall construction.

Use a different bar chart for each earthwork pavement layer compacted separately.

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Materials ManualMaterials ManualSection 2.3- Earthwork Record System

2.3.8 EXCAVATION OF UNSUITABLE MATERIALS

All computer-plotted embankment graphs shall be corrected for excavation of unsuitablematerials. The anticipated depth of excavation may be coded as an undercut depth,(Form 675 020 06 Embankment Subgrade and Base) to provide a blank space for(Form 675-020-06, Embankment, Subgrade and Base), to provide a blank space forhand corrections. If the graph is re-plotted, make an appropriate note to identifydeviation from the plans.

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Notes:Notes:

A) A separate line must be completed for each gauge used on the project.

B) If a gauge is calibrated or repaired during construction, comply with specification 120-10.1.1 and enter information above.

C) Enter Inspectors initials and TIN each time equipment is

compared.

D) Include and retain a copy of gauge calibration parameters.

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1. Financial Number: Enter the Project FIN #1. Financial Number: Enter the Project FIN #

2. Gauge Serial #: Enter the manufacturer's serial number for the nuclear moisture/density gauge.

3. Calibration Date: Enter the most recent gauge calibration date.

4. Dry Density: Enter the computed Dry Density

5. QC / VT / IA: QC / VT / IA: Enter the inspector type (QC / VT / IA) and inspector level (ECI 1 and/or 2).6. Initial Equipment Date: Enter the date the initial equipment check was performed.7. Initials: Enter the initials of the inspector just as they will appear in the Density Log Sheets.

8. TIN #: Enter the inspector's CTQP training identification number.9. Date Begun: Enter the date the inspector begins testing with the gauge listed or the date the ga ge is recei ed back follo ing recalibration or repairsdate the gauge is received back following recalibration or repairs.10. Date Ended: Enter the date the inspector completes testing with the gauge listed or the date the gauge is sent for recalibration or repairs.

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General Notes & Instructions: Earthwork Density Report

All required information on the Density Report shall be current, legible and written inink. No transcribed, rewritten, or otherwise copied Record Sheets shall be allowed orincluded. Dittos, arrows, white-out, and erasures shall be avoided. A correction shallbe indicated with a single line striking through the original data and the corrected datawritten close to it. All corrections or other notes made on the plot or Record pages shallbe initialed. Special Provisions or other issues effecting earthwork testing andsampling should be noted on the LOT INDEX PAGES. Retain a copy of the CalibrationParameter sheet in the Earthwork Record System for any gauge used on the project.Add a new Calibration Parameter sheet each time a Nuclear Gauge is recalibrated.

Lifts, Lots or partial lots affected by water and consequently not tested shall beidentified on the DENSITY RECORD AND LOT INDEX sheets. Example: “Lifts 1-3affected by water.”

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1. Project FIN: Enter the project Financial Identification Number

2. Type of Constr.: Enter type of Construction. (Embankment, Subgrade, Base, etc.)

3. Page: Enter the page number corresponding to the number of the Plot page where the test will be plotted followed by a letter sequence for the page. (i.e. 1A, 1B etc. for successive density report pages)

4. From Sta. - Beginning station of section represented.

5. To Sta. - Ending station of section represented.

6. Lot No.: Enter LOT number. (i.e. Lot# - Corresponding Page #) Start a new set of numbers for each type of construction on each sheet. i.e Pipe Backfill Embankment Subgrade Base MSE Wall)Backfill, Embankment, Subgrade, Base, MSE Wall)

7. RF: Mark if lots were tested during reduced frequency by placing an “X or √”.

8. Date: Enter date of Test

9. Tech. ID: Enter the nine digit technician ID used for CTQP qualification.

10. Gauge Serial No.: - Serial number of gauge used.

11. STD. Dns. Count: - Record the daily standard density count of gauge used to perform the density test.

12. STD. Mst. Count: - Record the daily standard moisture count of gauge used to perform the moisture test.

13. Max Density: Enter Laboratory Maximum Density Value (Proctor) for the Test to the nearest whole number.

14. Sample No.: Enter sample number for the maximum density proctor.

15. Test No.: This is an alphanumeric value starting with Q for QC, V for Verification and R for Resolution and followed by sequential digits starting with 0001. (This may be N/A if not a district requirement.)

16. Station: Enter the station location of the test

17. Offset: Enter the Offset Distance in feet (meter) from an offset, with the direction ‘L’ or ‘R’ following the number.

18. Lift Number: Enter the lift number and total lifts at the test location (i.e. 2/10)

19. Test Depth: Write the test depth in inches (millimeter).

20. Soil Dns. Count: - Record the soil density count reading.

21. Soil Mst. Count: - Record the moisture count of gauge used to perform the moisture test.

22. Wet Density: Enter the wet density result from the test to the nearest 0.1 PCF.

23. % Moisture: Write the % moisture value to the nearest 0.1 percent as follows.

•Use Nuclear Gauge % moisture for approved Limerock, Shell rock, and Cemented Coquina Base materials.

•If the Speedy Moisture tester was used for the materials specified above, use the dial reading directly.

•For all other materials, use the moisture number from an appropriate chart, based on the Speedy dial reading.

•Microwave moisture as determined by the FM5-537 can also be used for all the materials.

24 Dry Density: Wet Density x 100 Reporting Accuracy: nearest

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24. Dry Density: Wet Density x 100 Reporting Accuracy: nearest

100+ % Moisture 0.1 PCF (1.0kg/m3)

25. % Max Density: The result of Dry Density divided by Proctor and multiplied by 100. Report to the nearest 1.0 percent.

26. Status and Disposition: Use the Disposition as described at the bottom of the form.

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1. Project FIN: Enter the project Financial Identification Number.

2. Page: Enter the corresponding page number.2. Page: Enter the corresponding page number.

3. Sample Number: Enter the SIX character sample number i.e. 00001Q

The “Q” at the end indicates the sample was collected and tested by Quality Control Personnel

Sample numbers ending in “V or R” will be used for samples collected and tested by VT or RT Personnel

All samples should be recorded in the order they were obtained.

Verification, Resolution, and Independent Verification sample numbers should match the corresponding QC sample no.

Example: QC sample “00002Q” should be verified by Verification Sample “00002V” or resolved by Resolution Sample “00002R”.00002R .

When preparing Sample Transmittal Cards for V samples and R samples, note the “Q” sample number that the V or R should be compared to and also list any “Q” sample numbers that will be verified if comparison is favorable.

Example for “V” sample: Compares to 00002Q. Also verifies 00001Q, 00003Q, and 00004Q.

NOTE: THE RESULTS OF ALL “Q” SAMPLES MUST BE VERIFIED OR RESOLVED AS REQUIRED BY SPECIFICATION.

4. Material Description: Enter a description of material being sampled. p p g p

5. Max Density: Enter Laboratory Maximum Density Value (Proctor) for the sample.

6. Opt Moist: Enter Laboratory Optimum Moisture Value for the sample.

7. Type of Constr: Indicate the expected use of the material. i.e. , limerock base, pipe backfill etc. Skip sufficient lines to readily separate the material types OR use separate sheets for each Material number.

8. Lots Represented: Indicate the corresponding LOT numbers or project limits (for Embankment samples) represented by the Proctor results.

9. Sample Number: Enter the corresponding Verification sample number i.e. 00001V

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10. Max Density: Enter the corresponding Verification Maximum Density Value (Proctor).

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1. Project FIN: Enter the project Financial Identification Number.

2. Type of Const: Enter applicable Type of Construction if the LOTS are indexed (Numbered) by material number. If LOTS are indexed consecutively for the entire project enter “N/A” at the top and indicate the type of construction in REMARKS. (Pipe backfill, embankment, RE wall, baserock, etc.)

3. Page: Enter appropriate page number – All pages must be numbered

4. Lot No.: Enter LOT No. Each LOT must be verified as specified in the Specifications. p pIf not, it must be resolved as specified in the Specifications.

5. RF: Indicate if lots were tested during reduced frequency by placing an “X or √”.

6. Rdwy: Enter “L” for Left, “R” for Right, or “C” for Composite to identify the general LOT location

7. Station No. From: Enter beginning station of Lot.

8 St ti N T E t di t ti f L t8. Station No. To: Enter ending station of Lot.

9. Lift No.: Enter the lift number /total lifts (i.e. 1/10) at the LOT location – NOTE: If thick lift operations are used, indicate the Standard 6-inch lift numbers (i.e. 5-6/10)

10. Ver?: Enter “Y” if the QC test for this LOT was verified. Enter “N” if the QC test for this LOT was not verified and Resolution Test was required

11. Resolved?: If LOT not verified, enter Y if resolved; N if not resolved.

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12. Remarks: Remarks column is used to record any special conditions, comments or other information needed to explain or clarify project issues or conditions. Use this section to note Material type (if applicable), LOTS affected by water, thick lift operations, reduced frequency testing, use of flowable fill, etc.

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Notes:Notes:

A) A separate line must be completed for each gauge used on the project.

B) If a gauge is calibrated or repaired during construction, comply with specification 120-10.1.1 and enter information above.

C) Enter Inspectors initials and TIN each time equipment is compared.

D) Include and retain a copy of gauge calibration parameters.

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1. Financial Number: Enter Project FIN #1. Financial Number: Enter Project FIN #

2. Gauge Serial #: Enter the manufacturer's serial number for the nuclear moisture/density gauge.

3. Calibration Date: Enter the most recent gauge calibration date.4. Dry Density: Enter the computed Dry Density

5. QC / VT / IA: Enter the inspector type (QC / VT / IA) and inspector level (ECI 1 and/or 2)2).6. Initial Equipment Date: Enter the date the initial equipment or comparison analysis check was performed as per 120-10.1.1.7. Initials: Enter the initials of the inspector just as they will appear in the Density Log Sheets.

8. TIN #: Enter the inspector's CTQP training identification number.9 Date Begun: Enter the date the inspector begins testing with the gauge listed or the9. Date Begun: Enter the date the inspector begins testing with the gauge listed or the date the gauge is received back following recalibration or repairs.10. Date Ended: Enter the date the inspector completes testing with the gauge listed or the date the gauge is sent for recalibration or repairs.

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General Notes & Instructions: Verification Density Report

All required information on the Density Report shall be current, legible and written in ink.No transcribed, rewritten, or otherwise copied Record Sheets shall be allowed orincluded. Dittos, arrows, white-out, and erasures shall be avoided. A correction shall beindicated with a single line striking through the original data and the corrected datawritten close to it. All corrections or other notes made on the plot or Record pages shallbe initialed. Special Provisions or other issues effecting earthwork testing and samplingshould be noted. Retain a copy of the Calibration Parameter sheet in the EarthworkRecord System for any verification gauge used on the project. Add a new CalibrationParameter sheet each time a Nuclear Gauge is recalibrated.

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1. Project FIN: Enter the project Financial Identification Number

2. Type of Const.: Enter type of Construction. (Embankment, Subgrade, Base, etc.)

3. Page: Enter the page number corresponding to the number of the Plot page where the test will be plotted followed by an Alphabetic letter sequence for the page. (i.e. 1A, 1B etc. for successive density report pages)

4. From Sta. - Beginning station of Lot represented.

5. To Sta. - Ending station of Lot represented. * Get approval from the District Materials Earthwork Coordinator to write in “From Station” and “To Station” for the purpose of recording verification for multiple QC sheets on one pagefor the purpose of recording verification for multiple QC sheets on one page.

6. Lot number: Enter the Lot number using the following format (QC Lot# - Corresponding QC Page #)

7. Date: Enter date of Test

8. Tech. ID: Enter the nine digit technician ID used for CTQP qualification.

9. Gauge Serial No.: - Serial number of gauge used.

10. STD. Dns. Count: - Record the daily standard density count of gauge used to perform the density test.

11. STD. Mst. Count: - Record the daily standard moisture count of gauge used to perform the moisture test.

12. Max Density: Enter Laboratory Maximum Density Value (Proctor) for the Test to the nearest whole number.

13. Sample No.: Enter sample number for the maximum density proctor.

14. Test No.: This is an alphanumeric value starting with Q for QC, V for Verification and R for Resolution and followed by sequential digits

starting with 0001. (Test No. may not be applicable in all districts.)

15, Station: Enter the station location of the test

16. Offset: Enter the Offset Distance in feet (meter) from an offset, with the direction ‘L’ or ‘R’ following the number.

17. Lift Number: Enter the lift number and total lifts at the test location (i.e. 2/10)

18. Test Depth: Write the test depth in inches (millimeter).

19 Soil Dns Count: - Record the soil density count reading19. Soil Dns. Count: - Record the soil density count reading.

20. Soil Mst. Count: - Record the moisture count of gauge used to perform the moisture test.

21. Wet Density: Enter the wet density result from the test to the nearest 0.1 PCF.

22. % Moisture: Write the % moisture value to the nearest 0.1 percent as follows.

•Use Nuclear Gauge % moisture for approved Limerock, Shell rock, and Cemented Coquina Base materials.

•If the Speedy Moisture tester was used for the materials specified above, use the dial reading directly.

•For all other materials, use the moisture number from an appropriate chart, based on the Speedy dial reading.

•Microwave moisture as determined by the FM5-537 can also be used for all the materials.

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23. Dry Density: Wet Density x 100 Reporting Accuracy: nearest

100+ % Moisture 0.1 PCF (1.0kg/m3)

24. % Max Density: The result of Dry Density divided by Proctor and multiplied by 100. Report to the nearest 1.0 percent.

25. Lots Verified: List lots verified by this test. (QC Lot#s - Corresponding QC Page #s)

.

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1. Project FIN: Enter the project Financial Identification Number. j p j

2. Page: Enter the corresponding page number.

3. Sample Number: Enter the Five character QC sample number i.e. 00001Q

4. Material Description: Enter a description of material being sampled.

5. QC Max Density: Enter Laboratory Maximum Density Value (Proctor) for the sample.

6. QC Opt Moist: Enter Laboratory Optimum Moisture Value for the sample.

7. Type of Constr.: Enter the type of Construction. Use ‘L’ or ‘R’ to specify Left or Right roadway and/or side.

8. Lots Represented: Indicate the corresponding lot numbers represented by the Proctor results.

9 Sample Number: Enter the corresponding Verification sample number i e9. Sample Number: Enter the corresponding Verification sample number i.e. 00001V. (Make sure numbers match)

10. Max Density: Enter the corresponding Verification Maximum Density Value (Proctor).

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This is a typical Graph Plot sheet produced by the Departments Plot Program for an E b k t S tiEmbankment Section.

The scale, both Stationing and Elevation, will vary depending upon the data input into the program.

Note that the solid line on the graph represents the “Top of Embankment”. This is notthe Top of Roadway.

Al t th U P d t th t f th h h t Th f it hAlso note the User Pads at the top of the graph sheet. These are for items, such as Base, Subgrade, etc., that are a constant thickness throughout the project. Densities in these areas are plotted in these User pads.

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Remember – Lifts are counted starting from the bottom of the deepest excavation or g pgreatest embankment fill section.

And if you want, the lifts can be labeled off to the side for convenience.

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EXERCISE

You work for ABC Construction and have been assigned as the QC Density Inspectoron SR 001 (FIN #123456789), left roadway. The serial number of your nuclear gaugeis 12345 and was last calibrated 01/01/09. On April 10, 2009, you participated in theInitial Equipment Comparison testing, recording a Dry Density of 118.6 pcf. On April15, 2009, you arrive on site with your gauge (Serial # 12345) to begin QC Testing.Your daily standard counts for density is 2660 and for moisture is 666. From they ygauge diary you find the last four standard counts for each and determine the gaugeis within tolerance for Standard Counts.

Your company is placing embankment in 6 inch compacted lifts utilizing a gray sandwith traces of limerock. The first three lifts are affected by water and you are unable totest them. Your first test (Q0001) will be at Station 1222+05, 15 ft. Left of C/L ofConstruction on LOT 4 (lift 4). During the test, your gauge indicates a Soil DensityCount of 2100 and a Moisture Count of 600, with a Wet Density of 121.2 pcf and yourSpeedy Moisture test result was 10.1%, which converts to 11.2%.

The Verification Technician shows up to do the Verification Test for the LOTs inquestion and is using a gauge from the same manufacturer. Verification’s testindicates a Wet Density is 120.6 pcf and a converted Moisture of 10.6%.

Based upon the above information and the following 5 QC forms complete the QC

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Based upon the above information and the following 5 QC forms, complete the QCDensity Inspection, Nuclear Gauge & Initial Equipment Compare Log In Data sheet,QC Earthwork Density Record , the LOT Index and plot the test on the density loggraph.

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____

____

____

___

RF

Dat

eS

Fro

m

6 - 34Version 1.0- 3/09

Pro

ject

FIN

Typ

e C

ons

Lot

No.

R


11

10

10 15

06

11

10

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6 - 35Version 1.0- 3/09

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____

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Feb-05 6 - 36

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EXERCISEEXERCISE

You are responsible for Verification Testing on SR 001(FIN #123456789), left roadway.Your assigned nuclear gauge is serial number 111938 and was last calibrated11/01/08. On April 10, 2009, you participated in the Initial Equipment Comparisontesting, recording a Dry Density of 117.9 pcf. On April 15, 2009, you arrive on site withyour gauge (Serial #111938) to begin Verification Testing. Today’s standard counts are2734 for density and 644 for moisture From the gauge diary you find the last four2734 for density and 644 for moisture. From the gauge diary you find the last fourstandard counts for each and determine the gauge is within tolerance for StandardCounts.

The contractor has placed 4 consecutive LOTs (LOTs 5-8) of tan and brown fine sandwith traces of clay and all have passed required QC Density testing. Your randomVerification test location for Test. No. V0002 is determined to be LOT 8 (Lift 8 of 13),Station 1224+75 at 6 ft. left of C/L of Construction. During the test, your gaugeStation 1224 75 at 6 ft. left of C/L of Construction. During the test, your gaugeindicates a Soil Density Count of 2068 and a Moisture Count of 616. Your nucleardensity test result for Wet Density is 123.8 pcf and Speedy Moisture test is 13.0%,which convert to 14.9%. The Proctors had compared and so you are using the QCProctor of 108 pcf.

Based upon the above information and the following 3 QC forms, complete theVerification Density Inspection, Nuclear Gauge & Initial Equipment Compare Log In

6 - 37

y p , g q p p gData sheet, and Verification Earthwork Density Record.

Version 1.0- 3/09


Dat

eE

nd

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form

atio

n ab

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ng id

enti

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num

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stru

ctio

n, c

ompl

y w

ith

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ific

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para

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ers.

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t C

o

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ial

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ia

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spec

tor

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spec

tor's

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g co

nset

ain

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py o

f ga

uge

cali

brat

i

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ge &

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itia

l

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/VT

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stur

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nsit

y ga

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tor

type

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C /

VT

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rfor

med

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ity

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ets.

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#: E

nter

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the

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eli

sted

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e is

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ect.

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r

____

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atio

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te.

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C /

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nter

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ins

niti

al e

quip

men

t che

ck w

as p

eras

they

wil

l app

ear

in th

e D

enns

test

ing

wit

h th

e ga

uge

list

em

plet

es te

stin

g w

ith

the

gaug

e l

for

each

gau

ge u

sed

on th

e pr

oea

ch ti

me

equi

pmen

t is

com

par

um

ber

:___

____

Den

sity

In

spec

t

ial N

um

ber

Cal

i D

Ent

er th

e m

anuf

actu

rer's

ser

iate

: Ent

er th

e m

ost

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nt g

aug

nter

the

com

pute

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ry D

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tyen

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ate:

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itia

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f th

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spec

tor

just

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r th

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te th

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spec

tor

begi

nnt

er th

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te th

e in

spec

tor

com

ppa

rate

line

mus

t be

com

plet

ed

r In

spec

tors

init

ials

and

TIN

e

6 - 38Version 1.0- 3/09

Fin

anci

al N

uV

erif

icat

ion

Gau

ge S

eri

Gau

ge S

eria

l #:

Cal

ibra

tion

Dat

Dry

Den

sity

: En

Init

ial E

qu

ipm

eIn

itia

ls: E

nter

thD

ate

Beg

un

: En

Dat

e E

nd

ed:

En

Not

es:

A)

A s

epC

) E

nter


Pag

e___

____

% Max

.D

ens.

Lot

sA

ccep

ted

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D

ens.

%M

oist

.D

ryD

ens.

Rep

ort

ift

No.

Tes

tD

epth

Soi

lD

ns./M

st.

Cou

ntW D

wo

rk D

ensi

ty R

atio

nO

ffse

tL

i N

cati

on

-E

arth

w

____

____

____

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t.M

ax.

Den

s./

Sam

ple

No.

Tes

tN

o.St

a

Ver

ific

___

TO

ST

AT

ION

___

____

____

Gau

geS

eria

l No.

STD

Dns

./Ms t

Cou

nt

TIO

N__

____

____

____

_

N:_

____

____

____

____

_st

:___

____

____

____

___

Dat

eT

ech

ID.

6 - 39Version 1.0- 3/09

FR

OM

ST

AT

Pro

ject

FIN

Typ

e C

ons

Lot

No.

D


6 - 40Version 1.0- 3/09


6 - 41Version 1.0- 3/09


NOTES

6 - 42Version 1.0- 3/09

student manual lesson 6- earthwork record system level 1/06 -2009...student manual lesson 6-...

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