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Caltrans Bridge Design Aids PDF

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0% found this document useful (0 votes)

1K views475 pages

Caltrans Bridge Design Aids PDF

Uploaded by

Luis Ariel Morillo

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STATE OF CALIFORNIA

DEPARTMENT OF TRANSPORTATION
__________________________________________________________

APPLICABLE STANDARDS
BOOK 3

FOR DESIGN AND CONSTRUCTION ON STATE HIGHWAY IN

SAN MATEO COUNTY, AT VARIOUS LOCATIONS FROM 7.5 MILES NORTH
OF THE SANTA CLARA/SAN MATEO COUNTY LINE TO 0.2 MILE SOUTH OF
THE SAN MATEO/SAN FRANCISCO COUNTY LINE

DISTRICT 04, ROUTE 101

__________________________________________________________

For Use in Connection with Standard Specifications Dated MAY 2006, Standard Plans Dated MAY 2006,
and Labor Surcharge and Equipment Rental Rates.
__________________________________________________________

CONTRACT NO. 04-2A7904

04-SM-101-7.5/25.9 PM
Project ID 0400000843

Federal Aid Project

ACNH-Q101(202)N

Dated: April 11, 2011

Department of Transportation Book 3 – San Mateo 101, Ramp Metering System
E.A. 04-2A7904
Project ID 0400000843

TABLE OF CONTENTS
1 INDEX OF STANDARDS, MANUALS, GUIDELINES AND REFERENCES ...................................1-1
2 MODIFICATIONS TO DEPARTMENT (CALTRANS) MANUALS ..................................................2-1
3 MODIFICATIONS TO TECHNICAL MEMORANDA (NOT USED) ................................................3-1
4 DESIGN-BUILD MODIFICATIONS TO THE CALTRANS STANDARD SPECIFICATIONS
MAY 2006 EDITION .................................................................................................................................4-1
5 MODIFICATIONS TO SPECIAL PROVISIONS ..................................................................................5-1

April 11, 2011 i

Table of Contents
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1 INDEX OF STANDARDS, MANUALS, GUIDELINES AND

REFERENCES

April 11, 2011 1-1

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

February https://bookstore.transportation.org/item_det
144 AASHTO Implementation Manual for Quality Assurance IS 100 √
1996 ails.aspx?ID=252
Improving the Quality of Environmental https://bookstore.transportation.org/item_det
145 AASHTO May 2006 IS 43 √
Documents ails.aspx?ID=393
LRFD Movable Highway Bridge Design 2nd Edition https://bookstore.transportation.org/item_det
146 AASHTO IS 22
Specifications, 2008 Interim Revisions 2008 ails.aspx?ID=1174
LRFD Movable Highway Bridge Design
2nd Edition https://bookstore.transportation.org/item_det
147 AASHTO Specifications, 2nd Edition with 2008 IS 315
2007 ails.aspx?ID=1017
Interim Revisions
Movable Bridge Inspection, Evaluation, and 1st Edition https://bookstore.transportation.org/item_det
148 AASHTO IS 609
Maintenance Manual 1998 ails.aspx?ID=76
https://bookstore.transportation.org/item_det
149 AASHTO Programmatic Agreement Toolkit CD-ROM 2005 IS X 1 √
ails.aspx?ID=199
12th Edition https://bookstore.transportation.org/item_det
150 AASHTO Provisional Standards IS 354 √
2008 ails.aspx?ID=1215
Quality Assurance Guide Specification, 1st 1st Edition https://bookstore.transportation.org/item_det
151 AASHTO IS 57 √
Edition 1996 ails.aspx?ID=222
Recommendations for the Qualification of December https://bookstore.transportation.org/item_det
152 AASHTO IS X X X 19 √
Structural Bolting Inspectors, G 4.2 - 2006 2006 ails.aspx?ID=1004
Report of the AASHTO Task Force on 1st Edition https://bookstore.transportation.org/item_det
153 AASHTO IS 109 √
Corridor Preservation 1990 ails.aspx?ID=231
https://bookstore.transportation.org/item_det
154 AASHTO Roadside Design Guide Chapter Six Update 2006 IS X 47 √
ails.aspx?ID=391
https://bookstore.transportation.org/item_det
155 AASHTO SDMS™ Data Structure Technical Guide 2000 IS X X X 345 √
ails.aspx?ID=152

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-16
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Standard Specifications for Movable

https://bookstore.transportation.org/item_det
156 AASHTO Highway Bridges, with 1992, 1993, and 1995 August 1988 IS 85
ails.aspx?ID=82
Interims
Standard Specifications for Structural
5th Edition https://bookstore.transportation.org/item_det
157 AASHTO Supports for Highway Signs, Luminaires and IS 303 √
2009 ails.aspx?ID=1319
Traffic Signals
Strategic Highway Safety Plan - A
Comprehensive Plan to Substantially Reduce https://bookstore.transportation.org/item_det
158 AASHTO 2005 IS 44
Vehicle-Related Fatalities and Injuries on the ails.aspx?ID=153
Nation's Highways
Virtual Superpave Laboratory Interactive CD- https://bookstore.transportation.org/item_det
159 AASHTO 2005 IS X 1
ROM ails.aspx?ID=314
Millenium https://bookstore.transportation.org/item_det
160 AASHTO Uniform Vehicle Code—Millenium Edition IS 249 √
Edition ails.aspx?ID=1371
https://bookstore.transportation.org/item_det
161 AASHTO Guide for Design-Build Procurement January 2008 IS 211 √
ails.aspx?ID=1180
Guide for Contracting, Selecting, and
3rd Edition https://bookstore.transportation.org/item_det
162 AASHTO Managing Consultants in Preconstruction IS 97 √
1996 ails.aspx?ID=344
Engineering
Guide to Quality in Preconstruction https://bookstore.transportation.org/item_det
163 AASHTO 1st Edition IS 62 √
Engineering ails.aspx?ID=142
Best Practices in Environmental Partnering: https://bookstore.transportation.org/item_det
164 AASHTO 1998 IS X X X 70 √
Raising the Bar ails.aspx?ID=258
https://bookstore.transportation.org/Item_det
165 AASHTO Driving to Success with CSS 2007 IS 6 √
ails.aspx?id=1045

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-17
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Quality Control Manual for Hot Mix Asphalt

http://www.dot.ca.gov/hq/construc/qcqaman
267 Caltrans for the Quality Control Quality Assurance June 2009 W 84 √
1.pdf
Process
http://www.dot.ca.gov/hq/traffops/systemops
268 Caltrans Ramp Meter Design Manual January 2000 W 52 √
/ramp_meter/RMDM.pdf
Ready to List and Construction Contract September http://www.dot.ca.gov/hq/esc/oe/specificatio
269 Caltrans W 183 √
Award Guide (RTL Guide) 2008 ns/rtl_guide/
http://www.dot.ca.gov/hq/row/rowman/manu
270 Caltrans Right of Way Manual W 3,489 √
al/
http://www.dot.ca.gov/hq/opo/safety/safetym
271 Caltrans Safety Manual W 402 √
anual_toc.htm
Sample Mitigation Monitoring Reporting http://www.dot.ca.gov/hq/construc/environm
272 Caltrans W 4 √
Record (MMRR) form ental/sample_mmrr_ECL-memo.xls
Sample Permits, Agreements, and Mitigation http://www.dot.ca.gov/hq/construc/environm
273 Caltrans W 2 √
(PAM) form [xls] ental/Sample_PAM.xls
http://www.dot.ca.gov/hq/esc/techpubs/manu
274 Caltrans Seismic Design Criteria 2006 W al/othermanual/other-engin-manual/seismic- 116
design-criteria/sdc.html
http://www.dot.ca.gov/hq/esc/Translab/OPD/
275 Caltrans Shoulder Backing 09/30/06 W 7 √
ShoulderBackingGuideline.pdf
http://onramp.dot.ca.gov/hq/traffops/offelect/
Signal, Lighting and Electrical Systems 5th Edition electrical/htdocs/Signal/Report/SL&ES%20
276 Caltrans W 102 √
Design Guide April 2007 DG%20US%20custm%205.07.2007%20Fina
l.pdf

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-28
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Encroachment Permits Utility and Tree December http://www.dot.ca.gov/hq/traffops/developser

319 Caltrans W 20 √
Trimming Special Provisions 2008 v/permits/pdf/publications/utilities.pdf
Transportation- and Construction-Induced http://www.dot.ca.gov/hq/env/noise/pub/vibr
320 Caltrans June 2004 W 159 √
Vibration Guidance Manual ationmanFINAL.pdf
Traffic Noise Analysis Protocol for New
http://www.dot.ca.gov/hq/env/noise/pub/200
321 Caltrans Highway Construction, Reconstruction and 08/14/06 W 57 √
6_protocol.pdf
Retrofit Barrier Projects
Traffic Noise Analysis Protocol for New
http://www.dot.ca.gov/hq/env/noise/pub/prot
322 Caltrans Highway Construction and Highway October 1998 W 55 √
ocol.pdf
Reconstruction Projects
http://www.dot.ca.gov/hq/env/noise/pub/Tec
323 Caltrans Technical Noise Supplement October 1998 W 223 √
hnical%20Noise%20Supplement.pdf
Distance Limits for Traffic Noise Prediction http://www.dot.ca.gov/hq/env/noise/pub/Dist
324 Caltrans Models 04/24/02 W ance%20Limits%20for%20Traffic%20Noise 11 √
Technical Advisory, Noise TAN-02-02 %20Prediction%20Models.pdf
http://www.dot.ca.gov/hq/env/noise/pub/Gen
General Guidelines for Studying the Effects eral%20Guidelines%20For%20Studying%20
325 Caltrans 11/30/98 W 9 √
of Noise Barriers on Distant Receivers the%20Effects%20of%20Noisse%20Barriers
%20on%20Distance%20Receivers.pdf
Additional Calibration of Traffic Noise http://www.dot.ca.gov/hq/env/noise/pub/Tan-
326 Caltrans 08/27/03 W 28 √
Prediction Models 03-01_Final_with_Letter.pdf
Berm and Wall Options, Coding of Low
Barriers, Zero Height Index, Grade
http://www.dot.ca.gov/hq/env/noise/pub/Noi
327 Caltrans Corrections, and Other Issues in Sound32/ 01/17/02 W 12 √
se%20Technical%20Advisory.pdf
Sound 2000 and LeqV2 Traffic Noise
Prediction Programs

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-33
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Traffic Noise Attenuation as a Function of http://www.dot.ca.gov/hq/env/noise/pub/traff

328 Caltrans June 1995 W 116 √
Ground and Vegetation ic_noise_attent_ground_veg.pdf
http://www.dot.ca.gov/hq/env/noise/pub/CA
329 Caltrans California Vehicle Noise Emission Levels January 1987 W %20Vehicle%20Noise%20Emission%20Lev 285 √
els.pdf
http://www.dot.ca.gov/hq/esc/techpubs/manu
330 Caltrans Overhead Sign Structures Reference Sheet W al/bridgemanuals/reference- 174 √
sheets/refer_sheets.html
Main Streets: Flexibility in Design & http://www.dot.ca.gov/hq/oppd/context/main-
331 Caltrans January 2005 W 21 √
Operations streets-flexibility-in-design.pdf
An Analysis of Factors Contributing to
"Walking Along Roadway" Crashes;
February http://ntl.bts.gov/lib/19000/19900/19995/PB
332 FHWA Research Study and Guidelines for W 50
2002 2003102002.pdf
Sidewalks and Walkways
FHWA RD-01-101
BIKESAFE Bicycle Safety Guide
333 FHWA May 2006 W http://www.bicyclinginfo.org/bikesafe/ 384
FHWA-SA-05-006
Checklist and Guidelines for Review of
Geotechnical Reports and Preliminary Plans February http://www.fhwa.dot.gov/engineering/geotec
334 FHWA W 42 √
and Specifications 2003 h/pubs/reviewguide/checklist.pdf
FHWA-ED-88-053
Code of Federal Regulations, Title 23
http://www.access.gpo.gov/nara/cfr/waisidx_
335 FHWA (Highways), Chapter 1, Part 752 Landscape 2005 W 5 √
08/23cfr752_08.html
and Roadside Development

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-34
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

ACI-318-08
http://www.techstreet.com/cgi-
443 ACI Building Code Requirements for Structural 01/01/08 IS 456 √
bin/detail?product_id=1532965
Concrete and Commentary (Includes Errata)
http://store.ihs.com/specsstore/controller?eve
EIA/TIA
444 455-171A-FOTP-171 06/01/01 IS nt=DOCUMENT_DETAILS&docId=CTGO 1 √
Collaboration
PAAAAAAAAAAA
http://electronics.ihs.com/document/abstract/
445 TIA 455-59-FOTP-59 02/01/00 IS 2 √
FIZZIAAAAAAAAAAA
http://electronics.ihs.com/document/abstract/
446 TIA 492AAAA 01/01/98 IS 2 √
RXMKABAAAAAAAAAA
http://standardsdocuments.tiaonline.org/tia-
447 TIA 526-14-A-OFSTP-14 08/01/98 IS 2 √
526-14-a-ofstp-14.htm
Aluminum http://www.aluminum.org/AM/Template.cfm
448 Association for Alluminum Books and Alloys Number 319.0 Various IS ?Section=Best_Sellers&Template=/CM/HT 3 √
Alloy MLDisplay.cfm&ContentID=27631
American Public Works Association
http://www.apwa.net/Documents/ResourceC
449 APWA Standard Location for Utilities in Public 02/29/00 W 22 √
enter/Locations_of_utilities_in_PROW.pdf
Right of Ways
American Society of Testing and Materials http://www.astm.org/BOOKSTORE/BOS/sta
450 ASTM 2009 IS 87,397 √
Standards ndard_track1.htm
American with Disabilities Act Accessibility September http://www.access-
451 ADAAG W 142
Guidelines for Buildings and Facilities 2002 board.gov/adaag/html/adaag.htm

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-48
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

California Noxious Weed Law, California

California
Statutes and the current state list prohibited http://plants.usda.gov/java/noxious?rptType=
452 Department of 10/20/03 W 9
noxious weeds and restricted noxious weeds State&statefips=06
Agriculture
("Noxious Plants of California")
453 Statue California State Statutes XXXX IS http://www.leginfo.ca.gov/statute.html 1 √
454 Cal-OSHA Cal-OSHA Safety Manual IS http://www.oshasafety.com/#whatisit 67 √
American
Congress on
Surveying and
Definitions of Surveying and Associated http://cedb.asce.org/cgi/WWWdisplay.cgi?05
455 Mapping and the 1978 IS 211 √
Terms 00240
American
Society of Civil
Engineers
http://telecom-
info.telcordia.com/ido/AUX/GR_326_TOC.i
Document No. GR-326, Issue 3, Generic
September 03.pdf
456 Bellcore Requirements for Single-Mode Optical Fiber IS 9 √
1999
Connectors
http://telecom-info.telcordia.com/site-
cgi/ido/index.html
Electronics Industries Alliance (EIA) http://electronics.ihs.com/collections/eia/es5
457 EIA Various IS 2 √
Standards 8f.htm
US General
http://www.everyspec.com/FED-STD/FED-
458 Services Federal Color Standard, 595, Rev B 12/15/89 W 58 √
STD-595B_5532/
Administration

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-49
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Availability
Year/Last

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Illuminating
Engineering http://www.techstreet.com/cgi-
481 Roadway Lighting, ANSI Approved 07/01/00 IS 61 √
Society of North bin/detail?product_id=739518
America
http://www.usda.gov/rus/telecom/publication
s/publications.htm

http://www.usda.gov/rus/telecom/publication
s/pdf_files/1755-4-2004.pdf
482 USDA RUS 7 CFR 1755.900 02/17/09 W 379 √

http://ecfr.gpoaccess.gov/cgi/t/text/text-
idx?c=ecfr&sid=a86b99b8215fc05b2efa0ab5
7c6557a0&rgn=div8&view=text&node=7:11
.1.2.1.24.0.2.55&idno=7
http://www.usda.gov/rus/telecom/publication
483 USDA RUS Splicing Standard PC-2, Section 3.3 02/27/95 W 44 √
s/pdf_files/1753f401.pdf
International http://www.belden.com/pdfs/Catalogs/IMSA
Municipal %20Cat.pdf
484 IMSA Specification No. 50-2 W 16 √
Signal
Association http://www.acewireco.com/pdfs/3220.pdf
Standard for Welding Procedure and http://www.techstreet.com/cgi-
485 ANSI 11/04/04 IS 283 √
Performance Qualification bin/detail?product_id=1217427
Standard Location for Utilities in Public http://www.apwa.net/Documents/ResourceC
486 APWA 1968 W 22 √
Rights of Way enter/Locations_of_utilities_in_PROW.pdf

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-53
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Synthesis 360, Rock-Socketed Shafts for http://onlinepubs.trb.org/onlinepubs/nchrp/nc

487 NCHRP 09/01/06 W 145
Highway Structure Foundations hrp_syn_360.pdf
http://onlinepubs.trb.org/Onlinepubs/nchrp/n
488 NCHRP Synthesis 368, Cone Penetration Testing W 126 √
chrp_syn_368.pdf
US Army Corps
http://www.mvn.usace.army.mil/ops/regulato
489 of Engineers Wetlands Delineation Manual January 1987 W 143 √
ry/wlman87.pdf
(COE)
https://www.isarmc.org/store/?includes=prod
490 ISOA Guide for Plant Appraisal Workbook 2000 IS uct_info&category=3&subcategory=11&pro 12 √
duct=50
Institute of
Transportation Enhancing Intersection Safety Through December http://www.ite.org/emodules/scriptcontent/O
491 IS 105
Engineering Roundabouts 2008 rders/ProductDetail.cfm?pc=IR-127
(ITE)
Institute of
Transportation 6th Edition http://www.ite.org/emodules/scriptcontent/O
492 Traffic Engineering Handbook IS 917 √
Engineering 2009 rders/ProductDetail.cfm?pc=TB-010B
(ITE)
Institute of
Transportation http://www.ite.org/emodules/scriptcontent/O
493 Transportation Planning Handbook 3rd Edition IS 866
Engineering rders/ProductDetail.cfm?pc=TB-011B
(ITE)
Institute of
Transportation http://www.ite.org/emodules/scriptcontent/O
494 Trip Generation 8th Edition IS 1,920
Engineering rders/ProductDetail.cfm?pc=IR-016F
(ITE)

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-54
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Institute of
Transportation December http://www.ite.org/emodules/scriptcontent/O
495 Urban Street Geometric Design Handbook IS 461
Engineering 2008 rders/ProductDetail.cfm?pc=TB-018
(ITE)
Institute of
Transportation http://www.ite.org/emodules/scriptcontent/O
496 Traffic Engineering Handbook 5th Edition IS 722 √
Engineering rders/ProductDetail.cfm?pc=TB-010A
(ITE)
Institute of
Transportation Transportation Impact Analyses for Site http://www.ite.org/emodules/scriptcontent/O
497 January 2006 IS 142
Engineering Development rders/ProductDetail.cfm?pc=RP-020C
(ITE)
Institute of
Transportation http://www.ite.org/emodules/scriptcontent/O
498 Parking Generation 3rd Edition IS 295
Engineering rders/ProductDetail.cfm?pc=IR-034B
(ITE)
Institute of
Context Sensitive Solutions in Designing
Transportation http://www.ite.org/emodules/scriptcontent/O
499 Major Urban Thoroughfares for Walkable January 2005 IS 228 √
Engineering rders/ProductDetail.cfm?pc=RP-036
Communities
(ITE)
Institute of
Transportation http://www.ite.org/emodules/scriptcontent/O
500 Trip Generation 7th Edition IS 1,824
Engineering rders/ProductDetail.cfm?pc=IR-016E
(ITE)

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-55
Department of Transportation Book 3 - San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843
Format

Publication

Check List for

Revised Ref #

Availability
Year/Last

Hard Copy

Applicable
Electronic
Organization Standard Web Site or Remarks

# of Pages
CD-Rom
PDF File

Manuals
Updated
(Revision)

Institute of
2nd Edition
Transportation Trip Generation and Trip Generation http://www.ite.org/emodules/scriptcontent/O
501 & IS 3,821
Engineering Handbook rders/ProductDetail.cfm?pc=GP-001B
7th Edition
(ITE)
Institute of
Transportation Freeway and Interchange Geometric Design http://www.ite.org/emodules/scriptcontent/O
502 January 2005 IS 641 √
Engineering Handbook rders/ProductDetail.cfm?pc=TB-017
(ITE)
Methods Used in Tieback Wall Design and
US Army Corps
Construction to Prevent Local Anchor December
503 of Engineers W http://itl.erdc.usace.army.mil/pdf/ITL-TR-02- 184
Failure, Progressive Anchorage Failure, and 2002
(COE)
Ground Mass Stability Failure
Users Manual for Program PEAKFQ, Annual
U.S. Geological http://www.novaregion.org/DocumentView.a
504 Flood Frequency Analysis Using Bulletin 1/30/1998 W 103 √
Survey sp?DID=236
17B Guidelines

Total Number of Pages 211,261

April 11, 2011

Index of Caltrans Standards, Manuals, Guidelines and References 1-56
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

2 MODIFICATIONS TO DEPARTMENT (CALTRANS)

MANUALS

The following notes apply to the Caltrans Manuals used on this Project:
1. The Department (Caltrans) Manuals were created as an internal guidance document for use by
various Department (Caltrans) personnel. As such, the Manuals are written as a guidance
documents and not as mandatory requirements. For purposes of design-build projects, the Design-
Builder shall assume that all provisions of the Manual, including the figures and tables, are
mandatory and guidelines shall be assumed to be requirements. All words such as “should,”
“may,” “must,” “might,” “could,” and “can” shall mean “shall” unless the context requires
otherwise, as determined in the sole discretion of Department. The Design-Builder shall disregard
qualifying words such as “usually,” “normally,” and “generally.” It shall be in Department’s sole
discretion to determine when the context does not require a provision to be mandatory.
2. Department (Caltrans) Manuals are standard documents for use by Department (Caltrans)
personnel. For purposes of design-build projects, the Design-Builder shall assume that all of the
provisions of the Standards are requirements.
3. Individual manuals are available in electronic format. All the Department (Caltrans) manuals can
be accessed at the following Web Site: http://caltrans-opac.ca.gov/publicat.htm
4. If the department (Caltrans) Manual expires during the course of the Project the Design-Builder
shall contact Department to determine if they should continue to use the manual or if it will be
replaced.
5. Any references related to pay items or quantities, measurement for payment, method of
measurement, basis of payment, extra work, adjustment of unit prices, or similar phrases shall be
disregarded by the Design-Builder , since the Contract Price is full compensation for the Work.
6. No changes have been made to provisions in the Manual that do not apply to design-build
contracts, but that provide general information (e.g., descriptions of Department (Caltrans)
divisions and their duties, descriptions of legal authority, or descriptions of internal Department
(Caltrans) procedures); however, in some cases it may not be clear whether rights or
responsibilities are applicable to the Design-Builder. If it is unclear whether specific provisions in
the Manual are applicable to the Design-Builder, the Design-Builder shall raise the issue with
Department and Department shall make that determination in its sole discretion.
7. The Design-Builder shall disregard the paragraphs within the manuals relating to questions. All
questions shall be taken to the Department’s Contract Manager.
8. All references to the Engineer shall mean the Design-Builder unless otherwise directed by
Department.
9. All references to the Agency shall mean Department (Caltrans), unless noted otherwise.
10. All references to Caltrans shall mean the Design-Builder, unless otherwise noted.
11. All references to Caltrans offices and personnel shall mean the Design-Builder’s similar offices
and personnel.
12. When the Manual refers to an action being necessary or needed, the Design-Builder shall
construe the action as required unless the context requires otherwise, as determined in the sole
discretion of Department.

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Project ID 0400000843

13. In addition, phrases relating to items such as activity[ies] that “will be” conducted, that are “most
easily accomplished by”, that “are recommended”, that “is usually necessary”, that “should
preferably be” done, that “might require”, that “is necessary” or “as necessary”, that “are” (or
“is”) “required” or “done” shall be construed to be mandatory requirements unless the context
requires otherwise, as determined in the sole discretion of Department. Phrases relating to
problems with activity[ies] that should not be conducted, such as “is not normally used,” “is not
good practice,” “should never be done,” “cannot be used,” or “should be avoided” shall be
construed as prohibited. It shall be in Department’s sole discretion to determine when the context
either requires or does not require a provision to be mandatory.
14. Where the notes refer to items that are indicated in the plans or special provisions or required in
the plans or special provisions, the plans or special provisions shall mean the Design-Builder’s
plans or special provisions.
15. Where the notes refer to the Engineer, they shall mean the Design-Builder unless otherwise
specified below.
16. When the Manual refers to other manuals, the version of these manuals applicable to this design-
build project is the version current at the time of the date of this Invitation. For Bid (IFB) unless
modified by Addendum or Change Order.
17. References to approved products or materials shall mean Approved by Caltrans.
18. References to payment, pay items and quantities are hereby deleted.
19. All references to the Inspector, the Field Inspector, the Project Engineer, the Engineer, the
Materials Engineer, the District Materials Engineer, the Survey Crew, the Project Supervisor, the
Agency Certified Technician, the Certified Plant Technician, and the Representative of the Office
of Materials shall mean the Design-Builder, unless noted otherwise.
20. All references to the Department (Caltrans) facilities, including the Office of Materials
Laboratory, Central Laboratory, Cement Laboratory, Concrete & Metals Laboratory, Aggregate
Laboratory, Chemical Laboratory, Mix Design Laboratory, District Laboratory, and the
Laboratory shall mean the Design-Builder’s similar Laboratory facilities, unless noted otherwise.
21. The Design-Builder shall use forms as required to report the same information and in the same
format as the Caltrans forms shown in the Manuals.
22. The Design-Builder shall complete all laboratory testing at a Department certified and approved
facility with current AASHTO Materials Reference Laboratory (AMRL) certification.

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Modifications To Department (Caltrans) Manuals
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

3 MODIFICATIONS TO TECHNICAL MEMORANDA

(NOT USED)

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Modifications To Technical Memoranda
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

4 DESIGN-BUILD MODIFICATIONS TO THE CALTRANS

STANDARD SPECIFICATIONS MAY 2006 EDITION
General
These Contract Provisions are a revised version of Caltrans’s Standard Specifications – May 2006 Edition
and contain requirements generally applicable to the Work to be performed by Design-Builder. In certain
cases provisions in the Standard Specifications have been superseded by other provisions of the Contract
Documents. For ease of reference, this document uses the same section numbers as the Standard
Specifications and identifies provisions of the Contract Documents that have replaced or modified the
standard clauses. If there are conflicts between the “General” Modifications and the Specific
Modifications below, the Specific Modifications have precedence over the General Modifications. If the
Design-Builder believes that a modification is unclear, the Design-Builder shall have the obligation to
raise the issue with Department. Regardless of whether the Design-Builder raises the issue, Department
shall always have the right to notify the Design-Builder if the Design-Builder is interpreting the
modification incorrectly. Any references to other standards, codes, or criteria, or to the latest version of
other standards, codes, or criteria in the Technical Provisions of the Contract Documents shall mean the
latest version as of the Request for Proposals (RFP) issue date. Those standard specifications that are left
blank are not modified in this Modification document, but they may be modified by Special Provisions or
other Contract Documents. All Sections are incorporated herein, except as otherwise provided in the
Contract Documents, and with the following general and specific exceptions:
General Exceptions:
1. When these Specifications refer to “Measurement for Payment,” “Method of Measurement,” or
“Payment Quantities,” such language shall be disregarded. It is not the intent of the Design-Build
Contract that the various components of the Work will be measured for payment. Final payment will
be at the Contract Price for the completed Project irrespective of the quantities of the various
components incorporated in the Work.
2. When these Specifications refer to “basis of payment,” “unit prices,” or “adjustments of unit prices,”
such references and language shall be disregarded, except unit prices as identified in the Technical
Provisions, applicable to disincentives for Nonconforming Work or incentives for surface ride quality
shall be either the specific dollar amount set forth in the standard specifications or a unit price
proposed by the Design-Builder and Approved by Department.
3. When these Specifications refer to “extra work,” “compensation for,” “at the Department’s expense,”
“quantity adjustments,” “equivalent quantities,” or similar phrases, such references shall be
disregarded. It is intended that the payment of the Contract Price will be full compensation for all
Work performed pursuant to the Design-Build Contract unless specific provisions for additional
payments are contained in the Contract Documents. An exception to this general exclusion will be the
provisions of Sections 10 thru 95, as modified by the Special Provisions, relating to incentives for
surface ride quality and disincentives for Nonconforming Work.
4. When these specifications refer to the term “Special Provision,” such term shall mean Contract
Documents.
5. When these specifications refer to the term “incidental” such term shall mean that the costs shall be
included in the Design-Builder’s Price Proposal.

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E.A. 04-2A7904
Project ID 0400000843

A. Sections 1 thru 9 – General Provisions– Specific Modifications

Section 1 Definitions and Terms
Provisions regarding Definitions and Terms are deleted in their entirety and are replaced with the
following:
Section 1 General
1-1 General
1-1.01 General
Section 1 includes general rules of interpretation.
The Department is gradually standardizing the style and language of the specifications. The new style
and language includes:
1. Use of:
1.1. Imperative mood
1.2. Introductory modifiers
1.3. Conditional clauses
2. Elimination of:
2.1. Language variations
2.2. Definitions for industry-standard terms
2.3. Redundant specifications
2.4. Needless cross-references
The use of this new style does not change the meaning of a specification not yet using this style.
Sections 1 through 9 include general specifications applicable to every contract unless specified as
applicable under certain conditions.
Sections 10 through 15 include specifications for general construction applicable to every contract unless
specified as applicable under certain conditions.
The specifications are written to the Bidder before award and the Contractor after. Before award,
interpret sentences written in the imperative mood as starting with "The Bidder must" and interpret "you"
as "the Bidder" and "your" as "the Bidder's." After award, interpret sentences written in the imperative
mood as starting with "The Contractor must" and interpret "you" as "the Contractor" and "your" as "the
Contractor's."
Omission of "a," "an," and "the" is intentional. These articles have been omitted in some specifications
for streamlining purposes.
Unless an object or activity is specified to be less than the total, the quantity or amount is all of the object
or activity.
A plural term includes the singular.
All items in a list apply unless the items are specified as choices.
Headings are included for the purposes of organization and referencing. Inclusion of a heading with no
related content, "Reserved," or "Not Used" does not indicate that no specification exists for that subject;
applicable specifications may be covered in a general or referenced specification.

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Project ID 0400000843

Provisions regarding other General are set forth in Section 1 “Contract Components;
Interpretation of Contract Documents” of the Contract Documents.
1-2 References
1-2.01 References
Provisions regarding References are hereby deleted in their entirety and are set forth in Section 1
“Contract Components; Interpretation of Contract Documents” of the Contract Documents.
1-3 Abbreviations And Measurement Units
1-3.01 Abbreviations
Provisions regarding Abbreviations are hereby deleted in their entirety and are set forth in Exhibit A
“Acronyms And Definitions” of the Contract Documents.
1-3.02 Measurement Units
Measurement Units
Symbols as used
in Meaning
the specifications
A amperes
ACRE acre
CF cubic foot
CY cubic yard
EA each
g gram
GAL gallon
h hour
ksi kips per square inch
LB pound
LS lump sum
LF linear foot
LNMI lane mile
MFBM thousand foot board
measure
MI mile
MSYD thousand station yard
Ω ohm
pcf pounds per cubic foot
s second
STA 100 feet
SQFT square foot
SQYD square yard
TAB tablet
ton 2,000 pounds
V volt
W watt
WDAY working day

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
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Project ID 0400000843

1-4 Definitions
Provisions regarding Definitions & Glossary are hereby deleted in their entirety and are set forth in
Exhibit A “Acronyms And Definitions” of the Contract Documents.
1-5 Districts
District Composition and Office Addresses
District Counties Location Address Mailing Address
1 Del Norte (DN), Humboldt 1656 UNION ST PO BOX 3700
(Hum), Lake (Lak), Mendocino EUREKA, CA EUREKA CA 95502
(Men)
2 Lassen (Las), Modoc (Mod), 1657 RIVERSIDE DR PO BOX 496073
Plumas (Plu), Shasta (Sha), REDDING, CA REDDING CA 96049-6073
Siskiyou (Sis), Tehama (Teh),
Trinity (Tri)
3 Butte (But), Colusa (Col), El 703 B ST PO BOX 911
Dorado (ED), Glenn (Gle), MARYSVILLE, CA MARYSVILLE CA 95901
Nevada (Nev), Placer (Pla),
Sacramento (Sac), Sierra (Sie),
Sutter (Sut), Yolo (Yol), Yuba
(Yub)
4 Alameda (Ala), Contra Costa 111 GRAND AVE PO BOX 23660
(CC), Marin (Mrn), Napa (Nap), OAKLAND, CA OAKLAND CA 94623-0660
San Francisco (SF), San Mateo
(SM), Santa Clara (SCl), Solano
(Sol), Sonoma (Son)
5 Monterey (Mon), San Benito 50 HIGUERA ST 50 HIGUERA ST
(SBt), San Luis Obispo (SLO), SAN LUIS OBISPO, CA SAN LUIS OBISPO CA
Santa Barbara (SB), Santa Cruz 93401-5415
(SCr)
6 Fresno (Fre), Kern (Ker), Kings 1352 W. OLIVE AVE PO BOX 12616
(Kin), Madera (Mad), Tulare FRESNO, CA FRESNO CA 93728-2616
(Tul)
7 Los Angeles (LA), Ventura (Ven) 100 S. MAIN ST 100 S MAIN ST
LOS ANGELES, CA LOS ANGELES CA 90012
8 Riverside (Riv), San Bernardino 464 W 4TH ST 464 W 4TH ST
(SBd) SAN BERNARDINO, SAN BERNARDINO CA
CA 92401-1400
9 Inyo (Iny), Mono (Mno) 500 S MAIN ST 500 S MAIN ST
BISHOP, CA BISHOP CA 93514-3423
10 Alpine (Alp), Amador (Ama), 1976 E CHARTER PO BOX 2048
Calaveras (Cal), Mariposa (Mpa), WAY STOCKTON CA 95201
Merced (Mer), San Joaquin (SJ), STOCKTON, CA
Stanislaus (Sta), Tuolumne (Tuo)
11 Imperial (Imp), San Diego (SD) 4050 TAYLOR ST 4050 TAYLOR ST
SAN DIEGO, CA SAN DIEGO CA 92110-
2737
12 Orange (Ora) 3347 MICHELSON DR 3347 MICHELSON DR STE
STE 100 100
IRVINE, CA IRVINE CA 92612-0661

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
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Project ID 0400000843

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Offices of MSC 9-4/4I (916) 227-0716

Structure Design, DOCUMENTS UNIT OFFICES OF
Documents Unit STRUCTURE DESIGN
DEPARTMENT OF
TRANSPORTATION
1801 30TH ST
SACRAMENTO CA 95816-7006
Publication PUBLICATION UNIT
Distribution Unit DEPARTMENT OF
TRANSPORTATION
1900 ROYAL OAKS DRIVE
SACRAMENTO CA 95815-3800
Transportation MATERIALS AND (916) 227-7000
Laboratory ENGINEERING TESTING
SERVICES AND
GEOTECHNICAL SERVICES
DEPARTMENT OF
TRANSPORTATION
5900 FOLSOM BLVD
SACRAMENTO CA 95819-4612
Department's Pre- http://www.dot.ca.g
Qualified Products ov/hq/esc/approved_
List products_list

Section 2 Proposal Requirements and Conditions

Provisions regarding Proposal Requirements and Conditions & Bidding are deleted in their entirety and
are set forth in the RFP and the Contract Documents.

Section 3 Award and Execution of Contract

Provisions regarding Award and Execution of Contract are deleted in their entirety and are set forth in the
RFP and the Contract Documents.

Section 4 Scope of Work

4-1.01 Intent of Plans and Specifications
Provisions regarding Intent of Plans and Specifications are hereby deleted in their entirety and are set
forth in the RFP and the Contract Documents.

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Project ID 0400000843

4-1.02 Final Cleaning Up

Provisions regarding Final Cleaning Up are hereby deleted in their entirety and are set forth in Section 20
“Acceptance of Project” of the Contract Documents.
4-1.03 Changes
Provisions regarding Changes such as Increased or Decreased Quantities, Changes in Character of Work
and Extra Work, alterations of the Work, changed conditions, differing site conditions, suspension of
Work, and significant changes in the Work are hereby deleted in their entirety and are set forth in Section
13 “Changes in the Work” of the Contract Documents.
4-1.03A General
Provisions regarding General regarding alterations of the Work, changed conditions, differing site
conditions, suspension of Work, and significant changes in the Work are hereby deleted in their entirety
and are set forth in Section 13 “Changes in the Work” of the Contract Documents.
4-1.03B Increased or Decreased Quantities
Provisions regarding Increased or Decreased Quantities are hereby deleted in their entirety.
4-1.03C Changes in Character of Work
Provisions regarding Changes in Character of Work are hereby deleted in their entirety and are set forth in
Section 13 “Changes in the Work” of the Contract Documents.
4-1.03D Extra Work
Provisions regarding Extra Work and changes are hereby deleted in their entirety and are set forth in
Section 13 “Changes in the Work” of the Contract Documents.
4-1.04 Detours
Provisions regarding Detours are hereby deleted in their entirety and are substituted with the following:
GENERAL
Unless otherwise provided, a road undergoing improvements shall be kept open to all traffic by and at the
expense of the Design-Builder. Where so provided in the Contract, traffic shall be directed over an
approved detour route. The Design-Builder shall keep the portions of the Project being used by public
traffic, whether it is through or local traffic, in such condition that the traffic will be adequately
accommodated at all times. The Design-Builder shall provide and maintain temporary approaches,
crossings, and intersections, roads, streets, businesses, parking lots, residences, garages, farms, and other
abutting property in acceptable condition.
PLANNED DETOURS
Planned detours are those specifically identified in the Technical Provisions and within detour agreements
between the jurisdictional authorities. Planned detours may designate a route by naming specific streets to
follow, in which case the Design-Builder will be required to provide and install signs, signals, and
Maintenance of Traffic (MOT) devices as necessary to establish the route. The Design-Builder must
provide, install, and maintain signs, signals, and MOT devices as necessary to close the street or ramp.
DESIGN-BUILDER'S REQUEST FOR DETOUR
The Design-Builder may request that through traffic be detoured. The request shall contain all
information needed for justification and shall specify the routes to be established. If arrangements can be
made that are satisfactory to the agencies having jurisdiction over the roads to be used, Department may
then at its sole discretion establish an approved detour subject to the following conditions: (a) The

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
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Project ID 0400000843

Design-Builder shall design, provide, install, maintain, and remove all the necessary traffic control
devices on the detour roads. (b)The Design-Builder shall pay all expenses incurred in maintaining and
restoring the detour roads, except for snow removal. (c) The Design-Builder shall fulfill the obligations
for maintenance of local traffic by furnishing, placing, and maintaining all traffic control devices and
other traffic protection measures required on the roads undergoing improvements.
TEMPORARY BYPASSES
All temporary bypass facilities requested by the Design-Builder and accepted by Department shall be
constructed, maintained, and removed at the Design-Builder’s expense.
4-1.05 Use of Materials Found on the Work
Any materials required to be removed from the Project shall become the property of the Design-Builder
and shall be disposed of at an appropriate off-site disposal facility provided by the Design-Builder unless
otherwise provided in the Contract Documents

Section 5 Control of Work

5-1.01 Authority of the Engineer
Provisions regarding Authority of the Engineer are hereby deleted in their entirety and are set forth in
Section 5 “Control of Work” of the Contract Documents. Department has the authority by written order to
suspend the Work wholly or in part for the reasons delineated in Section 15 “Termination for
Convenience” of the Contract Documents. Failure to enforce a contract provision does not waive
enforcement of any contract provision.
5-1.02 Plans and Working Drawings
Provisions regarding Plans and Working Drawings, shop drawings, and other construction documents are
hereby deleted in their entirety and are set forth in the Technical Provisions, and the Engineering
Documents and requirements applicable to specific portions of the Work may be identified with
particularity in such sections.
5-1.02A Excavation Safety Plans
Provisions regarding Excavation Safety Plans are applicable to this project.
5-1.03 Conformity with Contract Documents and Allowable Deviations
The provisions regarding Conformity with Contract Documents and Allowable Deviations are revised as
follows:
All Work performed and all materials furnished shall conform to the Contract Documents.
All work performed and all materials furnished shall be in conformance with the lines, grades, cross-
sections, dimensions, and material requirements, including tolerances, required by the Contract
Documents. If Department finds that the material or the finished product in which the material is used is
not in conformance with the Contract Documents, Department will decide whether the Nonconforming
Work will be allowed to remain in place, or whether it must be removed and replaced or otherwise
corrected as a condition for Final Acceptance.
Plan dimensions and specification values are to be considered as the target value to be strived for and
complied with as the design value from which deviations (within tolerances) may be allowed. If any
changes to the Contract Document requirements are ordered or authorized by Department, the revised
values shall govern. It is the intent of the Contract requirements that the materials and workmanship shall

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

be uniform in character and shall conform to the prescribed target value or to the middle portion of the
tolerance range.
The purpose of the tolerance range is to accommodate occasional minor variations from the median zone
that are unavoidable for practical reasons. When a maximum or minimum value is specified, the
production and processing of material and the performance of the Work shall be so controlled that the
material or workmanship will not be of borderline quality or dimension. Department will allow an
industry standard tolerance where working tolerances are not specified.
Sections 10 thru 95 of these specifications provide guidelines, tolerances, and adjustments for many cases
of Nonconforming Work. When the Design-Builder or Department finds that the materials furnished, the
Work performed, or the finished product does not conform to the requirements of the Contract
Documents, including the adjustments set forth in Sections 10 thru 95, but Department determines, in its
sole discretion, that reasonably acceptable Work has been produced, Department will determine the extent
the Work will be Accepted and remain in place. If Accepted, (1) the Design-Builder shall document the
basis for Acceptance based on Department’s determination by Change Order, which will provide for an
appropriate reduction in the Contract price for such Work or materials not otherwise provided for in this
subsection, (2) Department will notify the Design-Builder in writing that the Contract unit price will be
reduced in accordance with this subsection, or (3) in lieu of a price reduction, Department may permit
correction or replacement of the finished product, provided the correction or replacement does not
adversely affect the Work. When such requirements specify a disincentive payment adjustment based on a
unit price, the unit price shall be as specified in the applicable specification, and if no unit price is
specified, the unit price shall be comparable to bid unit prices for similar work in the area.
The Design-Builder shall have the right to remove and replace the Nonconforming Work in lieu of
accepting a price reduction provided the correction or replacement does not adversely affect the Work.
However, it is in Department’s sole discretion to determine whether a price reduction may be made in lieu
of correction or replacement of Nonconforming Work. The reduction in Contract price shall take place as
provided in this Section 5, “Control of Work” based upon the Approved unit price. Design-Builder shall
prepare the Change Order in accordance with Section 13 “Changes in the Work” of the Contract
Documents.
When either the Design-Builder or Caltrans finds that the materials furnished, Work performed, or the
finished product are not in conformity with the Contract Documents and Department determines, in its
sole discretion, that it has resulted in an inferior or unsatisfactory product, the Work or materials shall be
removed and replaced or otherwise corrected at the expense of the Design-Builder.
When no other basis for Acceptance is set forth in the Contract Documents covering Work that is not
fully acceptable but that is allowed to remain in place, the Design-Builder shall document Department’s
basis of Acceptance and payment by Contract modification or change order, which will provide for an
appropriate adjustment in payment for the Nonconforming Work as justified by Department’s engineering
determinations of the reasonable value of the Work performed.
5-1.04 Coordination and Interpretation of Plans, Standard Specifications, and Special Provisions
Replace “5-1.04 Coordination and Interpretation of Plans, Standard Specifications, and Sepcial
Provisions” with “5-1.04 Contract Components”. Provisions regarding Contract Components are hereby
deleted in their entirety. Section 1 “Contract Components; Interpretation of Contract Documents” and the
Technical Provisions set forth the order of priority of the various Contract Documents.

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5-1.05 Order of Work

Provisions regarding Order of Work are hereby deleted in their entirety.
5-1.055 Subcontracting
5-1.055A General
No subcontract releases you from the contract or relieves you of your responsibility for a subcontractor's
work.
If you violate Pub Cont Code § 4100 et seq., the Department may exercise the remedies provided under
Pub Cont Code § 4110. The Department may refer the violation to the Contractors State License Board
as provided under Pub Cont Code § 4111.
Except for a building-construction non-federal-aid contract, perform work equaling at least 30 percent of
the value of the original total bid with your employees and with equipment owned or rented by you, with
or without operators.
Each subcontract must comply with the contract.
The Department encourages you to include a dispute resolution process in each subcontract.
Each subcontractor must have an active and valid State contractor's license with a classification
appropriate for the work to be performed (Bus & Prof Code, § 7000 et seq.).
Submit copies of subcontracts upon request.
Before subcontracted work starts, submit a Subcontracting Request form.
Do not use a debarred contractor; a current list of debarred contractors is available at the Department of
Industrial Relations' Web site.
Upon request, immediately remove and not again use a subcontractor who fails to prosecute the work
satisfactorily.
5-1.06 Superintendence
Provisions regarding Superintendence are hereby deleted in their entirety. Provisions regarding
responsibilities of Design-Builder and requirements for competent management are set forth in Section 2
“Obligations of Design-Builder” of the Contract Documents.
5-1.07 Lines and Grades
Provisions regarding Lines and Grades are hereby deleted in their entirety.
5-1.08 Inspection
Provisions regarding Inspection are applicable to this project.
5-1.09 Removal of Rejected and Unauthorized Work
Provisions regarding Removal of Rejected and Unauthorized Work are hereby deleted in their entirety
and are set forth in Section 5 “Control of Work” of the Contract Documents
5-1.10 Equipment and Plants
Replace “Section 5-1.10 Equipment and Plants” with “Section 5-1.10 Equipment”. Provisions regarding
Equipment are hereby deleted in their entirety and are set forth in Section 2 “Obligations of Design-
Builder” and Section 10 “Risk of Loss” of the Contract Documents.

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5-1.11 Alternative Equipment

Provisions regarding Alternative Equipment are applicable to this project
5-1.115 Alternative Methods of Construction
Provisions regarding Alternative Methods of Construction Equipment are hereby deleted in their entirety.
5-1.116 Differing Site Conditions
Provisions regarding Differing Site Conditions (23 CFR 635.109) are hereby deleted in their entirety and
set forth in Section 5 “Control of Work” of the Contract Documents.
5-1.12 Character of Workers
Provisions regarding Character of Workers are hereby deleted in their entirety and are set forth Section 7
“Equal Employment Opportunity; Subcontracts; Labor”; of the Contract Documents.
5-1.13 Final Inspection
Provisions regarding interim completion and Final Inspection are hereby deleted in their entirety and are
set forth in Section 20 “Acceptance of Project” of the Contract Documents.
5-1.14 Cost Reduction Incentive
Provisions regarding Cost Reduction Incentive are hereby deleted in their entirety.
5-1.18 Property and Facility Preservation
5-1.18A General
Preserve property and facilities, including:
1. Adjacent property
2. Department's instrumentation
3. ESAs
4. Lands administered by other agencies
5. Railroads and railroad equipment
6. Roadside vegetation not to be removed
7. Utilities
8. Waterways
Immediately report damage to the Engineer.
If you cause damage, you are responsible.
Install sheet piling, cribbing, bulkheads, shores, or other supports necessary to support existing facilities
or support material carrying the facilities.
Dispose of temporary facilities when they are no longer needed.
If you damage plants not to be removed:
1. Dispose of them outside the right of way unless the Engineer allows you to reduce them to chips
and spread the chips within the highway at locations designated by the Engineer
2. Replace them
Replace plants with plants of the same species.

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E.A. 04-2A7904
Project ID 0400000843

Replace trees with 24-inch-box trees.

Replace shrubs with No. 15 container shrubs.
Replace ground cover plants with plants from flats. Replace Carpobrutus ground cover plants with plants
from cuttings. Plant ground cover plants 1 foot on center.
If a plant establishment period is specified, replace plants before the start of the plant establishment
period; otherwise, replace plants at least 30 days before Contract acceptance.
Water each plant immediately after planting and saturate the backfill soil around and below the roots or
ball of earth around the roots of each plant. Water as necessary to maintain plants in a healthy condition
until Contract acceptance.
The Department may make a temporary repair to restore service to a damaged facility.
If working on or adjacent to railroad property, do not interfere with railroad operations.
For an excavation on or affecting railroad property, submit work plans showing the system to be used to
protect railroad facilities. Allow 65 days for the Engineer's review of the plans. Do not perform work
based on the plans until the Engineer notifies you they are accepted.
5-1.18B Nonhighway Facilities (Including Utilities)
The Department may rearrange a nonhighway facility during the Contract. Rearrangement of a
nonhighway facility includes installation, relocation, alteration, or removal of the facility.
The Department may authorize facility owners and their agents to enter the highway to perform
rearrangement work for their facilities or to make connections or repairs to their property. Coordinate
activities to avoid delays.
Notify the Engineer at least 3 business days before you contact the regional notification center under Govt
Code § 4216 et seq. Failure to contact the notification center prohibits excavation.
Before starting work that could damage or interfere with underground infrastructure, locate the
infrastructure described in the Contract, including laterals and other appurtenances, and determine the
presence of other underground infrastructure inferred from visible facilities such as buildings, meters, or
junction boxes.
Notify the Engineer if the infrastructure described in the Contract cannot be found. If after giving the
notice, you find the infrastructure in a substantially different location than described, finding the
infrastructure is paid for as extra work as specified in Section 4-1.03D, "Extra Work."
Underground infrastructure described in the Contract may be in different locations than described, and
additional infrastructure may exist.
Upon discovering an underground main or trunk line not described in the Contract, immediately notify the
Engineer and the infrastructure owner. The Engineer orders the locating and protecting of the
infrastructure. The locating and protecting is paid for as extra work as specified in Section 4-1.03D,
"Extra Work." If ordered, repair infrastructure damage. If the damage is not due to your negligence, the
repair is paid for as extra work as specified in Section 4-1.03D, "Extra Work."
If necessary underground infrastructure rearrangement is not described in the Contract, the Engineer may
order you to perform the work. The rearrangement is paid for as extra work as specified in Section 4-
1.03D, "Extra Work."

April 11, 2011 4-12

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

If you want infrastructure rearrangement different from that described in the Contract:
1. Notify the Engineer
2. Make an arrangement with the infrastructure owner
3. Obtain authorization for the rearrangement
4. The Department does not adjust time or payment for rearrangement different from the Contract
5. Pay the infrastructure owner any additional cost
Immediately notify the Engineer of a delay due to the presence of main line underground infrastructure
not described in the Contract or in a substantially different location or due to rearrangement different from
the Contract. The Department pays for one of these delays in the same manner as specified for a right of
way delay in Section 8-1.09, "Right of Way Delays."

April 11, 2011 4-13

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Section 6 Control of Material

6-1 General,
6.-1.0 Source of Supply and Quality of Materials
Provisions regarding Source of Supply and Quality of Materials are hereby deleted in their entirety and
are set forth in Section 5 “Control of Work” of the Contract Documents.
6.-1.02 State Furnished Materials
Provisions regarding State Furnished Materials are applicable to this project
6.-1.03 Storage of Materials
Provisions regarding Storage of Materials are hereby deleted in their entirety and are set forth in Section 5
“Control of Work” of the Contract Documents.
6.-1.04 Defective Materials
Provisions regarding Defective Materials are hereby deleted in their entirety and are set forth in Section 5
“Control of Work” of the Contract Documents.
6.-1.05 Trade Names and Alternatives
Provisions regarding Trade Names and Alternatives are hereby deleted in their entirety.
6.-1.06 Plant Inspection
Provisions regarding Plant Inspection are applicable to this project
6.-1.07 Certificates of Compliance
Provisions regarding Certificates of Compliance are applicable to this project
6.-1.08 Foreign Materials
Provisions regarding Foreign Materials are applicable to this project
6.-1.085 Buy America (23 CFR 635.410)
For a Federal-aid contract, furnish steel and iron materials to be incorporated into the work that are
produced in the United States except:
1. Foreign pig iron and processed, pelletized, and reduced iron ore may be used in the domestic
production of the steel and iron materials [60 Fed Reg 15478 (03/24/1995)]
2. If the total combined cost of the materials does not exceed the greater of 0.1 percent of the total
bid or $2,500, material produced outside the United States may be used
Production includes:
1. Processing steel and iron materials, including smelting or other processes that alter the physical
form or shape (such as rolling, extruding, machining, bending, grinding, and drilling) or chemical
composition
2. Coating application, including epoxy coating, galvanizing, and painting, that protects or enhances
the value of steel and iron materials
For steel and iron materials to be incorporated into the work, submit a Certificate of Compliance under
Section 6-1.07, "Certificates of Compliance," of the Standard Specifications that certifies all production
processes occurred in the United States except for the above exceptions.

April 11, 2011 4-14

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

6.-1.087 Buy America (Pub Res Code § 42703(d))

Furnish crumb rubber to be incorporated into the work that is produced in the United States and is derived
from waste tires taken from vehicles owned and operated in the United States.
For crumb rubber to be incorporated into the work, submit a Certificate of Compliance under Section 6-
1.07, "Certificates of Compliance," of the Standard Specifications that certifies only crumb rubber
manufactured in the United States and derived from waste tires taken from vehicles owned and operated
in the United States is used.
6.-1.09 State Specification Numbers
Provisions regarding State Specification Numbers are applicable
6-2 Local Materials,
6.-2.01 General
Provisions regarding General are hereby deleted in their entirety and are set forth in Section 5 “Control of
Work” of the Contract Documents.
6.-2.02 Possible Local Material Sources
Provisions regarding Possible Local Material Sources are hereby deleted in their entirety and are set forth
in Section 5 “Control of Work” of the Contract Documents.
6.-2.03 Mandatory Local Material Sources
Provisions regarding Mandatory Local Material Sources are hereby deleted in their entirety and are set
forth in Section 5 “Control of Work” of the Contract Documents.
6-3 Testing,
6.-3.0 General
Provisions regarding General are hereby deleted in their entirety and are set forth in Section 5 “Control of
Work” of the Contract Documents.
6.-3.02 Testing by Contractor
Provisions regarding Testing by Contractor are hereby deleted in their entirety and are set forth in Section
5 “Control of Work” of the Contract Documents. Provisions regarding quality control and quality
assurance are hereby deleted in their entirety and are set forth in the Technical Provisions. The provisions
regarding Caltrans oversight of the Work are hereby deleted in their entirety and are set forth in Section 5
“Control of Work” of the Contract Documents. Unless otherwise designated, when AASHTO, ASTM,
FSS, AWS, CRSI, UL, and other specifications, standards, methods, tests, or practices are cited in these
Specifications, the reference shall be to the latest edition as revised or updated by approved supplements
or interim editions published and issued as of the RFP issue date unless otherwise indicated. By mutual
agreement, the referenced provisions may govern as updated to the time of application.

April 11, 2011 4-15

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Section 7 Legal Relations and Responsibility

7-1.01 Laws to be Observed
Provisions regarding Laws to be Observed are deleted in their entirety and are replaced with the
following:
Comply with laws, regulations, orders, decrees, and PLACs applicable to the project. Indemnify and
defend the State against any claim or liability arising from the violation of a law, regulation, order,
decree, or PLAC by you or your employees. Immediately report to the Engineer in writing a discrepancy
or inconsistency between the contract and a law, regulation, order, decree, or PLAC.
7-1.01A Labor Code Requirements
Provisions regarding Labor Code Requirements are applicable to this project. Replace the first clause
with the following:
Work on the job site must comply with Labor Code §§ 1727 and 1770-1815 and 8 CA Code of Regs §
16000 et seq. Work includes roadside production and processing of materials.
7-1.01A(1) Hours of Labor
Provisions regarding Hours of Labor are applicable to this project.
7-1.01A(2) Prevailing Wages
Provisions regarding Prevailing Wages are applicable to this project with the modifications noted below.
Replace item 3 in the first paragraph with the following:

3. Upon becoming aware of the subcontractor's failure to pay the specified prevailing rate of wages
to the subcontractor's workers, the Contractor must diligently take corrective action to stop or
rectify the failure, including withholding sufficient funds due the subcontractor for work
performed on the public works project.

Replace the second paragraph with the following:

Pursuant to Section 1775 of the Labor Code, the Division of Labor Standards Enforcement must notify
the Contractor on a public works project within 15 days of the receipt by the Division of Labor Standards
Enforcement of a complaint of the failure of a subcontractor on that public works project to pay workers
the general prevailing rate of per diem wages. If the Division of Labor Standards Enforcement
determines that employees of a subcontractor were not paid the general prevailing rate of per diem wages
and if the Department did not withhold sufficient money under the contract to pay those employees the
balance of wages owed under the general prevailing rate of per diem wages, the Contractor must withhold
an amount of moneys due the subcontractor sufficient to pay those employees the general prevailing rate
of per diem wages if requested by the Division of Labor Standards Enforcement. The Contractor must
pay any money withheld from and owed to a subcontractor upon receipt of notification by the Division of
Labor Standards Enforcement that the wage complaint has been resolved. If notice of the resolution of
the wage complaint has not been received by the Contractor within 180 days of the filing of a valid notice
of completion or acceptance of the public works project, whichever occurs later, the Contractor must pay
all moneys withheld from the subcontractor to the Department. The Department withholds these moneys
pending the final decision of an enforcement action.

April 11, 2011 4-16

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Replace the seventh paragraph with the following:

Changes in general prevailing wage determinations apply to the contract when the Director of Industrial
Relations has issued them at least 10 days before release of the RFP (Labor Code § 1773.6 and 8 CA
Code of Regs 16204).
7-1.01A(2)(a) Travel and Subsistence Payments
Provisions regarding Travel and Subsistence Payments are applicable to this project.
7-1.01A(3) Payroll Records
Provisions regarding Payroll Records are applicable to this project with the modifications noted below.
Replace the second paragraph with the following:
The Department withholds the penalties specified in subdivision (g) of Labor Code § 1776 for
noncompliance with the requirements in Section 1776.
Replace the fourth paragraph with the following:
The Department withholds for delinquent or inadequate payroll records (Labor Code § 1771.5). If the
Contractor has not submitted an adequate payroll record by the month's 15th day for the period ending on
or before the 1st of that month, the Department withholds 10 percent of the monthly progress estimate,
exclusive of mobilization. The Department does not withhold more than $10,000 or less than $1,000.
Delete the fifth paragraph.
7-1.01A(4) Labor Nondiscrimination
Provisions regarding Labor Nondiscrimination are applicable to this project.
7-1.01A(5) Apprentices
Provisions regarding Apprentices are applicable to this project.
7-1.01A(6) (Blank)
7-1.01A(7) (Blank)
7-1.01B Fair Labor Standards Act
Provisions regarding Fair Labor Standards Act are applicable to this project.
7-1.01C Contractor’s Licensing Laws
Provisions regarding Contractor’s Licensing Laws are applicable to this project.
7-1.01D Vehicle Code
Provisions regarding Vehicle Code are applicable to this project.
7-1.01E Trench Safety
Provisions regarding Trench Safety are applicable to this project.
7-1.01F Air Pollution Control
Provisions regarding Air Pollution Control are deleted in their entirety and are replaced with the
following:
7-1.01F Environmental Stewardship
Comply with Section 14. “Environmental Stewardship” of the Amended Standard Specifications

April 11, 2011 4-17

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

7-1.01G Water Pollution

Provisions regarding Water Pollution are applicable to this project.
7-1.01H Use of Pesticides
Provisions regarding Use of Pesticides are applicable to this project.
7-1.01I (Blank)
7-1.01J Assignment of Antitrust Action
Provisions regarding Assignment of Antitrust Actions are applicable to this project.
7-1.02 Load Limitations
Provisions regarding Load Limitations are applicable to this project with the modifications noted below.
Replace the fourth sentence in the second paragraph with the following:
Trucks used to haul treated base, portland cement concrete, or hot mix asphalt shall enter onto the base to
dump at the nearest practical entry point ahead of spreading equipment.
Add the following between the fourth and the fifth paragraph:
Loads imposed on existing, new, or partially completed structures shall not exceed the load carrying
capacity of the structure or any portion of the structure as determined by AASHTO LRFD with interims
and California Amendments, Design Strength Limit State II. The compressive strength of concrete (f'c)
to be used in computing the load carrying capacity shall be the smaller of the following:
1. Actual compressive strength at the time of loading
2. Value of f'c shown on the plans for that portion of the structure or 2.5 times the value of fc
(extreme fiber compressive stress in concrete at service loads) shown on the plans for portions of the
structure where no f'c is shown
7-1.03 Payment of Taxes
Provisions regarding Payment of Taxes are deleted in their entirety and are set forth in Section 11
“Payment” of the Contract Documents.
7-1.04 Permits and Licenses
Provisions regarding Permits and Licenses are deleted in their entirety and are set forth in Section 2
“Obligations of Design-Builder” and are set forth in the Technical Provisions of the Contract Documents.
7-1.05 Patents
Provisions regarding Patents are deleted in their entirety and are set forth in Section 18 “Indemnification”
of the Contract Documents.
7-1.06 Safety and Health Provisions
Provisions regarding Safety and Health Provisions are deleted in their entirety and are set forth in Section
16, “Default” of the Contract Documents.
7-1.07 (Blank)
Replace the section including the heading with the following:
7-1.07 Lead Compliance Plan
Prepare a work plan to prevent or minimize worker exposure to lead while managing and handling earth
materials, paint system debris, traffic stripe residue, and pavement marking residue containing lead.

April 11, 2011 4-18

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Regulations containing specific Cal/OSHA requirements when working with lead include 8 CA Code of
Regs § 1532.1.
The plan must contain the items listed in 8 CA Code of Regs § 1532.1(e)(2)(B). Before submittal, a CIH
must sign and seal the plan. Submit the plan at least 7 days before starting any activity that presents the
potential for lead exposure. The Engineer notifies you of the acceptability of the plan within 4 business
days of receipt.
Before starting any activity that presents the potential for lead exposure to employees who have no prior
training, including State employees, provide a safety training program to these employees that complies
with 8 CA Code of Regs § 1532.1 and your lead compliance program.
Submit copies of air monitoring or job site inspection reports made by or under the direction of the CIH
under 8 CA Code of Regs § 1532.1 within 10 days after the date of monitoring or inspection.
Supply personal protective equipment, training, and washing facilities required by your lead compliance
plan for 5 State employees.
The Contract Price includes full compensation for furnishing all labor, materials, tools, equipment, and
incidentals, and for doing all the work involved in preparing and implementing the plan as specified in
this section.

7-1.08 Public Convenience

Provisions regarding Public Convenience are applicable to this project, with the modifications noted
below, except when these Specifications refer to “extra work,” “compensation for,” “at the Department’s
expense,” “quantity adjustments,” “equivalent quantities,” or similar phrases, such references shall be
disregarded. It is the intent that the payment of the Contract Price will be full compensation for all Work
performed pursuant to the Design-Build Contract unless specific provisions for additional payments are
contained in the Contract Documents.
Replace the section with the following:
Compliance with the provisions of this section does not relieve you of your responsibility for public
safety.
Construction activities must not inconvenience the public or abutting property owners. Schedule and
conduct work to avoid unnecessary inconvenience to the public and abutting property owners. Avoid
undue delay in construction activities to reduce the public's exposure to construction.
Where possible, route traffic on new or existing paved surfaces.
Maintain convenient access to driveways, houses, and buildings. When the abutting property owner's
access across the right of way line is to be eliminated or replaced under the contract, the existing access
must not be closed until the replacement access facilities are usable. Construct temporary approaches to
crossings and intersecting highways.
Provide a reasonably smooth and even surface for use by traffic at all time during excavation of roadways
and construction of embankments. Before other grading activities, place fill at culverts and bridges to
allow traffic to cross. If ordered, excavate roadway cuts in layers and construct embankments in partial
widths at a time alternating construction from one side to the other and routing traffic over the side
opposite the one under construction. Install or construct culverts on only 1/2 the width of the traveled
way at a time; keep the traveled way portion being used by traffic open and unobstructed until the
opposite side of the traveled way is ready for use by traffic.

April 11, 2011 4-19

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Upon completion of rough grading or placing any subsequent layer, bring the surface of the roadbed to a
smooth and even condition, free of humps and depressions and satisfactory for the use of the public.
After subgrade preparation for a specified layer of material has been completed, repair any damage to the
roadbed or completed subgrade, including damage due to use by the public.
While subgrade and paving activities are underway, allow the public to use the shoulders. If half-width
paving methods are used, allow the public to use the side of the roadbed opposite the one under
construction. If enough width is available, keep open a passageway wide enough to accommodate at least
2 lanes of traffic at locations where subgrade and paving activities are underway. Shape shoulders or
reshape subgrade as necessary to accommodate traffic during subgrade preparation and paving activities.
Apply water or dust palliative for the prevention or alleviation of dust nuisance.
Install signs, lights, flares, temporary railing (Type K), barricades and other facilities to direct traffic.
Furnish flaggers whenever necessary to direct the movement of the public through or around the work.
You will be required to pay the cost of replacing or repairing all facilities installed under extra work for
the convenience or direction or warning of the public which are lost while in your custody, or are
damaged by your operations to such an extent as to require replacement or repair.
The Engineer may order or consent to your request to open a completed section of surfacing, pavement,
or structure roadway surface for public use. You will not be compensated for any delay to your
construction activities caused by the public. This does not relieve you from any other contractual
responsibility.
7-1.09 Public Safety
Provisions regarding Public Safety are applicable to this project, with the modifications noted below,
except when these Specifications refer to Section 5-1.02 Plans and Working Drawings. Provisions
regarding plans, working drawings, shop drawings, and other construction documents are hereby deleted
in their entirety and are set forth in the Technical Provisions, and the Engineering Documents and
requirements applicable to specific portions of the Work may be identified with particularity in such
sections.
Replace the section with the following:
You are responsible to provide for public safety.
Do not construct a temporary facility that interferes with the safe passage of traffic.
Control dust resulting from the work, inside and outside the right-of-way.
Move workers, equipment, and materials without endangering traffic.
Whenever your operations create a condition hazardous to the public, furnish, erect and maintain those
fences, temporary railing, barricades, lights, signs, and other devices and take any other necessary
protective measures to prevent damage or injury to the public.
Any fences, temporary railing, barricades, lights, signs, or other devices furnished, erected and
maintained by you are in addition to those for which payment is provided elsewhere in the specifications.
Provide flaggers whenever necessary to ensure that the public is given safe guidance through the work
zone. Except as ordered, at locations where traffic is being routed through construction under one-way
controls, move your equipment in compliance with the one-way controls.
Use of signs, lights, flags, or other protective devices must conform with the California MUTCD and as
ordered. Signs, lights, flags or other protective devices must not obscure the visibility of, nor conflict in

April 11, 2011 4-20

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

intent, meaning and function of either existing signs, lights and traffic control devices or any construction
area signs or traffic control devices.
Keep existing traffic signals and highway lighting in operation. Other entities perform routine
maintenance of these facilities during the work.
Cover signs that direct traffic to a closed area. Providing, maintaining, and removing the covers on
construction area signs is paid as extra work under Section 4-1.03D, "Extra Work."
Install temporary illumination in a manner which the illumination and the illumination equipment does
not interfere with public safety. The installation of general roadway illumination does not relieve you
from furnishing and maintaining any protective devices.
Equipment must enter and leave the highway via existing ramps and crossovers and must move in the
direction of public traffic. All movements of workmen and construction equipment on or across lanes
open to public traffic must be performed in a manner that will not endanger the public. Your vehicles or
other mobile equipment leaving an open traffic lane to enter the construction area, must slow down
gradually in advance of the location of the turnoff to give traffic following an opportunity to slow down.
When leaving a work area and entering a roadway carrying public traffic, your vehicles and equipment
must yield to public traffic.
Immediately remove hauling spillage from roadway lanes or shoulders open to traffic. When hauling on
roadways, trim loads and remove material from shelf areas to minimize spillage.
Notify the Engineer not less than 20 days and not more than 90 days before the anticipated start of an
activity that will change the vertical or horizontal clearance available to public traffic, including
shoulders.
If vertical clearance is temporarily reduced to 15.5 feet or less, place low clearance warning signs in
accordance with the California MUTCD and as ordered. Signs must comply with the dimensions, color,
and legend requirements of the California MUTCD and these specifications except that the signs must
have black letters and numbers on an orange retroreflective background. W12-2P signs must be
illuminated so that the signs are clearly visible.
Pave or provide full width continuous and cleared wood walks for pedestrian openings through falsework.
Protect pedestrians from falling objects and curing water for concrete. Extend overhead protection for
pedestrians not less than 4 feet beyond the edge of the bridge deck. Illuminate all pedestrian openings
through falsework. Temporary pedestrian facilities must comply with the American with Disabilities Act
of 1990 (ADA).
Do not store vehicles, material, or equipment in a way that:
1. Creates a hazard to the public
2. Obstructs traffic control devices

Do not install or place temporary facilities used to perform the work which interfere with the free and safe
passage of public traffic.
If you appear to be neglectful or negligent in furnishing warning devices and taking protective measures,
the Engineer may direct your attention to the existence of a hazard and the necessary warning devices
must be furnished and installed and protective measures taken by you. If the Engineer points out the
inadequacy of warning devices and protective measures, that action on the part of the Engineer does not
relieve you from your responsibility for public safety or abrogate the obligation to furnish and pay for
these devices and measures.

April 11, 2011 4-21

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Install temporary railing (Type K) or other approved protection system under the following conditions:
1. Excavations: Where the near edge of the excavation is within 15 feet from the edge of an open
traffic lane
2. Temporarily Unprotected Permanent Obstacles: When the work includes the installation of a
fixed obstacle together with a protective system, such as a sign structure together with protective railing,
and you elect to install the obstacle before installing the protective system; or you, for your convenience
and as authorized, remove a portion of an existing protective railing at an obstacle and do not replace such
railing completely the same day
3. Storage Areas: When material or equipment is stored within 15 feet of the edge of an open traffic
lane and the storage is not otherwise prohibited by the provisions of these Standard Specifications and the
special provisions
4. Height Differentials: When construction operations create a height differential greater than 0.15
feet within 15 feet of the edge of traffic lane
Temporary railing (Type K) does not need to be installed where excavations within 15 feet from edge of
an open traffic lane are:
1. Covered with steel plates or concrete covers of adequate thickness to prevent accidental entry by
traffic or the public
2. In side slopes, where the downhill slope is 4:1 (horizontal:vertical) or less unless a naturally
occurring condition
3. Protected by existing barrier or railing
Offset the approach end of temporary railing (Type K) a minimum of 15 feet from the edge of an open
traffic lane. Install the temporary railing on a skew toward the edge of the traffic lane of not more than
one foot transversely to 10 feet longitudinally with respect to the edge of the traffic lane. If the 15-foot
minimum offset cannot be achieved, the temporary railing must be installed on the 10 to 1 skew to obtain
the maximum available offset between the approach end of the railing and the edge of the traffic lane, and
an array of temporary crash cushion modules must be installed at the approach end of the temporary
railing.
Secure in place temporary railing (Type K) before starting work for which the temporary railing is
required.
Where 2 or more lanes in the same direction are adjacent to the area where the work is being performed,
including shoulders, the adjacent lane must be closed under any of the following conditions:
1. Work is off the traveled way but within 6 feet of the edge of traveled way, and approach speed is
greater than 45 miles per hour
2. Work is off the traveled way but within 3 feet of the edge of traveled way, and approach speed is
less than 45 miles per hour
Closure of the adjacent traffic lane is not required when:
1. Performing work behind a barrier
2. Paving, grinding, or grooving
3. Installing, maintaining, or removing traffic control devices except temporary railing (Type K)
Do not reduce an open traffic lane width to less than 10 feet. When traffic cones or delineators are used
for temporary edge delineation, the line of cones or delineators is considered the edge of the traveled way.

April 11, 2011 4-22

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

If a traffic lane is closed with channelizers for excavation work, move the devices to the adjacent edge of
the traveled way when not excavating. Space the devices the same as specified for the lane closure.
Do not move or temporarily suspend anything over a traffic lane open to the public unless the public is
protected.
7-1.10 Use of Explosives
Provisions regarding Use of Explosives are applicable to this project
7-1.11 Preservation of Property
Provisions regarding Preservation of Property are deleted in their entirety and are replaced with the
following:
Comply with Section 5-1.18, "Property and Facility Preservation."
7-1.12 Indemnification and Insurance
Provisions regarding Indemnification and Insurance are deleted in their entirety and are set forth in
Section 18 “Indemnification” and Section 9 “Insurance” of the Contract Documents.
7-1.12A Indemnification
Provisions regarding Indemnification are deleted in their entirety and are set forth in Section 18
“Indemnification” of the Contract Documents.
7-1.12B Insurance
Provisions regarding Insurance are deleted in their entirety and are set forth in Section 9 “Insurance” of
the Contract Documents.
7-1.12B(1) Casualty Insurance
Provisions regarding Casualty Insurance are deleted in their entirety and are set forth in Section 9
“Insurance” of the Contract Documents.
7-1.12B(1)(a) Workers’ Compensation and Employer’s Liability Insurance
Provisions regarding Workers’ Compensation and Employer’s Liability Insurance are deleted in their
entirety and are set forth in Section 9 “Insurance” of the Contract Documents.
7-1.12B(1)(b) Liability Insurance
Provisions regarding Liability Insurance are deleted in their entirety and are set forth in Section 9
“Insurance” of the Contract Documents.
7-1.12B(1)(c) Liability Limits/Additional Insureds
Provisions regarding Liability Limits/Additional Insureds are deleted in their entirety and are set forth in
Section 9 “Insurance” of the Contract Documents.
7-1.12B(2) Automobile Liability Insurance
Provisions regarding Automobile Liability Insurance are deleted in their entirety and are set forth in
Section 9 “Insurance” of the Contract Documents.
7-1.12B(3) Policy Forms, Endorsements and Certificates
Provisions regarding Policy Forms, Endorsements and Certificates are deleted in their entirety and are set
forth in Section 9 “Insurance” of the Contract Documents.

April 11, 2011 4-23

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

7-1.12B(4) Enforcement
Provisions regarding Enforcement are deleted in their entirety and are set forth in Section 9 “Insurance”
of the Contract Documents.
7-1.12B(5) Self-Insurance
Provisions regarding Self-Insurance are deleted in their entirety and are set forth in Section 9 “Insurance”
of the Contract Documents.
7-1.12B(6) Miscellaneous
Provisions regarding Miscellaneous are deleted in their entirety and are set forth in Section 9 “Insurance”
of the Contract Documents
7-1.125 Legal Actions Against the Department
Provisions regarding Legal Actions Against the Department are applicable to this project with the
modifications noted below.
Replace the section with the following:
If legal action is brought against the Department over compliance with a State or Federal law, rule, or
regulation applicable to highway work, then:
1. If the Department, in complying with a court order, prohibits you from performing work, the
resulting delay is a suspension related to your performance, unless the Department terminates the
contract.
2. If a court order other than an order to show cause or the final judgment in the action prohibits the
Department from requiring you to perform work, the Department may delete the prohibited work or
terminate the contract.
7-1.13 Disposal of Materials Outside the Highway Right of Way
Provisions regarding Disposal of Materials Outside the Highway Right of Way are applicable to this
project, with the modifications noted below, except when these Specifications refer to Section 2-1.03
“Examination of Plans, Specifications, Contract, and Site of Work. Provisions regarding plans, working
drawings, shop drawings, and other construction documents are hereby deleted in their entirety and are set
forth in the Technical Provisions, and the Engineering Documents and requirements applicable to specific
portions of the Work may be identified with particularity in such sections.
Delete the fifth and sixth paragraphs.
7-1.14 Cooperation
Provisions regarding Cooperation are applicable to this project.
7-1.15 Relief from Maintenance and Responsibility
Provisions regarding Relief from Maintenance and Responsibility are deleted in their entirety and are set
forth in Section 10 “Risk of Loss” of the Contract Documents.
7-1.16 Contractor’s Responsibility for the Work and Materials
Provisions regarding Contractor’s Responsibility for the Work and Materials are deleted in their entirety
and are set forth in Section 10 “Risk of Loss” of the Contract Documents.
7-1.165 Damage by Storm, Flood, Tsunami or Earthquake
Provisions regarding Damage by Storm, Flood, Tsunami or Earthquake are deleted in their entirety and
are set forth in Section 13 “Changes in the Work” of the Contract Documents.

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7-1.17 Acceptance of Contract

Provisions regarding Acceptance of Contract are deleted in their entirety and are set forth in Section 20
“Acceptance of Project” of the Contract Documents.
7-1.18 Property Rights in Materials
Provisions regarding Property Rights in Materials are deleted in their entirety and are set forth in Section
11 “Payment” of the Contract Documents.
7-1.19 Rights in Land and Improvements
Provisions regarding Rights in Land and Improvements are applicable to this project.
7-1.20 Personal Liability
Provisions regarding Personal liability are deleted in their entirety and are set forth in Section 23
“Miscellaneous Provisions” of the Contract Documents.
7-1.21 Repair of Equipment
Provisions regarding Repair of Equipment are deleted in their entirety and are set forth in Section 10
“Risk of Loss” and Section 21 “Warranties” of the Contract Documents.
7-1.22 Material Plants
Provisions regarding Material Plants are deleted in their entirety.
7-1.50 Federal Laws For Federal-Aid Contracts
7-1.50A General
Section 7-1.50, "Federal Laws for Federal-Aid Contracts," includes specifications required in a Federal-
aid construction contract and applies to a Federal-aid contract.
Form FHWA-1273 is included in the contract in Section 7-1.50B, "FHWA-1273." Some contract terms
on the form are different than those used in other contract parts as shown in the following table:

FHWA-1273 Terms and Department Equivalencies

FHWA-1273 Term Equivalent Term Used in Other
Contract Parts
SHA Department
SHA contracting officer Engineer
SHA resident engineer Engineer

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7-1.50B FHWA-1273
FHWA-1273 Electronic version -- March 10, 1994
with revised Section VI
REQUIRED CONTRACT PROVISIONS FEDERAL-AID CONSTRUCTION CONTRACTS
I. General
II. Nondiscrimination
III. Nonsegregated Facilities
IV. Payment of Predetermined Minimum Wage
V. Statements and Payrolls
VI. Record of Materials, Supplies, and Labor
VII. Subletting or Assigning the Contract
VIII. Safety: Accident Prevention
IX. False Statements Concerning Highway Projects
X. Implementation of Clean Air Act and Federal Water Pollution Control Act
XI. Certification Regarding Debarment, Suspension, Ineligibility, and Voluntary Exclusion
XII. Certification Regarding Use of Contract Funds for Lobbying
ATTACHMENTS
A. Employment Preference for Appalachian Contracts (included in Appalachian contracts only)
I. GENERAL
1. These contract provisions shall apply to all work performed on the contract by the contractor’s
own organization and with the assistance of workers under the contractor’s immediate
superintendence and to all work performed on the contract by piecework, station work, or by
subcontract.
2. Except as otherwise provided for in each section, the contractor shall insert in each subcontract all
of the stipulations contained in these Required Contract Provisions, and further require their
inclusion in any lower tier subcontract or purchase order that may in turn be made. The Required
Contract Provisions shall not be incorporated by reference in any case. The prime contractor shall
be responsible for compliance by any subcontractor or lower tier subcontractor with these
Required Contract Provisions.
3. A breach of any of the stipulations contained in these Required Contract Provisions shall be
sufficient grounds for termination of the contract.
4. A breach of the following clauses of the Required Contract Provisions may also be grounds for
debarment as provided in 29 CFR 5.12:

Section I, paragraph 2;
Section IV, paragraphs 1, 2, 3, 4, and 7;
Section V, paragraphs 1 and 2a through 2g.

5. Disputes arising out of the labor standards provisions of Section IV (except paragraph 5) and
Section V of these Required Contract Provisions shall not be subject to the general disputes
clause of this contract. Such disputes shall be resolved in accordance with the procedures of the
U.S. Department of Labor (DOL) as set forth in 29 CFR 5, 6, and 7. Disputes within the meaning
of this clause include disputes between the contractor (or any of its subcontractors) and the
contracting agency, the DOL, or the contractor’s employees or their representatives.
6. Selection of Labor: During the performance of this contract, the contractor shall not:

a. discriminate against labor from any other State, possession, or territory of the United States
(except for employment preference for Appalachian contracts, when applicable, as specified
in Attachment A), or

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b. employ convict labor for any purpose within the limits of the project unless it is labor
performed by convicts who are on parole, supervised release, or probation.

II. NONDISCRIMINATION
(Applicable to all Federal-aid construction contracts and to all related subcontracts of $10,000 or
more.)
1. Equal Employment Opportunity: Equal employment opportunity (EEO) requirements not to
discriminate and to take affirmative action to assure equal opportunity as set forth under laws,
executive orders, rules, regulations (28 CFR 35, 29 CFR 1630 and 41 CFR 60) and orders of the
Secretary of Labor as modified by the provisions prescribed herein, and imposed pursuant to 23
U.S.C. 140 shall constitute the EEO and specific affirmative action standards for the contractor’s
project activities under this contract. The Equal Opportunity Construction Contract Specifications
set forth under 41 CFR 60-4.3 and the provisions of the American Disabilities Act of 1990 (42
U.S.C. 12101 et seq.) set forth under 28 CFR 35 and 29 CFR 1630 are incorporated by reference
in this contract. In the execution of this contract, the contractor agrees to comply with the
following minimum specific requirement activities of EEO:

a. The contractor will work with the State highway agency (SHA) and the Federal Government
in carrying out EEO obligations and in their review of his/her activities under the contract.
b. The contractor will accept as his operating policy the following statement:

"It is the policy of this Company to assure that applicants are employed, and that employees
are treated during employment, without regard to their race, religion, sex, color, national
origin, age or disability. Such action shall include: employment, upgrading, demotion, or
transfer; recruitment or recruitment advertising; layoff or termination; rates of pay or other
forms of compensation; and selection for training, including apprenticeship,
preapprenticeship, and/or on-the-job training."

2. EEO Officer: The contractor will designate and make known to the SHA contracting officers an
EEO Officer who will have the responsibility for and must be capable of effectively
administering and promoting an active contractor program of EEO and who must be assigned
adequate authority and responsibility to do so.
3. Dissemination of Policy: All members of the contractor’s staff who are authorized to hire,
supervise, promote, and discharge employees, or who recommend such action, or who are
substantially involved in such action, will be made fully cognizant of, and will implement, the
contractor’s EEO policy and contractual responsibilities to provide EEO in each grade and
classification of employment. To ensure that the above agreement will be met, the following
actions will be taken as a minimum:

a. Periodic meetings of supervisory and personnel office employees will be conducted before
the start of work and then not less often than once every six months, at which time the
contractor’s EEO policy and its implementation will be reviewed and explained. The
meetings will be conducted by the EEO Officer.
b. All new supervisory or personnel office employees will be given a thorough indoctrination by
the EEO Officer, covering all major aspects of the contractor’s EEO obligations within thirty
days following their reporting for duty with the contractor.
c. All personnel who are engaged in direct recruitment for the project will be instructed by the
EEO Officer in the contractor’s procedures for locating and hiring minority group employees.
d. Notices and posters setting forth the contractor’s EEO policy will be placed in areas readily
accessible to employees, applicants for employment and potential employees.

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e. The contractor’s EEO policy and the procedures to implement such policy will be brought to
the attention of employees by means of meetings, employee handbooks, or other appropriate
means.

4. Recruitment: When advertising for employees, the contractor will include in all advertisements
for employees the notation: "An Equal Opportunity Employer." All such advertisements will be
placed in publications having a large circulation among minority groups in the area from which
the project work force would normally be derived.

a. The contractor will, unless precluded by a valid bargaining agreement, conduct systematic
and direct recruitment through public and private employee referral sources likely to yield
qualified minority group applicants. To meet this requirement, the contractor will identify
sources of potential minority group employees, and establish with such identified sources
procedures whereby minority group applicants may be referred to the contractor for
employment consideration.
b. In the event the contractor has a valid bargaining agreement providing for exclusive hiring
hall referrals, he is expected to observe the provisions of that agreement to the extent that the
system permits the contractor's compliance with EEO contract provisions. (The DOL has held
that where implementation of such agreements have the effect of discriminating against
minorities or women, or obligates the contractor to do the same, such implementation violates
Executive Order 11246, as amended.)
c. The contractor will encourage his present employees to refer minority group applicants for
employment. Information and procedures with regard to referring minority group applicants
will be discussed with employees.

5. Personnel Actions: Wages, working conditions, and employee benefits shall be established and
administered, and personnel actions of every type, including hiring, upgrading, promotion,
transfer, demotion, layoff, and termination, shall be taken without regard to race, color, religion,
sex, national origin, age or disability. The following procedures shall be followed:

a. The contractor will conduct periodic inspections of project sites to insure that working
conditions and employee facilities do not indicate discriminatory treatment of project site
personnel.
b. The contractor will periodically evaluate the spread of wages paid within each classification
to determine any evidence of discriminatory wage practices.
c. The contractor will periodically review selected personnel actions in depth to determine
whether there is evidence of discrimination. Where evidence is found, the contractor will
promptly take corrective action. If the review indicates that the discrimination may extend
beyond the actions reviewed, such corrective action shall include all affected persons.
d. The contractor will promptly investigate all complaints of alleged discrimination made to the
contractor in connection with his obligations under this contract, will attempt to resolve such
complaints, and will take appropriate corrective action within a reasonable time. If the
investigation indicates that the discrimination may affect persons other than the complainant,
such corrective action shall include such other persons. Upon completion of each
investigation, the contractor will inform every complainant of all of his avenues of appeal.

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6. Training and Promotion:

a. The contractor will assist in locating, qualifying, and increasing the skills of minority group
and women employees, and applicants for employment.
b. Consistent with the contractor’s work force requirements and as permissible under Federal
and State regulations, the contractor shall make full use of training programs, i.e.,
apprenticeship, and on-the-job training programs for the geographical area of contract
performance. Where feasible, 25 percent of apprentices or trainees in each occupation shall
be in their first year of apprenticeship or training. In the event a special provision for training
is provided under this contract, this subparagraph will be superseded as indicated in the
special provision.
c. The contractor will advise employees and applicants for employment of available training
programs and entrance requirements for each.
d. The contractor will periodically review the training and promotion potential of minority
group and women employees and will encourage eligible employees to apply for such
training and promotion.

7. Unions: If the contractor relies in whole or in part upon unions as a source of employees, the
contractor will use his/her best efforts to obtain the cooperation of such unions to increase
opportunities for minority groups and women within the unions, and to effect referrals by such
unions of minority and female employees. Actions by the contractor either directly or through a
contractor’s association acting as agent will include the procedures set forth below:

a. The contractor will use best efforts to develop, in cooperation with the unions, joint training
programs aimed toward qualifying more minority group members and women for
membership in the unions and increasing the skills of minority group employees and women
so that they may qualify for higher paying employment.
b. The contractor will use best efforts to incorporate an EEO clause into each union agreement
to the end that such union will be contractually bound to refer applicants without regard to
their race, color, religion, sex, national origin, age or disability.
c. The contractor is to obtain information as to the referral practices and policies of the labor
union except that to the extent such information is within the exclusive possession of the
labor union and such labor union refuses to furnish such information to the contractor, the
contractor shall so certify to the SHA and shall set forth what efforts have been made to
obtain such information.
d. In the event the union is unable to provide the contractor with a reasonable flow of minority
and women referrals within the time limit set forth in the collective bargaining agreement, the
contractor will, through independent recruitment efforts, fill the employment vacancies
without regard to race, color, religion, sex, national origin, age or disability; making full
efforts to obtain qualified and/or qualifiable minority group persons and women. (The DOL
has held that it shall be no excuse that the union with which the contractor has a collective
bargaining agreement providing for exclusive referral failed to refer minority employees.) In
the event the union referral practice prevents the contractor from meeting the obligations
pursuant to Executive Order 11246, as amended, and these specifications, such contractor
shall immediately notify the SHA.

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8. Selection of Subcontractors, Procurement of Materials and Leasing of Equipment: The

contractor shall not discriminate on the grounds of race, color, religion, sex, national origin, age
or disability in the selection and retention of subcontractors, including procurement of materials
and leases of equipment.

a. The contractor shall notify all potential subcontractors and suppliers of his/her EEO
obligations under this contract.
b. Disadvantaged business enterprises (DBE), as defined in 49 CFR 23, shall have equal
opportunity to compete for and perform subcontracts which the contractor enters into
pursuant to this contract. The contractor will use his best efforts to solicit bids from and to
utilize DBE subcontractors or subcontractors with meaningful minority group and female
representation among their employees. Contractors shall obtain lists of DBE construction
firms from SHA personnel.
c. The contractor will use his best efforts to ensure subcontractor compliance with their EEO
obligations.

9. Records and Reports: The contractor shall keep such records as necessary to document
compliance with the EEO requirements. Such records shall be retained for a period of three years
following completion of the contract work and shall be available at reasonable times and places
for inspection by authorized representatives of the SHA and the FHWA.

a. The records kept by the contractor shall document the following:

1. The number of minority and non-minority group members and women employed in
each work classification on the project;
2. The progress and efforts being made in cooperation with unions, when applicable,
to increase employment opportunities for minorities and women;
3. The progress and efforts being made in locating, hiring, training, qualifying, and
upgrading minority and female employees; and
4. The progress and efforts being made in securing the services of DBE
subcontractors or subcontractors with meaningful minority and female
representation among their employees.

b. The contractors will submit an annual report to the SHA each July for the duration of the
project, indicating the number of minority, women, and non-minority group employees
currently engaged in each work classification required by the contract work. This information
is to be reported on Form FHWA-1391. If on-the-job training is being required by special
provision, the contractor will be required to collect and report training data.

III. NONSEGREGATED FACILITIES

(Applicable to all Federal-aid construction contracts and to all related subcontracts of $10,000 or
more.)
a. By submission of this bid, the execution of this contract or subcontract, or the consummation of
this material supply agreement or purchase order, as appropriate, the bidder, Federal-aid
construction contractor, subcontractor, material supplier, or vendor, as appropriate, certifies that
the firm does not maintain or provide for its employees any segregated facilities at any of its
establishments, and that the firm does not permit its employees to perform their services at any
location, under its control, where segregated facilities are maintained. The firm agrees that a
breach of this certification is a violation of the EEO provisions of this contract. The firm further

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certifies that no employee will be denied access to adequate facilities on the basis of sex or
disability.
b. As used in this certification, the term "segregated facilities" means any waiting rooms, work
areas, restrooms and washrooms, restaurants and other eating areas, timeclocks, locker rooms,
and other storage or dressing areas, parking lots, drinking fountains, recreation or entertainment
areas, transportation, and housing facilities provided for employees which are segregated by
explicit directive, or are, in fact, segregated on the basis of race, color, religion, national origin,
age or disability, because of habit, local custom, or otherwise. The only exception will be for the
disabled when the demands for accessibility override (e.g. disabled parking).
c. The contractor agrees that it has obtained or will obtain identical certification from proposed
subcontractors or material suppliers prior to award of subcontracts or consummation of material
supply agreements of $10,000 or more and that it will retain such certifications in its files.

IV. PAYMENT OF PREDETERMINED MINIMUM WAGE

(Applicable to all Federal-aid construction contracts exceeding $2,000 and to all related
subcontracts, except for projects located on roadways classified as local roads or rural minor
collectors, which are exempt.)
1. General:
a. All mechanics and laborers employed or working upon the site of the work will be paid
unconditionally and not less often than once a week and without subsequent deduction or
rebate on any account [except such payroll deductions as are permitted by regulations (29
CFR 3) issued by the Secretary of Labor under the Copeland Act (40 U.S.C. 276c)] the full
amounts of wages and bona fide fringe benefits (or cash equivalents thereof) due at time of
payment. The payment shall be computed at wage rates not less than those contained in the
wage determination of the Secretary of Labor (hereinafter "the wage determination") which is
attached hereto and made a part hereof, regardless of any contractual relationship which may
be alleged to exist between the contractor or its subcontractors and such laborers and
mechanics. The wage determination (including any additional classifications and wage rates
conformed under paragraph 2 of this Section IV and the DOL poster (WH-1321) or Form
FHWA-1495) shall be posted at all times by the contractor and its subcontractors at the site of
the work in a prominent and accessible place where it can be easily seen by the workers. For
the purpose of this Section, contributions made or costs reasonably anticipated for bona fide
fringe benefits under Section 1(b) (2) of the Davis- Bacon Act (40 U.S.C. 276a) on behalf of
laborers or mechanics are considered wages paid to such laborers or mechanics, subject to the
provisions of Section IV, paragraph 3b, hereof. Also, for the purpose of this Section, regular
contributions made or costs incurred for more than a weekly period (but not less often than
quarterly) under plans, funds, or programs, which cover the particular weekly period, are
deemed to be constructively made or incurred during such weekly period. Such laborers and
mechanics shall be paid the appropriate wage rate and fringe benefits on the wage
determination for the classification of work actually performed, without regard to skill,
except as provided in paragraphs 4 and 5 of this Section IV.
b. Laborers or mechanics performing work in more than one classification may be compensated
at the rate specified for each classification for the time actually worked therein, provided, that
the employer’s payroll records accurately set forth the time spent in each classification in
which work is performed.
c. All rulings and interpretations of the Davis-Bacon Act and related acts contained in 29 CFR
1, 3, and 5 are herein incorporated by reference in this contract.

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2. Classification:

a. The SHA contracting officer shall require that any class of laborers or mechanics employed
under the contract, which is not listed in the wage determination, shall be classified in
conformance with the wage determination.
b. The contracting officer shall approve an additional classification, wage rate and fringe
benefits only when the following criteria have been met:

1. the work to be performed by the additional classification requested is not

performed by a classification in the wage determination;
2. the additional classification is utilized in the area by the construction industry;
3. the proposed wage rate, including any bona fide fringe benefits, bears a reasonable
relationship to the wage rates contained in the wage determination; and
4. with respect to helpers, when such a classification prevails in the area in which the
work is performed.

c. If the contractor or subcontractors, as appropriate, the laborers and mechanics (if known) to
be employed in the additional classification or their representatives, and the contracting
officer agree on the classification and wage rate (including the amount designated for fringe
benefits where appropriate), a report of the action taken shall be sent by the contracting
officer to the DOL, Administrator of the Wage and Hour Division, Employment Standards
Administration, Washington, D.C. 20210. The Wage and Hour Administrator, or an
authorized representative, will approve, modify, or disapprove every additional classification
action within 30 days of receipt and so advise the contracting officer or will notify the
contracting officer within the 30-day period that additional time is necessary.
d. In the event the contractor or subcontractors, as appropriate, the laborers or mechanics to be
employed in the additional classification or their representatives, and the contracting officer
do not agree on the proposed classification and wage rate (including the amount designated
for fringe benefits, where appropriate), the contracting officer shall refer the questions,
including the views of all interested parties and the recommendation of the contracting
officer, to the Wage and Hour Administrator for determination. Said Administrator, or an
authorized representative, will issue a determination within 30 days of receipt and so advise
the contracting officer or will notify the contracting officer within the 30-day period that
additional time is necessary.
e. The wage rate (including fringe benefits where appropriate) determined pursuant to paragraph
2c or 2d of this Section IV shall be paid to all workers performing work in the additional
classification from the first day on which work is performed in the classification.

3. Payment of Fringe Benefits:

a. Whenever the minimum wage rate prescribed in the contract for a class of laborers or
mechanics includes a fringe benefit which is not expressed as an hourly rate, the contractor or
subcontractors, as appropriate, shall either pay the benefit as stated in the wage determination
or shall pay another bona fide fringe benefit or an hourly case equivalent thereof.
b. If the contractor or subcontractor, as appropriate, does not make payments to a trustee or
other third person, he/she may consider as a part of the wages of any laborer or mechanic the
amount of any costs reasonably anticipated in providing bona fide fringe benefits under a
plan or program, provided, that the Secretary of Labor has found, upon the written request of
the contractor, that the applicable standards of the Davis-Bacon Act have been met. The

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Secretary of Labor may require the contractor to set aside in a separate account assets for the
meeting of obligations under the plan or program.

4. Apprentices and Trainees (Programs of the U.S. DOL) and Helpers:

a. Apprentices:

1. Apprentices will be permitted to work at less than the predetermined rate for the work they
performed when they are employed pursuant to and individually registered in a bona fide
apprenticeship program registered with the DOL, Employment and Training Administration,
Bureau of Apprenticeship and Training, or with a State apprenticeship agency recognized by
the Bureau, or if a person is employed in his/her first 90 days of probationary employment as
an apprentice in such an apprenticeship program, who is not individually registered in the
program, but who has been certified by the Bureau of Apprenticeship and Training or a State
apprenticeship agency (where appropriate) to be eligible for probationary employment as an
apprentice.
2. The allowable ratio of apprentices to journeyman-level employees on the job site in any craft
classification shall not be greater than the ratio permitted to the contractor as to the entire
work force under the registered program. Any employee listed on a payroll at an apprentice
wage rate, who is not registered or otherwise employed as stated above, shall be paid not less
than the applicable wage rate listed in the wage determination for the classification of work
actually performed. In addition, any apprentice performing work on the job site in excess of
the ratio permitted under the registered program shall be paid not less than the applicable
wage rate on the wage determination for the work actually performed. Where a contractor or
subcontractor is performing construction on a project in a locality other than that in which its
program is registered, the ratios and wage rates (expressed in percentages of the journeyman-
level hourly rate) specified in the contractor’s or subcontractor’s registered program shall be
observed.
3. Every apprentice must be paid at not less than the rate specified in the registered program for
the apprentice’s level of progress, expressed as a percentage of the journeyman-level hourly
rate specified in the applicable wage determination. Apprentices shall be paid fringe benefits
in accordance with the provisions of the apprenticeship program. If the apprenticeship
program does not specify fringe benefits, apprentices must be paid the full amount of fringe
benefits listed on the wage determination for the applicable classification. If the
Administrator for the Wage and Hour Division determines that a different practice prevails
for the applicable apprentice classification, fringes shall be paid in accordance with that
determination.
4. In the event the Bureau of Apprenticeship and Training, or a State apprenticeship agency
recognized by the Bureau, withdraws approval of an apprenticeship program, the contractor
or subcontractor will no longer be permitted to utilize apprentices at less than the applicable
predetermined rate for the comparable work performed by regular employees until an
acceptable program is approved.

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b. Trainees:

1. Except as provided in 29 CFR 5.16, trainees will not be permitted to work at less than the
predetermined rate for the work performed unless they are employed pursuant to and
individually registered in a program which has received prior approval, evidenced by formal
certification by the DOL, Employment and Training Administration.
2. The ratio of trainees to journeyman-level employees on the job site shall not be greater than
permitted under the plan approved by the Employment and Training Administration. Any
employee listed on the payroll at a trainee rate who is not registered and participating in a
training plan approved by the Employment and Training Administration shall be paid not less
than the applicable wage rate on the wage determination for the classification of work
actually performed. In addition, any trainee performing work on the job site in excess of the
ratio permitted under the registered program shall be paid not less than the applicable wage
rate on the wage determination for the work actually performed.
3. Every trainee must be paid at not less than the rate specified in the approved program for
his/her level of progress, expressed as a percentage of the journeyman-level hourly rate
specified in the applicable wage determination. Trainees shall be paid fringe benefits in
accordance with the provisions of the trainee program. If the trainee program does not
mention fringe benefits, trainees shall be paid the full amount of fringe benefits listed on the
wage determination unless the Administrator of the Wage and Hour Division determines that
there is an apprenticeship program associated with the corresponding journeyman-level wage
rate on the wage determination which provides for less than full fringe benefits for
apprentices, in which case such trainees shall receive the same fringe benefits as apprentices.
4. In the event the Employment and Training Administration withdraws approval of a training
program, the contractor or subcontractor will no longer be permitted to utilize trainees at less
than the applicable predetermined rate for the work performed until an acceptable program is
approved.

c. Helpers:

Helpers will be permitted to work on a project if the helper classification is specified and
defined on the applicable wage determination or is approved pursuant to the conformance
procedure set forth in Section IV.2. Any worker listed on a payroll at a helper wage rate, who
is not a helper under an approved definition, shall be paid not less than the applicable wage
rate on the wage determination for the classification of work actually performed.
5. Apprentices and Trainees (Programs of the U.S. DOT):

Apprentices and trainees working under apprenticeship and skill training programs which have
been certified by the Secretary of Transportation as promoting EEO in connection with Federal-
aid highway construction programs are not subject to the requirements of paragraph 4 of this
Section IV. The straight time hourly wage rates for apprentices and trainees under such programs
will be established by the particular programs. The ratio of apprentices and trainees to
journeymen shall not be greater than permitted by the terms of the particular program.
6. Withholding:

The SHA shall upon its own action or upon written request of an authorized representative of the
DOL withhold, or cause to be withheld, from the contractor or subcontractor under this contract
or any other Federal contract with the same prime contractor, or any other Federally-assisted
contract subject to Davis-Bacon prevailing wage requirements which is held by the same prime
contractor, as much of the accrued payments or advances as may be considered necessary to pay

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laborers and mechanics, including apprentices, trainees, and helpers, employed by the contractor
or any subcontractor the full amount of wages required by the contract. In the event of failure to
pay any laborer or mechanic, including any apprentice, trainee, or helper, employed or working
on the site of the work, all or part of the wages required by the contract, the SHA contracting
officer may, after written notice to the contractor, take such action as may be necessary to cause
the suspension of any further payment, advance, or guarantee of funds until such violations have
ceased.
7. Overtime Requirements:

No contractor or subcontractor contracting for any part of the contract work which may require or
involve the employment of laborers, mechanics, watchmen, or guards (including apprentices,
trainees, and helpers described in paragraphs 4 and 5 above) shall require or permit any laborer,
mechanic, watchman, or guard in any workweek in which he/she is employed on such work, to
work in excess of 40 hours in such workweek unless such laborer, mechanic, watchman, or guard
receives compensation at a rate not less than one-and-one-half times his/her basic rate of pay for
all hours worked in excess of 40 hours in such workweek.
8. Violation:

Liability for Unpaid Wages; Liquidated Damages: In the event of any violation of the clause set forth in
paragraph 7 above, the contractor and any subcontractor responsible thereof shall be liable to the affected
employee for his/her unpaid wages. In addition, such contractor and subcontractor shall be liable to the
United States (in the case of work done under contract for the District of Columbia or a territory, to such
District or to such territory) for liquidated damages. Such liquidated damages shall be computed with
respect to each individual laborer, mechanic, watchman, or guard employed in violation of the clause set
forth in paragraph 7, in the sum of $10 for each calendar day on which such employee was required or
permitted to work in excess of the standard work week of 40 hours without payment of the overtime
wages required by the clause set forth in paragraph 7.
9. Withholding for Unpaid Wages and Liquidated Damages:

The SHA shall upon its own action or upon written request of any authorized representative of the
DOL withhold, or cause to be withheld, from any monies payable on account of work performed
by the contractor or subcontractor under any such contract or any other Federal contract with the
same prime contractor, or any other Federally-assisted contract subject to the contract Work
Hours and Safety Standards Act, which is held by the same prime contractor, such sums as may
be determined to be necessary to satisfy any liabilities of such contractor or subcontractor for
unpaid wages and liquidated damages as provided in the clause set forth in paragraph 8 above.
V. STATEMENTS AND PAYROLLS
(Applicable to all Federal-aid construction contracts exceeding $2,000 and to all related
subcontracts, except for projects located on roadways classified as local roads or rural collectors,
which are exempt.)
1. Compliance with Copeland Regulations (29 CFR 3):

The contractor shall comply with the Copeland Regulations of the Secretary of Labor which are
herein incorporated by reference.
2. Payrolls and Payroll Records:

a. Payrolls and basic records relating thereto shall be maintained by the contractor and each
subcontractor during the course of the work and preserved for a period of 3 years from the

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date of completion of the contract for all laborers, mechanics, apprentices, trainees,
watchmen, helpers, and guards working at the site of the work.
b. The payroll records shall contain the name, social security number, and address of each such
employee; his or her correct classification; hourly rates of wages paid (including rates of
contributions or costs anticipated for bona fide fringe benefits or cash equivalent thereof the
types described in Section 1(b)(2)(B) of the Davis Bacon Act); daily and weekly number of
hours worked; deductions made; and actual wages paid. In addition, for Appalachian
contracts, the payroll records shall contain a notation indicating whether the employee does,
or does not, normally reside in the labor area as defined in Attachment A, paragraph 1.
Whenever the Secretary of Labor, pursuant to Section IV, paragraph 3b, has found that the
wages of any laborer or mechanic include the amount of any costs reasonably anticipated in
providing benefits under a plan or program described in Section 1(b)(2)(B) of the Davis
Bacon Act, the contractor and each subcontractor shall maintain records which show that the
commitment to provide such benefits is enforceable, that the plan or program is financially
responsible, that the plan or program has been communicated in writing to the laborers or
mechanics affected, and show the cost anticipated or the actual cost incurred in providing
benefits. Contractors or subcontractors employing apprentices or trainees under approved
programs shall maintain written evidence of the registration of apprentices and trainees, and
ratios and wage rates prescribed in the applicable programs.
c. Each contractor and subcontractor shall furnish, each week in which any contract work is
performed, to the SHA resident engineer a payroll of wages paid each of its employees
(including apprentices, trainees, and helpers, described in Section IV, paragraphs 4 and 5, and
watchmen and guards engaged on work during the preceding weekly payroll period). The
payroll submitted shall set out accurately and completely all of the information required to be
maintained under paragraph 2b of this Section V. This information may be submitted in any
form desired. Optional Form WH-347 is available for this purpose and may be purchased
from the Superintendent of Documents (Federal stock number 029- 005-0014-1), U.S.
Government Printing Office, Washington, D.C. 20402. The prime contractor is responsible
for the submission of copies of payrolls by all subcontractors.
d. Each payroll submitted shall be accompanied by a "Statement of Compliance," signed by the
contractor or subcontractor or his/her agent who pays or supervises the payment of the
persons employed under the contract and shall certify the following:

1. that the payroll for the payroll period contains the information required to be
maintained under paragraph 2b of this Section V and that such information is
correct and complete;
2. that such laborer or mechanic (including each helper, apprentice, and trainee)
employed on the contract during the payroll period has been paid the full weekly
wages earned, without rebate, either directly or indirectly, and that no deductions
have been made either directly or indirectly from the full wages earned, other than
permissible deductions as set forth in the Regulations, 29 CFR 3;
3. that each laborer or mechanic has been paid not less that the applicable wage rate
and fringe benefits or cash equivalent for the classification of worked performed,
as specified in the applicable wage determination incorporated into the contract.

e. The weekly submission of a properly executed certification set forth on the reverse side of
Optional Form WH-347 shall satisfy the requirement for submission of the "Statement of
Compliance" required by paragraph 2d of this Section V.
f. The falsification of any of the above certifications may subject the contractor to civil or
criminal prosecution under 18 U.S.C. 1001 and 31 U.S.C. 231.

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g. The contractor or subcontractor shall make the records required under paragraph 2b of this
Section V available for inspection, copying, or transcription by authorized representatives of
the SHA, the FHWA, or the DOL, and shall permit such representatives to interview
employees during working hours on the job. If the contractor or subcontractor fails to submit
the required records or to make them available, the SHA, the FHWA, the DOL, or all may,
after written notice to the contractor, sponsor, applicant, or owner, take such actions as may
be necessary to cause the suspension of any further payment, advance, or guarantee of funds.
Furthermore, failure to submit the required records upon request or to make such records
available may be grounds for debarment action pursuant to 29 CFR 5.12.

VI. RECORD OF MATERIALS, SUPPLIES, AND LABOR

(As of May 22, 2007, Form FHWA-47 is no longer required.)

VII. SUBLETTING OR ASSIGNING THE CONTRACT

1. The contractor shall perform with its own organization contract work amounting to not less than
30 percent (or a greater percentage if specified elsewhere in the contract) of the total original
contract price, excluding any specialty items designated by the State. Specialty items may be
performed by subcontract and the amount of any such specialty items performed may be deducted
from the total original contract price before computing the amount of work required to be
performed by the contractor’s own organization (23 CFR 635).

a. "Its own organization" shall be construed to include only workers employed and paid directly
by the prime contractor and equipment owned or rented by the prime contractor, with or
without operators. Such term does not include employees or equipment of a subcontractor,
assignee, or agent of the prime contractor.
b. "Specialty Items" shall be construed to be limited to work that requires highly specialized
knowledge, abilities, or equipment not ordinarily available in the type of contracting
organizations qualified and expected to bid on the contract as a whole and in general are to be
limited to minor components of the overall contract.

2. The contract amount upon which the requirements set forth in paragraph 1 of Section VII is
computed includes the cost of material and manufactured products which are to be purchased or
produced by the contractor under the contract provisions.
3. The contractor shall furnish (a) a competent superintendent or supervisor who is employed by the
firm, has full authority to direct performance of the work in accordance with the contract
requirements, and is in charge of all construction operations (regardless of who performs the
work) and (b) such other of its own organizational resources (supervision, management, and
engineering services) as the SHA contracting officer determines is necessary to assure the
performance of the contract.
4. No portion of the contract shall be sublet, assigned or otherwise disposed of except with the
written consent of the SHA contracting officer, or authorized representative, and such consent
when given shall not be construed to relieve the contractor of any responsibility for the
fulfillment of the contract. Written consent will be given only after the SHA has assured that each
subcontract is evidenced in writing and that it contains all pertinent provisions and requirements
of the prime contract.

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VIII. SAFETY: ACCIDENT PREVENTION

1. In the performance of this contract the contractor shall comply with all applicable Federal, State,
and local laws governing safety, health, and sanitation (23 CFR 635). The contractor shall
provide all safeguards, safety devices and protective equipment and take any other needed actions
as it determines, or as the SHA contracting officer may determine, to be reasonably necessary to
protect the life and health of employees on the job and the safety of the public and to protect
property in connection with the performance of the work covered by the contract.
2. It is a condition of this contract, and shall be made a condition of each subcontract, which the
contractor enters into pursuant to this contract, that the contractor and any subcontractor shall not
permit any employee, in performance of the contract, to work in surroundings or under conditions
which are unsanitary, hazardous or dangerous to his/her health or safety, as determined under
construction safety and health standards (29 CFR 1926) promulgated by the Secretary of Labor,
in accordance with Section 107 of the Contract Work Hours and Safety Standards Act (40 U.S.C.
333).
3. Pursuant to 29 CFR 1926.3, it is a condition of this contract that the Secretary of Labor or
authorized representative thereof, shall have right of entry to any site of contract performance to
inspect or investigate the matter of compliance with the construction safety and health standards
and to carry out the duties of the Secretary under Section 107 of the Contract Work Hours and
Safety Standards Act (40 U.S.C. 333).

IX. FALSE STATEMENTS CONCERNING HIGHWAY PROJECTS

In order to assure high quality and durable construction in conformity with approved plans and
specifications and a high degree of reliability on statements and representations made by
Engineers, contractors, suppliers, and workers on Federal-aid highway projects, it is essential that
all persons concerned with the project perform their functions as carefully, thoroughly, and
honestly as possible. Willful falsification, distortion, or misrepresentation with respect to any
facts related to the project is a violation of Federal law. To prevent any misunderstanding
regarding the seriousness of these and similar acts, the following notice shall be posted on each
Federal-aid highway project (23 CFR 635) in one or more places where it is readily available to
all persons concerned with the project:

NOTICE TO ALL PERSONNEL ENGAGED ON FEDERAL-AID HIGHWAY

PROJECTS
18 U.S.C. 1020 reads as follows:
"Whoever, being an officer, agent, or employee of the United States, or of any State or Territory,
or whoever, whether a person, association, firm, or corporation, knowingly makes any false
statement, false representation, or false report as to the character, quality, quantity, or cost of the
material used or to be used, or the quantity or quality of the work performed or to be performed,
or the cost thereof in connection with the submission of plans, maps, specifications, contracts, or
costs of construction on any highway or related project submitted for approval to the Secretary of
Transportation; or
Whoever knowingly makes any false statement, false representation, false report or false claim
with respect to the character, quality, quantity, or cost of any work performed or to be performed,
or materials furnished or to be furnished, in connection with the construction of any highway or
related project approved by the Secretary of Transportation; or
Whoever knowingly makes any false statement or false representation as to material fact in any
statement, certificate, or report submitted pursuant to provisions of the Federal-aid Roads Act
approved July 1, 1916, (39 Stat. 355), as amended and supplemented;
Shall be fined not more that $10,000 or imprisoned not more than 5 years or both."

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X. IMPLEMENTATION OF CLEAN AIR ACT AND FEDERAL WATER POLLUTION

CONTROL ACT
(Applicable to all Federal-aid construction contracts and to all related subcontracts of $100,000 or
more.)
By submission of this bid or the execution of this contract, or subcontract, as appropriate, the
bidder, Federal-aid construction contractor, or subcontractor, as appropriate, will be deemed to
have stipulated as follows:
1. That any facility that is or will be utilized in the performance of this contract, unless such
contract is exempt under the Clean Air Act, as amended (42 U.S.C. 1857 et seq., as amended
by Pub.L. 91-604), and under the Federal Water Pollution Control Act, as amended (33
U.S.C. 1251 et seq., as amended by Pub.L. 92-500), Executive Order 11738, and regulations
in implementation thereof (40 CFR 15) is not listed, on the date of contract award, on the
U.S. Environmental Protection Agency (EPA) List of Violating Facilities pursuant to 40 CFR
15.20.
2. That the firm agrees to comply and remain in compliance with all the requirements of Section
114 of the Clean Air Act and Section 308 of the Federal Water Pollution Control Act and all
regulations and guidelines listed thereunder.
3. That the firm shall promptly notify the SHA of the receipt of any communication from the
Director, Office of Federal Activities, EPA, indicating that a facility that is or will be utilized
for the contract is under consideration to be listed on the EPA List of Violating Facilities.
4. That the firm agrees to include or cause to be included the requirements of paragraph 1 through
4 of this Section X in every nonexempt subcontract, and further agrees to take such action as
the government may direct as a means of enforcing such requirements.

XI. CERTIFICATION REGARDING DEBARMENT, SUSPENSION, INELIGIBILITY AND

VOLUNTARY EXCLUSION
1. Instructions for Certification - Primary Covered Transactions:

(Applicable to all Federal-aid contracts - 49 CFR 29)

a. By signing and submitting this proposal, the prospective primary participant is providing the
certification set out below.
b. The inability of a person to provide the certification set out below will not necessarily result
in denial of participation in this covered transaction. The prospective participant shall submit
an explanation of why it cannot provide the certification set out below. The certification or
explanation will be considered in connection with the department or agency’s determination
whether to enter into this transaction. However, failure of the prospective primary participant
to furnish a certification or an explanation shall disqualify such a person from participation in
this transaction.
c. The certification in this clause is a material representation of fact upon which reliance was
placed when the department or agency determined to enter into this transaction. If it is later
determined that the prospective primary participant knowingly rendered an erroneous
certification, in addition to other remedies available to the Federal Government, the
department or agency may terminate this transaction for cause of default.
d. The prospective primary participant shall provide immediate written notice to the department
or agency to whom this proposal is submitted if any time the prospective primary participant
learns that its certification was erroneous when submitted or has become erroneous by reason
of changed circumstances.
e. The terms "covered transaction," "debarred," "suspended," "ineligible," "lower tier covered
transaction," "participant," "person," "primary covered transaction," "principal," "proposal,"
and "voluntarily excluded," as used in this clause, have the meanings set out in the

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Definitions and Coverage sections of rules implementing Executive Order 12549. You may
contact the department or agency to which this proposal is submitted for assistance in
obtaining a copy of those regulations.
f. The prospective primary participant agrees by submitting this proposal that, should the
proposed covered transaction be entered into, it shall not knowingly enter into any lower tier
covered transaction with a person who is debarred, suspended, declared ineligible, or
voluntarily excluded from participation in this covered transaction, unless authorized by the
department or agency entering into this transaction.
g. The prospective primary participant further agrees by submitting this proposal that it will
include the clause titled "Certification Regarding Debarment, Suspension, Ineligibility and
Voluntary Exclusion-Lower Tier Covered Transaction," provided by the department or
agency entering into this covered transaction, without modification, in all lower tier covered
transactions and in all solicitations for lower tier covered transactions.
h. A participant in a covered transaction may rely upon a certification of a prospective
participant in a lower tier covered transaction that is not debarred, suspended, ineligible, or
voluntarily excluded from the covered transaction, unless it knows that the certification is
erroneous. A participant may decide the method and frequency by which it determines the
eligibility of its principals. Each participant may, but is not required to, check the
nonprocurement portion of the "Lists of Parties Excluded From Federal Procurement or
Nonprocurement Programs" (Nonprocurement List) which is compiled by the General
Services Administration.
i. Nothing contained in the foregoing shall be construed to require establishment of a system of
records in order to render in good faith the certification required by this clause. The
knowledge and information of participant is not required to exceed that which is normally
possessed by a prudent person in the ordinary course of business dealings.
j. Except for transactions authorized under paragraph f of these instructions, if a participant in a
covered transaction knowingly enters into a lower tier covered transaction with a person who
is suspended, debarred, ineligible, or voluntarily excluded from participation in this
transaction, in addition to other remedies available to the Federal Government, the
department or agency may terminate this transaction for cause or default.

*****

Certification Regarding Debarment, Suspension, Ineligibility and

Voluntary Exclusion--Primary Covered Transactions

1. The prospective primary participant certifies to the best of its knowledge and belief, that it and its
principals:

a. Are not presently debarred, suspended, proposed for debarment, declared ineligible, or
voluntarily excluded from covered transactions by any Federal department or agency;
b. Have not within a 3-year period preceding this proposal been convicted of or had a civil
judgement rendered against them for commission of fraud or a criminal offense in connection
with obtaining, attempting to obtain, or performing a public (Federal, State or local)
transaction or contract under a public transaction; violation of Federal or State antitrust
statutes or commission of embezzlement, theft, forgery, bribery, falsification or destruction of
records, making false statements, or receiving stolen property;

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c. Are not presently indicted for or otherwise criminally or civilly charged by a governmental
entity (Federal, State or local) with commission of any of the offenses enumerated in
paragraph 1b of this certification; and
d. Have not within a 3-year period preceding this application/proposal had one or more public
transactions (Federal, State or local) terminated for cause or default.

2. Where the prospective primary participant is unable to certify to any of the statements in this
certification, such prospective participant shall attach an explanation to this proposal.

*****

2. Instructions for Certification - Lower Tier Covered Transactions:

(Applicable to all subcontracts, purchase orders and other lower tier transactions of $25,000 or
more - 49 CFR 29)
a. By signing and submitting this proposal, the prospective lower tier is providing the
certification set out below.
b. The certification in this clause is a material representation of fact upon which reliance was
placed when this transaction was entered into. If it is later determined that the prospective
lower tier participant knowingly rendered an erroneous certification, in addition to other
remedies available to the Federal Government, the department, or agency with which this
transaction originated may pursue available remedies, including suspension and/or
debarment.
c. The prospective lower tier participant shall provide immediate written notice to the person to
which this proposal is submitted if at any time the prospective lower tier participant learns
that its certification was erroneous by reason of changed circumstances.
d. The terms "covered transaction," "debarred," "suspended," "ineligible," "primary covered
transaction," "participant," "person," "principal," "proposal," and "voluntarily excluded," as
used in this clause, have the meanings set out in the Definitions and Coverage sections of
rules implementing Executive Order 12549. You may contact the person to which this
proposal is submitted for assistance in obtaining a copy of those regulations.
e. The prospective lower tier participant agrees by submitting this proposal that, should the
proposed covered transaction be entered into, it shall not knowingly enter into any lower tier
covered transaction with a person who is debarred, suspended, declared ineligible, or
voluntarily excluded from participation in this covered transaction, unless authorized by the
department or agency with which this transaction originated.
f. The prospective lower tier participant further agrees by submitting this proposal that it will
include this clause titled "Certification Regarding Debarment, Suspension, Ineligibility and
Voluntary Exclusion-Lower Tier Covered Transaction," without modification, in all lower
tier covered transactions and in all solicitations for lower tier covered transactions.
g. A participant in a covered transaction may rely upon a certification of a prospective
participant in a lower tier covered transaction that is not debarred, suspended, ineligible, or
voluntarily excluded from the covered transaction, unless it knows that the certification is
erroneous. A participant may decide the method and frequency by which it determines the
eligibility of its principals. Each participant may, but is not required to, check the
Nonprocurement List.
h. Nothing contained in the foregoing shall be construed to require establishment of a system of
records in order to render in good faith the certification required by this clause. The
knowledge and information of participant is not required to exceed that which is normally
possessed by a prudent person in the ordinary course of business dealings.

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i. Except for transactions authorized under paragraph e of these instructions, if a participant in a

covered transaction knowingly enters into a lower tier covered transaction with a person who
is suspended, debarred, ineligible, or voluntarily excluded from participation in this
transaction, in addition to other remedies available to the Federal Government, the
department or agency with which this transaction originated may pursue available remedies,
including suspension and/or debarment.

*****

Certification Regarding Debarment, Suspension, Ineligibility and Voluntary Exclusion--Lower Tier

Covered Transactions:

1. The prospective lower tier participant certifies, by submission of this proposal, that neither it nor
its principals is presently debarred, suspended, proposed for debarment, declared ineligible, or
voluntarily excluded from participation in this transaction by any Federal department or agency.
2. Where the prospective lower tier participant is unable to certify to any of the statements in this
certification, such prospective participant shall attach an explanation to this proposal.

*****

XII. CERTIFICATION REGARDING USE OF CONTRACT FUNDS FOR LOBBYING

(Applicable to all Federal-aid construction contracts and to all related subcontracts which exceed
$100,000 - 49 CFR 20)
1. The prospective participant certifies, by signing and submitting this bid or proposal, to the best of
his or her knowledge and belief, that:

a. No Federal appropriated funds have been paid or will be paid, by or on behalf of the
undersigned, to any person for influencing or attempting to influence an officer or employee
of any Federal agency, a Member of Congress, an officer or employee of Congress, or an
employee of a Member of Congress in connection with the awarding of any Federal contract,
the making of any Federal grant, the making of any Federal loan, the entering into of any
cooperative agreement, and the extension, continuation, renewal, amendment, or modification
of any Federal contract, grant, loan, or cooperative agreement.
b. If any funds other than Federal appropriated funds have been paid or will be paid to any
person for influencing or attempting to influence an officer or employee of any Federal
agency, a Member of Congress, an officer or employee of Congress, or an employee of a
Member of Congress in connection with this Federal contract, grant, loan, or cooperative
agreement, the undersigned shall complete and submit Standard Form-LLL, "Disclosure
Form to Report Lobbying," in accordance with its instructions.

2. This certification is a material representation of fact upon which reliance was placed when this
transaction was made or entered into. Submission of this certification is a prerequisite for making
or entering into this transaction imposed by 31 U.S.C. 1352. Any person who fails to file the
required certification shall be subject to a civil penalty of not less than $10,000 and not more than
$100,000 for each such failure.
3. The prospective participant also agrees by submitting his or her bid or proposal that he or she
shall require that the language of this certification be included in all lower tier subcontracts,
which exceed $100,000 and that all such recipients shall certify and disclose accordingly.

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7-1.50C Female and Minority Goals

To comply with Section II, "Nondiscrimination," of "Required Contract Provisions Federal-Aid
Construction Contracts," the Department is including in Section 7-1.50C, "Female and Minority Goals,"
female and minority utilization goals for Federal-aid construction contracts and subcontracts that exceed
$10,000.
The nationwide goal for female utilization is 6.9 percent.
The goals for minority utilization [45 Fed Reg 65984 (10/3/1980)] are as follows:

Minority Utilization Goals

Economic Area Goal
(Percent)
174 Redding CA:
Non-SMSA Counties: 6.8
CA Lassen; CA Modoc; CA Plumas; CA Shasta; CA Siskiyou; CA Tehema
175 Eureka, CA
Non-SMSA Counties: 6.6
CA Del Norte; CA Humboldt; CA Trinity
176 San Francisco-Oakland-San Jose, CA:
SMSA Counties:
7120 Salinas-Seaside-Monterey, CA 28.9
CA Monterey
7360 San Francisco-Oakland 25.6
CA Alameda; CA Contra Costa; CA Marin; CA San Francisco; CA San Mateo
7400 San Jose, CA
CA Santa Clara, CA 19.6
7485 Santa Cruz, CA
CA Santa Cruz 14.9
7500 Santa Rosa
CA Sonoma 9.1
8720 Vallejo-Fairfield-Napa, CA
CA Napa; CA Solano 17.1
Non-SMSA Counties:
CA Lake; CA Mendocino; CA San Benito 23.2

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177 Sacramento, CA:

SMSA Counties:
6920 Sacramento, CA 16.1
CA Placer; CA Sacramento; CA Yolo
Non-SMSA Counties 14.3
CA Butte; CA Colusa; CA El Dorado; CA Glenn; CA Nevada; CA Sierra; CA
Sutter; CA Yuba
178 Stockton-Modesto, CA:
SMSA Counties:
5170 Modesto, CA 12.3
CA Stanislaus
8120 Stockton, CA 24.3
CA San Joaquin
Non-SMSA Counties 19.8
CA Alpine; CA Amador; CA Calaveras; CA Mariposa; CA Merced; CA
Toulumne
179 Fresno-Bakersfield, CA
SMSA Counties:
0680 Bakersfield, CA 19.1
CA Kern
2840 Fresno, CA 26.1
CA Fresno
Non-SMSA Counties: 23.6
CA Kings; CA Madera; CA Tulare
180 Los Angeles, CA:
SMSA Counties:
0360 Anaheim-Santa Ana-Garden Grove, CA 11.9
CA Orange
4480 Los Angeles-Long Beach, CA 28.3
CA Los Angeles
6000 Oxnard-Simi Valley-Ventura, CA 21.5
CA Ventura
6780 Riverside-San Bernardino-Ontario, CA 19.0
CA Riverside; CA San Bernardino

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7480 Santa Barbara-Santa Maria-Lompoc, CA 19.7

CA Santa Barbara
Non-SMSA Counties 24.6
CA Inyo; CA Mono; CA San Luis Obispo
181 San Diego, CA:
SMSA Counties
7320 San Diego, CA 16.9
CA San Diego
Non-SMSA Counties 18.2
CA Imperial

For each July during which work is performed under the contract, you and each non-material-supplier
subcontractor with a subcontract of $10,000 or more must complete Form FHWA PR-1391 (Appendix C
to 23 CFR 230). Submit the forms by August 15.
7-1.50D Training
Section 7-1.50D, "Training," applies if a number of trainees or apprentices is specified in the special
provisions.
As part of your equal opportunity affirmative action program, provide on-the-job training to develop full
journeymen in the types of trades or job classifications involved.
You have primary responsibility for meeting this training requirement.
If you subcontract a contract part, determine how many trainees or apprentices are to be trained by the
subcontractor.
Include these training requirements in your subcontract.
Where feasible, 25 percent of apprentices or trainees in each occupation must be in their 1st year of
apprenticeship or training.
Distribute the number of apprentices or trainees among the work classifications on the basis of your needs
and the availability of journeymen in the various classifications within a reasonable recruitment area.
Before starting work, submit to the Department:
1. Number of apprentices or trainees to be trained for each classification
2. Training program to be used
3. Training starting date for each classification
Obtain the Department's approval for this submitted information before you start work. The Department
credits you for each apprentice or trainee you employ on the work who is currently enrolled or becomes
enrolled in an approved program.

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Project ID 0400000843

The primary objective of Section 7-1.50D, "Training," is to train and upgrade minorities and women
toward journeymen status. Make every effort to enroll minority and women apprentices or trainees, such
as conducting systematic and direct recruitment through public and private sources likely to yield
minority and women apprentices or trainees, to the extent they are available within a reasonable
recruitment area. Show that you have made the efforts. In making these efforts, do not discriminate
against any applicant for training.
Do not employ as an apprentice or trainee an employee:
1. In any classification in which the employee has successfully completed a training course leading
to journeyman status or in which the employee has been employed as a journeyman
2. Who is not registered in a program approved by the US Department of Labor, Bureau of
Apprenticeship and Training
Ask the employee if the employee has successfully completed a training course leading to journeyman
status or has been employed as a journeyman. Your records must show the employee's answers to the
questions.
In your training program, establish the minimum length and training type for each classification. The
Department and FHWA approves a program if one of the following is met:
1. It is calculated to:
1.1. Meet the your equal employment opportunity responsibilities
1.2. Qualify the average apprentice or trainee for journeyman status in the classification involved by
the end of the training period
2. It is registered with the U.S. Department of Labor, Bureau of Apprenticeship and Training and it
is administered in a way consistent with the equal employment responsibilities of federal-aid highway
construction contracts
Obtain the State's approval for your training program before you start work involving the classification
covered by the program.
Provide training in the construction crafts, not in clerk-typist or secretarial-type positions. Training is
allowed in lower level management positions such as office engineers, estimators, and timekeepers if the
training is oriented toward construction applications. Training is allowed in the laborer classification if
significant and meaningful training is provided and approved by the division office. Off-site training is
allowed if the training is an integral part of an approved training program and does not make up a
significant part of the overall training.
The Department reimburses you 80 cents per hour of training given an employee on this contract under an
approved training program:
1. For on-site training
2. For off-site training if the apprentice or trainee is currently employed on a federal-aid project and
you do at least one of the following:
2.1. Contribute to the cost of the training
2.2. Provide the instruction to the apprentice or trainee
2.3. Pay the apprentice's or trainee's wages during the off-site training period
3. If you comply with Section 7-1.50D, "Training"

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Project ID 0400000843

Each apprentice or trainee must:

1. Begin training on the project as soon as feasible after the start of work involving the apprentice's
or trainee's skill
2. Remain on the project as long as training opportunities exist in the apprentice's or trainee's work
classification or until the apprentice or trainee has completed the training program
Furnish the apprentice or trainee:
1. Copy of the program you will comply with in providing the training
2. Certification showing the type and length of training satisfactorily completed
Maintain records and submit reports documenting your performance under Section 7-1.50D, "Training."

Section 8 Prosecution and Progress

Provisions regarding Section 8 “Prosecution and Progress” are deleted in their entirety and are replaced
with the following:
8-1.01 (Blank)
8-1.02 Assignment
Provisions regarding Assignment are deleted in their entirety and are set forth in Section 23
“Miscellaneous Provisions” of the Contract Documents.
8-1.025 Preconstruction Conference
Provisions regarding Preconstruction Conference are deleted in their entirety.
8-1.03 Beginning of Work
Provisions regarding Beginning of Work are deleted in their entirety and are set forth in Section 4 “Time
within which Project shall be Completed; Scheduling” of the Contract Documents.
8-1.04 Progress Schedule
Provisions regarding Progress Schedule are deleted in their entirety and are replaced with the following:
8-1.04A General
Reserved
8-1.04B Critical Path Method Schedule
The following definitions apply to critical path method schedules:
activity: Task, event, or other project element on a schedule that contributes to completing the project.
Activities have a description, start date, finish date, duration, and one or more logic ties.
baseline schedule: The initial schedule showing the original work plan beginning on the date of contract
approval. This schedule shows no completed work to date and no negative float or negative lag to any
activity.
controlling activity: Construction activity that extends the scheduled completion date if delayed.
critical path: Longest continuous chain of activities for the project that has the least amount of total float
of all chains. In general, a delay on the critical path extends the scheduled completion date.

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Project ID 0400000843

critical path method (CPM): Network based planning technique using activity durations and
relationships between activities to calculate a schedule for the entire project.
revised schedule: Schedule that incorporates a proposed or past change to logic or activity durations.
scheduled completion date: Planned project completion date shown on the current schedule.
updated schedule: Current schedule developed from the accepted baseline and any subsequent accepted
updated or revised schedules through regular monthly review to incorporate actual past progress.
Before or at the preconstruction conference, submit a CPM baseline schedule.
Submit a monthly updated schedule that includes the status of work completed to date and the work yet to
be performed as planned.
On each schedule, show:
1. Planned and actual start and completion date of each work activity, including applicable:
1.1. Submittal development
1.2. Submittal review and approval
1.3. Material procurement
1.4. Contract milestones and constraints
1.5. Equipment and plant setup
1.6. Interfaces with outside entities
1.7. Erection and removal of falsework and shoring
1.8. Test periods
1.9. Major traffic stage change
1.10. Final cleanup
2. Order that you propose to prosecute the work
3. Logical links between the time-scaled work activities
4. All controlling activities
5. Legible description of each activity
6. At least one predecessor and one successor to each activity, except for project start and project
end milestones
7. Duration of not less than one working day for each activity
8. Start milestone date as the contract approval date
You may include changes on updated schedules that do not alter the critical path or extend the schedule
completion date compared to the current schedule. Changes may include:
1. Adding or deleting activities
2. Changing activity constraints
3. Changing durations
4. Changing logic

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
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Project ID 0400000843

If any proposed change in planned work results in altering the critical path or extending the scheduled
completion date, submit a revised schedule within 15 days of the proposed change.
For each schedule submittal:
1. Submit a plotted original, time-scaled network diagram on a sheet of at least 8.5" x 11" with a
title block and timeline
2. If a computer program is used to make the schedule, submit a read-only compact disc or diskette
containing the schedule data. Label the compact disc or diskette with:
2.1. Contract number
2.2. CPM schedule number and date produced
2.3. File name
Full compensation for this work is included in the Contract Prices paid for the items of work involved,
and no additional compensation will be allowed therefor.
8-1.05 Temporary Suspension of Work
Provisions regarding Temporary Suspension of Work are deleted in their entirety and are set forth in
Section 14 “Suspension of Work” of the Contract Documents.
8-1.06 Time of Completion
Provisions regarding Time of Completion of Work are deleted in their entirety and are set forth in Section
4 “Time within which Project shall be Completed; Scheduling” and Section 20 “Acceptance of Project”
of the Contract Documents.
8-1.07 Liquidated Damages
Provisions regarding Liquidated Damages are deleted in their entirety and are set forth in Section 17
“Damages” of the Contract Documents
8-1.08 Termination of Control
Provisions regarding Termination of Control are deleted in their entirety and are set forth in Section 15
“Termination for Convenience” of the Contract Documents
8-1.09 Right of Way Delays
Provisions regarding Right of Way Delays are deleted in their entirety and are set forth in Section 6
“Access to Site; Utility Relocations; Environmental Mitigation”, Section 11 “Payment” and Section 13
“Changes in Work” of the Contract Documents
8-1.10 (Blank)
8-1.11 Termination of Contract
Provisions regarding Termination of Contract are deleted in their entirety and are set forth in Section 15
“Termination for Convenience” of the Contract Documents

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
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Project ID 0400000843

Section 9 Measurement and Payment

Provisions regarding Section 9 “Measurement and Payment” are deleted in their entirety and are replaced
with the following:
9-1.01 Measurement of Quantities
Provisions regarding measurement of quantities are hereby deleted and replaced with the following: The
purpose of measurement of quantities is to identify Quality Control and Verification testing frequency
requirements as contained in the Materials Control Schedule and in tracking production rates for monthly
payments to the Design-Builder based on percentage complete. All specifications within the Caltrans
Standard Specifications for Construction containing sections describing Method of Measurement and
Basis of Payment shall have the sections describing Method of Measurement and Basis of Payment
deleted. The Design-Builder hereby acknowledges and agrees that the single lump sum Contract Price
constitutes full compensation for performance of all of the Work, subject only to those exceptions
specified in the Contract Documents.
9-1.02 Scope of Payment
Provisions regarding scope of payment are hereby deleted in their entirety and are set forth in Section 11
“Payment” of the Contract Documents.
9-1.03 Force Account Payment
Provisions regarding Force Account Payment are applicable to this project.
9-1.03A General
For work paid by force account, the Engineer compares the Department's records to your daily force
account work report. When you and the Engineer agree on the contents of the daily force account work
reports, the Engineer accepts the report and the Department pays for the work. If the records differ, the
Department pays for the work based only on the information shown on the Department's records.
If a subcontractor performs work at force account, accept an additional 10 percent markup to the total cost
of that work paid at force account, including markups specified in Section 9-1.03, as reimbursement for
additional administrative costs.
The markups specified in labor, materials, and equipment include compensation for all delay costs,
overhead costs, and profit.
If an item's payment is adjusted for work-character changes, the Department excludes your cost of
determining the adjustment.
Payment for owner-operated labor and equipment is made at the market-priced invoice submitted.
9-1.03B Labor
Labor payment is full compensation for the cost of labor used in the direct performance of the work plus a
35 percent markup. Force account labor payment consists of:
1. Employer payment to the worker for:
1.1. Basic hourly wage
1.2. Health and welfare
1.3. Pension
1.4. Vacation
1.5. Training

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Project ID 0400000843

1.6. Other State and federal recognized fringe benefit payments

2. Labor surcharge percentage in Labor Surcharge and Equipment Rental Rates current during the
work paid at force account for:
2.1. Workers' compensation insurance
2.2. Social security
2.3. Medicare
2.4. Federal unemployment insurance
2.5. State unemployment insurance
2.6. State training taxes
3. Subsistence and travel allowances paid to the workers
4. Employer payment to supervisors, if authorized
The 35 percent markup consists of payment for all overhead costs related to labor but not designated as
costs of labor used in the direct performance of the work including:
1. Home office overhead
2. Field office overhead
3. Bond costs
4. Profit
5. Labor liability insurance
6. Other fixed or administrative costs that are not costs of labor used in the direct performance of the
work
9-1.03C Materials
Material payment is full compensation for materials you furnish and use in the work. The Engineer
determines the cost based on the material purchase price, including delivery charges, except:
1. A 15 percent markup is added.
2. Supplier discounts are subtracted whether you took them or not.
3. If the Engineer believes the material purchase prices are excessive, the Department pays the
lowest current wholesale price for a similar material quantity.
4. If you procured the materials from a source you wholly or partially own, the determined cost is
based on the lower of the:
4.1. Price paid by the purchaser for similar materials from that source on Contract items
4.2. Current wholesale price for those materials
5. If you do not submit a material cost record within 30 days of billing, the determined cost is based
on the lowest wholesale price:
5.1. During that period
5.2. In the quantities used

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Project ID 0400000843

9-1.03D Equipment Rental

9-1.03D(1) General
Equipment rental payment is full compensation for:
1. Rental equipment costs, including moving rental equipment to and from the site of work
performed by change order using its own power.
2. Transport equipment costs for rental equipment that cannot be transported economically using its
own power. No payment is made during transport for the transported equipment.
3. 15 percent markup.
If you want to return the equipment to a location other than its original location, the payment to move the
equipment must not exceed the cost of returning the equipment to its original location. If you use the
equipment for work other than work paid by force account, the transportation cost is included in the other
work.
Before moving or loading the equipment, obtain authorization for the equipment rental's original location.
The Engineer determines rental costs:
1. Using rates in Labor Surcharge and Equipment Rental Rates:
1.1. By classifying equipment using manufacturer's ratings and manufacturer-approved changes.
1.2. Current during the work paid by force account.
1.3. Regardless of equipment ownership; but the Department uses the rental document rates or
minimum rental cost terms if:
1.3.1. Rented from equipment business you do not own.
1.3.2. The Labor Surcharge and Equipment Rental Rates hourly rate is $10.00 per hour or less.
2. Using rates established by the Engineer for equipment not listed in Labor Surcharge and
Equipment Rental Rates. You may submit cost information that helps the Engineer establish the rental
rate; but the Department uses the rental document rates or minimum rental cost terms if:
2.1. Rented from equipment business you do not own.
2.2. The Engineer establishes a rate of $10.00 per hour or less.
3. Using rates for transport equipment not exceeding the hourly rates charged by established haulers.
Equipment rental rates include the cost of:
1. Fuel
2. Oil
3. Lubrication
4. Supplies
5. Small tools that are not consumed by use
6. Necessary attachments
7. Repairs and maintenance
8. Depreciation
9. Storage

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Project ID 0400000843

10. Insurance
11. Incidentals
The Department pays for small tools consumed by use. The Engineer determines payment for small tools
consumed by use based on Contractor-submitted invoices.
9-1.03D(2) Equipment On the Job Site
For equipment on the job site at the time required to perform work paid by force account, the time paid is
the time:
1. To move the equipment to the location of work paid by force account plus an equal amount of
time to move the equipment to another location on the job site when the work paid by force account is
completed
2. To load and unload equipment
3. Equipment is operated to perform work paid by force account and:
3.1. Hourly rates are paid in 1/2-hour increments
3.2 Daily rates are paid in 1/2-day increments
When rented equipment on the job site is used to perform work at force account not required by the
original contract work, the Engineer may authorize rates in excess of those in Labor Surcharge and
Equipment Rental Rates if:
1. You submit a request to use rented equipment
2. Equipment is not available from your owned equipment fleet or from your subcontractors
3. Rented equipment is from an independent rental company
4. Proposed equipment rental rate is reasonable
5. Engineer authorizes the equipment source and the rental rate before you use the equipment
The Department pays for fuel consumed during operation of rented equipment not included in the
invoiced rental rate.
9-1.03D(3) Equipment Not On the Job Site Required for Original Contract Work
For equipment not on the job site at the time required to perform work paid by force account and required
for original Contract work, the time paid is the time the equipment is operated to perform work paid by
force account and the time to move the equipment to a location on the job site when the work paid by
force account is completed.
The minimum total time paid is:
1. 1 day if daily rates are paid
2. 8 hours if hourly rates are paid
If daily rates are recorded, equipment:
1. Idled is paid as 1/2 day
2. Operated 4 hours or less is paid as 1/2 day
3. Operated 4 hours or more is paid as 1 day
If the minimum total time exceeds 8 hours and if hourly rates are listed, the Department rounds up hours
operated to the nearest 1/2-hour increment and pays based on the following table. The table does not

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
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E.A. 04-2A7904
Project ID 0400000843

apply when equipment is not operated due to breakdowns; in which case rental hours are the hours the
equipment was operated.

Equipment Rental Hours

Hours operated Hours paid
0.0 4.00
0.5 4.25
1.0 4.50
1.5 4.75
2.0 5.00
2.5 5.25
3.0 5.50
3.5 5.75
4.0 6.00
4.5 6.25
5.0 6.50
5.5 6.75
6.0 7.00
6.5 7.25
7.0 7.5
7.5 7.75
>8.0 hours used
9-1.03D(4) Equipment Not On the Job Site Not Required for Original Contract Work
For equipment not on the job site at the time required to perform work paid by force account and not
required for original Contract work, the time paid is the time:
1. To move the equipment to the location of work paid by force account plus an equal amount of
time to return the equipment to its source when the work paid by force account is completed
2. To load and unload equipment
3. Equipment is operated to perform work paid by force account
For this equipment, the Engineer may authorize rates in excess of those in Labor Surcharge and
Equipment Rental Rates subject to the following:
1. Equipment is not available from your normal sources or from one of your subcontractors
2. Proposed equipment rental rate is reasonable
3. Engineer authorizes the equipment source and the rental rate before you use the equipment

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
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E.A. 04-2A7904
Project ID 0400000843

9-1.03D(5) Non-Owner-Operated Dump Truck Rental

Submit the rental rate for non-owner-operated dump truck rental. The Engineer determines the payment
rate. Payment for non-owner-operated dump truck rental is for the cost of renting a dump truck, including
its driver. For the purpose of markup payment only, the non-owner-operated dump truck is rental
equipment and the owner is a subcontractor.
9-1.04 Not used
9-1.05 Not used
9-1.06 Not used
9-1.07 Not used
9-1.08 Not used
9-1.09 Clerical Errors
For 3 years after Contract acceptance, estimates and payments are open to correction and adjustment for
clerical errors. Either the Department or the Contractor pays to the other the amount due except for
clerical errors resulting in an adjustment less than $200; in which case, no payment is made.
9-1.10 Not used
B. Sections 10 through 95
General Modifications
1. On technical issues “The Engineer” shall mean the Design-Builder.
2. On Administrative issues “The Engineer” shall mean Department.
If the Design-Builder believes that a definition of “The Engineer” is unclear, the Design-Builder shall
have the obligation to raise the issue with Caltrans. Regardless of whether the Design-Builder raises the
issue, Department shall always have the right to notify the Design-Builder if the Design-Builder is
interpreting the definition of “The Engineer” incorrectly.

Specific Modifications
For any specific modifications on Section 10 through 95, please refer to the Exhibit 4-A, “Amendments to
the Standard Specifications – Section 10 to Section 95”.

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Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

EXHIBIT 4-A
Amendments to the Standard Specifications - Section 10 to Section 95

April 11,2011 4-36

Design-Build Modifications To The Caltrans Standard Specifications May 2006 Edition
Exhibit 4-A Amendments to the Standard Specifications - Section 10 to Section 95
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

AMENDMENTS ISSUE DATE: 11-30-10

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 10 DUST CONTROL

(Issued 02-06-09)

Replace Section 10 with:

SECTION 10 (BLANK)

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 11 MOBILIZATION
(Issued 06-05-09)

Replace Section 11 with:

SECTION 11 (BLANK)

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 12 CONSTRUCTION AREA TRAFFIC CONTROL DEVICES

(Issued 11-07-08)

In Section 12-1.01 in the 2nd paragraph, replace the 1st sentence with:
Attention is directed to Part 6 of the California MUTCD.

April 11,2011 4-37

Replace Section 12-2.01 with:

12-2.01 FLAGGERS
Flaggers while on duty and assigned to traffic control or to give warning to the public that the
highway is under construction and of any dangerous conditions to be encountered as a result
thereof, shall perform their duties and shall be provided with the necessary equipment in
conformance with Part 6 of the California MUTCD. The equipment shall be furnished and kept
clean and in good repair by the Contractor at the Contractor's expense.
All flaggers shall wear safety apparel meeting the requirements of ANSI/ISEA 107-2004 for
Class 2 or 3 garment and complying with 71 Fed Reg 67792.

In Section 12-3.01 replace the 1st paragraph with:

In addition to the requirements in Part 6 of the California MUTCD, all devices used by the
Contractor in the performance of the work shall conform to the provisions in this Section 12-3.

In Section 12-3.06 in the 1st paragraph, replace the 2nd sentence with:
Construction area signs are shown in or referred to in Part 6 of the California MUTCD.

In Section 12-3.06 in the 4th paragraph, replace the 1st sentence with:
All construction area signs shall conform to the dimensions, color and legend requirements of
the plans, Part 6 of the California MUTCD and these specifications.

In Section 12-3.06 in the 8th paragraph, replace the 1st sentence with:
Used signs with the specified sheeting material will be considered satisfactory if they conform to
the requirements for visibility and legibility and the colors conform to the requirements in Part 6
of the California MUTCD.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 14 (BLANK)
(Issued 06-05-09)

April 11,2011 4-38

Replace Section 14 with:

SECTION 14 ENVIRONMENTAL STEWARDSHIP
14-1 GENERAL
14-1.01 GENERAL
Environmental stewardship includes both environmental compliance and environmental
resource management.
If an ESA is shown on the plans:

1. The boundaries shown are approximate; the Department marks the exact boundaries on
the ground
2. Do not enter the ESA unless authorized
3. If the ESA is breached, immediately:
3.1. Secure the area and stop all operations within 60 feet of the ESA boundary
3.2. Notify the Engineer
4. If the ESA is damaged, the Department determines what efforts are necessary to remedy
the damage and who performs the remedy; you are responsible for remedies and charges.

14-2 CULTURAL RESOURCES

14-2.01 GENERAL
Reserved

14-2.02 ARCHAEOLOGICAL RESOURCES

If archaeological resources are discovered at the job site, do not disturb the resources and
immediately:

1. Stop all work within a 60-foot radius of the discovery

2. Protect the discovery area
3. Notify the Engineer

The Department investigates. Do not take archaeological resources from the job site. Do not
resume work within the discovery area until authorized.
If, in the opinion of the Engineer, completion of the work is delayed or interfered with by reason
of an archaeological find, or investigation or recovery of archeological materials, you will be
compensated for resulting losses, and an extension of time will be granted, in the same manner
as provided for in Section 8-1.09, "Right of Way Delays."
If ordered, furnish resources to assist in the investigation or recovery of archaeological
resources. This work will be paid for as extra work as specified in Section 4-1.03D, "Extra
Work."

April 11,2011 4-39

14-2.03 ARCHAEOLOGICAL MONITORING AREA

Section 14-2.03 applies if an AMA is described in the Contract.
The Department assigns an archaeological monitor to monitor job site activities within the AMA.
Do not work within the AMA unless the archeological monitor is present.
The Engineer and the Department archaeological monitor conduct an AMA location field review
with you at least 5 business days before start of work. The Department marks the exact
boundaries of the AMA on the ground.
If temporary fence (Type ESA) for an AMA is described in the Contract, install temporary fence
(Type ESA) to define the boundaries of the AMA during the AMA location field review.
At least 5 business days before starting work within an AMA, submit a schedule of days and
hours to be worked for the Engineer's approval. If you require changes in the schedule, submit
an update for the Engineer's approval at least 5 business days before any changed work day.
If archaeological resources are discovered within an AMA, comply with Section 14-2.02,
"Archaeological Resources."

14-2.04 HISTORIC STRUCTURES

Reserved

14-3 COMMUNITY IMPACTS AND ENVIRONMENTAL JUSTICE

Reserved

14-4 NATIVE AMERICAN CONCERNS

Reserved

14-5 AESTHETICS
Reserved

14-6 BIOLOGICAL RESOURCES

14-6.01 GENERAL
Reserved

14-6.02 BIRD PROTECTION

Protect migratory and nongame birds, their occupied nests, and their eggs.
The Department anticipates nesting or attempted nesting from February 15 to September 1.
The federal Migratory Bird Treaty Act, 16 USC § 703–711, and 50 CFR Pt 10 and Fish & Game
Code §§ 3503, 3513, and 3800 protect migratory and nongame birds, their occupied nests, and
their eggs.

April 11,2011 4-40

The federal Endangered Species Act of 1973, 16 USC §§ 1531 and 1543, and the California
Endangered Species Act, Fish & Game Code §§ 2050–2115.5, prohibit the take of listed
species and protect occupied and unoccupied nests of threatened and endangered bird
species.
The Bald and Golden Eagle Protection Act, 16 USC § 668, prohibits the destruction of bald and
golden eagles and their occupied and unoccupied nests.
If migratory or nongame bird nests are discovered that may be adversely affected by
construction activities or an injured or killed bird is found, immediately:

1. Stop all work within a 100-foot radius of the discovery.

2. Notify the Engineer.

The Department investigates. Do not resume work within the specified radius of the discovery
until authorized.
When ordered, use exclusion devices, take nesting prevention measures, remove and dispose
of partially constructed and unoccupied nests of migratory or nongame birds on a regular basis
to prevent their occupation, or perform any combination of these. This work will be paid for as
extra work as specified in Section 4-1.03D, "Extra Work."
Prevent nest materials from falling into waterways.
Bird protection that causes a delay to the controlling activity is a condition unfavorable to the
suitable prosecution of work as specified in Section 8-1.05, "Temporary Suspension of Work."

14-7 PALEONTOLOGICAL RESOURCES

If paleontological resources are discovered at the job site, do not disturb the material and
immediately:

1. Stop all work within a 60-foot radius of the discovery

2. Protect the area
3. Notify the Engineer

The Department investigates and modifies the dimensions of the protected area if necessary.
Do not take paleontological resources from the job site. Do not resume work within the
specified radius of the discovery until authorized.

14-8 NOISE AND VIBRATION

14-8.01 GENERAL
Reserved

14-8.02 NOISE CONTROL

Do not exceed 86 dBa at 50 feet from the job site activities from 9 p.m. to 6 a.m.

April 11,2011 4-41

Equip an internal combustion engine with the manufacturer-recommended muffler. Do not

operate an internal combustion engine on the job site without the appropriate muffler.

14-9 AIR QUALITY

14-9.01 AIR POLLUTION CONTROL
Comply with air pollution control rules, regulations, ordinances, and statutes that apply to work
performed under the Contract, including air pollution control rules, regulations, ordinances, and
statutes provided in Govt Code § 11017 (Pub Cont Code § 10231).
Do not burn material to be disposed of.

14-9.02 DUST CONTROL

Prevent and alleviate dust by applying water, dust palliative, or both under Section 14-9.01.
Apply water under Section 17, "Watering."
Apply dust palliative under Section 18,"Dust Palliative."
If ordered, apply water, dust palliative, or both to control dust caused by public traffic. This work
will be paid for as extra work as specified in Section 4-1.03D, "Extra Work."

14-10 SOLID WASTE DISPOSAL AND RECYCLING

14-10.01 SOLID WASTE DISPOSAL AND RECYCLING
Submit an annual Solid Waste Disposal and Recycling Report between January 1 and 15 for
each year work is performed under the Contract at any time during the previous calendar year.
Show the types and amounts of project-generated solid waste taken to or diverted from landfills
or reused on the project from January 1 through December 31 of the previous calendar year.
Submit a final annual Solid Waste Disposal and Recycling Report within 5 business days after
Contract acceptance. Show the types and amounts of project-generated solid waste taken to or
diverted from landfills or reused on the project from January 1 to Contract acceptance.
For each failure to submit a completed form, the Department withholds $10,000.

14-11 HAZARDOUS WASTE AND CONTAMINATION

14-11.01 GENERAL
Reserved

14-11.02 ASBESTOS AND HAZARDOUS SUBSTANCES

Upon discovery, immediately stop working in and notify the Engineer of areas where asbestos
or a hazardous substance is present if the:

1. Contractor reasonably believes the substance is asbestos as defined in Labor Code §

6501.7 or a hazardous substance as defined in Health & Safety Code §§ 25316 and 25317

April 11,2011 4-42

2. Presence is not described in the Contract

3. Substance has not been made harmless

14-12 OTHER INTERAGENCY RELATIONS

Reserved
14-13 PAYMENT
Payment for work specified in Section 14 is included in the payment for the bid items involved
unless:

1. Bid item for the work is shown in the verified Bid Item List
2. Work is specified as paid for as extra work

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 15 EXISTING HIGHWAY FACILITIES

(Issued 05-01-09)

In Section 15-1.02 replace the 1st paragraph with:

Existing facilities which are to remain in place shall be protected in conformance with the
provisions in Sections 5-1.18, "Property and Facility Preservation," and 7-1.12, "Indemnification
and Insurance."

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
SECTION 19 EARTHWORK
(Issued 11-21-08)

Replace Section 19-1.02 with:

19-1.02 (BLANK)

Replace Section 19-1.03 with:

19-1.03 GRADE TOLERANCE
Immediately prior to placing subsequent layers of material thereon, the grading plane shall
conform to one of the following:

April 11,2011 4-43

A. When hot mix asphalt is to be placed on the grading plane, the grading plane at any point
shall not vary more than 0.05 foot above or below the grade established by the Engineer.
B. When subbase or base material to be placed on the grading plane is to be paid for by the
ton, the grading plane at any point shall not vary more than 0.10 foot above or below the
grade established by the Engineer.
C. When the material to be placed on the grading plane is to be paid for by the cubic yard,
the grading plane at any point shall be not more than 0.05 foot above the grade
established by the Engineer.

In Section 19-3.025C replace the 1st paragraph with:

Cementitious material used in soil cement bedding shall conform to the provisions in Section 90-
2.01, "Cementitious Materials." Supplementary cementitious material will not be required.

In Section 19-3.025C replace the 4th paragraph with:

The aggregate, cementitious material, and water shall be proportioned either by weight or by
volume. Soil cement bedding shall contain not less than 282 pounds of cementitious material
per cubic yard. The water content shall be sufficient to produce a fluid, workable mix that will
flow and can be pumped without segregation of the aggregate while being placed.

In Section 19-3.062 replace the 1st paragraph with:

Slurry cement backfill shall consist of a fluid, workable mixture of aggregate, cementitious
material, and water.

In Section 19-3.062 replace the 5th paragraph with:

Cementitious material shall conform to the provisions in Section 90-2.01, "Cementitious
Materials." Supplementary cementitious material will not be required.

In Section 19-3.062 replace the 8th paragraph with:

The aggregate, cementitious material, and water shall be proportioned either by weight or by
volume. Slurry cement backfill shall contain not less than 188 pounds of cementitious material
per cubic yard. The water content shall be sufficient to produce a fluid, workable mix that will
flow and can be pumped without segregation of the aggregate while being placed.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-44

SECTION 20 EROSION CONTROL AND HIGHWAY PLANTING

(Issued 08-17-07)

Replace Section 20-2.03 with:

20-2.03 SOIL AMENDMENT
Soil amendment shall comply with the requirements in the California Food and Agricultural
Code.
Soil amendment producers shall comply with the following:

1. Be fully permitted to produce compost as specified under the California Integrated Waste
Management Board, Local Enforcement Agencies and any other State and Local
Agencies that regulate Solid Waste Facilities. If exempt from State permitting
requirements, the composting facility must certify that it follows guidelines and
procedures for production of compost meeting the environmental health standards of
Title 14, California Code of Regulations, Division 7, Chapter 3.1, Article 7.
2. Be a participant in United States Composting Council's Seal of Testing Assurance
program.

Soil amendment shall be composted and may be derived from any single, or mixture of any of
the following feedstock materials:

1. Green material consisting of chipped, shredded, or ground vegetation; or clean processed

recycled wood products
2. Biosolids
3. Manure
4. Mixed food waste

Soil amendment feedstock materials shall be composted to reduce weed seeds, pathogens and
deleterious materials as specified under Title 14, California Code of Regulations, Division 7,
Chapter 3.1, Article 7, Section 17868.3.
Soil amendment shall not be derived from mixed municipal solid waste and must be reasonably
free of visible contaminates. Soil amendment must not contain paint, petroleum products,
pesticides or any other chemical residues harmful to animal life or plant growth. Soil
amendment must not possess objectionable odors.
Metal concentrations in soil amendment must not exceed the maximum metal concentrations
listed in Title 14, California Code of Regulations, Division 7, Chapter 3.1, Section 17868.2.
Soil amendment must comply with the following:

April 11,2011 4-45

Physical/Chemical Requirements
Property Test Method Requirement
pH *TMECC 04.11-A, Elastometric pH 1:5 Slurry
6.0–8.0
Method, pH Units
Soluble Salts TMECC 04.10-A, Electrical Conductivity 1:5 Slurry
0-10.0
Method dS/m (mmhos/cm)
Moisture Content TMECC 03.09-A, Total Solids & Moisture at 70+/- 5
30–60
deg C, % Wet Weight Basis
Organic Matter TMECC 05.07-A, Loss-On-Ignition Organic Matter
30–65
Content Method (LOI), % Dry Weight Basis
Maturity TMECC 05.05-A, Germination and Vigor
Seed Emergence 80 or Above
Seedling Vigor 80 or Above
% Relative to Positive Control
Stability TMECC 05.08-B, Carbon Dioxide Evolution Rate
8 or below
mg CO2-C/g OM per day
Particle Size TMECC 02.02-B Sample Sieving for Aggregate Size 95% Passing 5/8 inch
Classification % Dry Weight Basis 70% Passing 3/8 inch
Pathogen TMECC 07.01-B, Fecal Coliform Bacteria < 1000
MPN/gram dry wt. Pass
Pathogen TMECC 07.01-B, Salmonella < 3 MPN/4 grams dry
wt. Pass
Physical TMECC 02.02-C, Man Made Inert Removal and
Contaminants Classification:
Plastic, Glass and Metal, % > 4mm fraction Combined Total: < 1.0
Physical TMECC 02.02-C, Man Made Inert Removal and
Contaminants Classification:
Sharps (Sewing needles, straight pins and hypodermic None Detected
needles), % > 4mm fraction
*TMECC refers to "Test Methods for the Examination of Composting and Compost," published by the
United States Department of Agriculture and the United States Compost Council (USCC).

Prior to application, the Contractor shall provide the Engineer with a copy of the soil amendment
producer's Compost Technical Data Sheet and a copy of the compost producers STA
certification. The Compost Technical Data Sheet shall include laboratory analytical test results,
directions for product use, and a list of product ingredients.
Prior to application, the Contractor shall provide the Engineer with a Certificate of Compliance in
conformance with the provisions in Section 6-1.07, "Certificates of Compliance," of the Standard
Specifications.

In Section 20-2.10 delete the 8th, 9th, and 10th paragraphs.

In Section 20-3.04A delete the last paragraph.

April 11,2011 4-46

Replace Section 20-4.055 with:

20-4.055 PRUNING
Pruning of plants shall be consistent with American National Standards Institute (ANSI), "Tree,
Shrub and Other Woody Plant Maintenance Standard Practices," ANSI 300 (Part 1)-2001 and
"Best Management Practices Tree Pruning," 2002 (ISBN 1-881956318), published by the
International Society of Arboriculture, P.O. Boc 3129, Champaign, IL 61826.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 24 LIME STABILIZATION

(Issued 06-05-09)

Replace Section 24 with:

SECTION 24 LIME STABILIZED SOIL
24-1.01 GENERAL
24-1.01A Summary
Section 24 includes specifications for stabilizing soil by mixing lime and water with soil and
compacting the mixture to the specified dimensions.

24-1.01B Definitions
lime: Quicklime made from high-calcium or dolomitic sources specified under ASTM C 51.
For high-calcium quicklime, the calcium oxide content must be greater than 90 percent.
For dolomitic quicklime, the calcium oxide content must be greater than 55 percent and
the combined calcium oxide and magnesium oxide content must be greater than 90
percent.
mellowing period: The time between the initial and final mixing to promote initial chemical
reactions between lime, water, and soil.

24-1.01C Submittals
From 30 to 180 days before use, submit one 10-pound sample of each lime product proposed
and from each source.
Submit lime samples in airtight containers under ASTM C 50. Mark the sample date on the
container. Include the MSDS and chemical and physical analysis with the submittal.
With the lime samples, submit a Certificate of Compliance from the pre-qualified lime source
under Section 6-1.07, "Certificates of Compliance," with a statement certifying the lime
furnished is the same as that pre-qualified.

April 11,2011 4-47

Fifteen days before starting soil stabilization activities, submit for the Engineer's approval a
laboratory to perform quality control tests. The laboratory must be qualified under the
Department's Independent Assurance Program.
Before you apply lime in slurry form, submit the slurry's lime content for Engineer's approval 25
days before application.
Before performing quality control sampling and testing, submit the time and location the
sampling and testing will occur. Submit quality control testing results within 24 hours of
receiving the results.
Submit a weighmaster certificate or bill of lading with each load of lime delivered to the jobsite.

24-1.01D Quality Control and Assurance

General
Perform quality control testing in the presence of the Engineer.
Place unique, sequentially numbered lock seals on each load and affix them to trailer blow down
valves that are locked open. The bill of lading for each lime delivery must have that specific lock
seal number legibly and visibly imprinted.
The Engineer samples each lime delivery truck at the job site and randomly tests them off-site.

Pre-qualification of Lime Sources

Lime sources must be listed on the Department's pre-qualified products list. The list is available
at the METS web site.
The pre-qualified list for lime sources describes the application procedures for inclusion on
the list.

Preparing Soil
After you prepare an area for lime soil stabilization, test the soil to be stabilized every 500 cubic
yards for relative compaction under California Test 231 and moisture content under California
Test 226, and verify the surface grades.

Applying Lime
The Engineer determines the final application rate for each lime product proposed from the
samples submitted. If the soil being stabilized changes, the Engineer changes the application
rate. Based on California Test 373, the Engineer reports the application rates as the percent of
lime by dry weight of soil. The Engineer provides the optimum moisture content determined
under California Test 373 for each application rate.
Before applying lime, measure the temperature at the ground surface.
If lime in dry form is used, the Engineer verifies the application rate using the drop pan method
once per 40,000 square feet stabilized, or twice per day, whichever is greater.

April 11,2011 4-48

If lime in slurry form is used, report the quantity of slurry placed by measuring the volume of
slurry in the holding tank once per 40,000 square feet stabilized, or twice per day, whichever is
greater.

Mixing
For each day of initial mixing, test the moisture content. Sample the material immediately after
initial mixing.
Randomly test the adequacy of the final mixing with a phenolphthalein indicator solution.
During mixing operations, measure the ground temperature at full mixing depth.
After mixing and before compacting, determine maximum density under California Test 216
from composite samples of the mixed material and at each distinct change in material. Test the
moisture content of the mixed material under California Test 226. Test the gradation for
compliance with "Materials."

Compaction
Test relative compaction on a wet weight basis.
After initial compaction, determine in-place density under California Test 231 and moisture
content under California Test 226 at the same locations. The testing frequency must be 1 test
per 250 cubic yards of lime stabilized soil. Test in 0.50-foot depth intervals.
Before requesting to compact material in layers greater than 0.50 foot, construct a test strip in
the production area and demonstrate the test strip passes compaction tests using the proposed
thickness. The test strip must contain no more material than 1 day's production. The Engineer
tests at not more than 0.50-foot depth intervals regardless of the thickness of your layers.
Construct test pads by scraping away material to the depth ordered by the Engineer. If a
compaction test fails corrective action must include the layers of material already placed above
the test pad elevation.

Finish Grading
Do not proceed with construction activities for subsequent layers of material until the Engineer
verifies the final grades of the lime stabilized soil.

Dispute Resolution
You and the Engineer must work together to avoid potential conflicts and to resolve disputes
regarding test result discrepancies. Notify the Engineer within 5 days of receiving a test result if
you dispute the test result.
If you or the Engineer dispute each other's test results, submit written quality control test results
and copies of paperwork including worksheets used to determine the disputed test results to the
Engineer. An Independent Third Party (ITP) performs referee testing. Before the ITP
participates in a dispute resolution, the ITP must be accredited under the Department's
Independent Assurance Program. The ITP must be independent of the project. By mutual
agreement, the ITP is chosen from:

April 11,2011 4-49

1. A Department laboratory
2. A Department laboratory in a district or region not in the district or region the project is
located
3. The Transportation Laboratory
4. A laboratory not currently employed by you or your lime producer

If split quality control or acceptance samples are not available, the ITP uses any available
material representing the disputed material for evaluation.

24-1.02 MATERIALS
24-1.02A Lime
Lime must comply with ASTM C 977 and the following:

Lime
Quality ASTM Specification
Characteristic
Available C 25a High Calcium
Calcium and Quicklime:
Magnesium CaO > 90
Oxide(min., %) Dolomitic
Quicklime:
CaO > 55 and
CaO + MgO > 90
Loss on ignition C 25 7 (total loss)
(max., %) 5 (carbon dioxide)
2 (free moisture)
Slaking rate C 110 30 °C rise in 8
minutes
Notes:
a
You may use ASTM C25 or ASTM C1301 and
ASTM C1271.

A 0.5-pound sample of lime dry-sieved in a mechanical sieve shaker for 10 minutes ±30
seconds must comply with:

Sieve Sizes Percentage

Passing
3/8-inch 98-100

Slurry must:

1. Be free of contaminants

April 11,2011 4-50

2. Contain at least the minimum dry solids

3. Have uniform consistency

If you prepare lime slurry, prepare it at the jobsite.

24-1.02B Water
If available, use potable water. Inform the Engineer if a water source other than potable water is
used. If not using potable water, water for mixing soil and lime must:

1. Contain no more than 650 parts per million of chlorides as Cl, and no more than 1,300
parts per million of sulfates as SO4
2. Not contain an amount of impurities that will cause a reduction in the strength of the
stabilize soil

24-1.02C Mixed Material

Take a composite sample from 5 random locations after initial mixing. The moisture content of
the composite sample tested under California Test 226 must be a minimum of 3 percent greater
than optimum. Determine the moisture versus density relationship of the composite sample
material determined under California Test 216, except Part 2, Section E, Paragraph 6 is
modified as follows:

After adjustment of the moisture content, compact each of the remaining test specimens
in the mold, then record the water adjustment, tamper reading, and the corresponding
adjusted wet density from the chart on Table 1 using the column corresponding to the
actual wet weight of the test specimen compacted. Note each of these wet weights on
Line I.

The mixed material before compaction excluding rock must comply with:

Sieve Sizes Percentage

Passing
1" 98 - 100
No. 4 60 - 100

24-1.02D Curing Treatment

Curing treatment may be any of the following:

1. Water cure
2. Curing seal
3. Moist material blanket

April 11,2011 4-51

Curing seal must be SS or CSS grade asphaltic emulsion under Section 94, "Asphaltic
Emulsions."

24-1.03 CONSTRUCTION
24-1.03A General
If using different types of lime or lime from more than one source, do not mix them. The
Engineer determines separate application rates.
Deliver lime in full loads unless it is the last load needed for a work shift.
Apply lime at ground temperatures above 35 °F. Do not apply lime if you expect the ground
temperature to drop below 35 °F before you complete mixing and compacting.
During mixing, maintain the in-place moisture of the soil to be stabilized a minimum 3 percent
above the optimum moisture determined under California Test 216 as modified in "Mixed
Material." During compaction and finish grading, add water to the surface to prevent drying until
the next layer of mixed material is placed, or until you apply curing treatment.
Scarify the surface of lime stabilized soil at least 2 inches between each layer. Do not scarify
the final surface of the lime stabilized soil.
Between the time of applying lime and 3 days after applying curing treatment, only allow
equipment or vehicles on the soil being stabilized that are essential to the work.

24-1.03B Preparing Soil

Except for soil clods, remove rocks or solids larger than 1/3 of the layer thickness. Regardless
of the layer thickness, remove rocks and solids greater than 4 inches. Notify the Engineer if you
encounter rocks or solids greater than 1/3 of the layer thickness.
Before adding lime, place the soil to be stabilized to within 0.08 foot of the specified lines and
grades and compact to not less than 90 percent relative compaction.

24-1.03C Applying Lime

Apply lime uniformly over the area to be stabilized using a vane spreader.
The Engineer determines the final application rate. Do not vary from this application rate by
more than 5 percent.
Apply lime in dry form. If you request and the Engineer approves, you may apply lime in slurry
form.
Lime slurry must be in suspension during application. Apply lime slurry uniformly making
successive passes over a measured section or roadway until the specified lime content is
reached. Apply the residue from lime slurry over the length of the roadway being processed.

24-1.03D Mixing
Lime and soil to be stabilized must be mixed uniformly at least twice to within 0.10 foot of the
specified depth at any point. If the mixing depth exceeds the specified depth by more than 10

April 11,2011 4-52

percent, add lime in proportion to the exceeded depth. The Department does not pay for this
added lime.
Mix lime on the same day it is applied. After the initial mixing, allow a mellowing period for at
least 36 hours before final mixing. Moisture content during the mellowing period determined
under California Test 226 must be at least 3 percent higher than the optimum moisture content.
You may add water and mix during the mellowing period.
Remix until the mixture is uniform with no streaks or pockets of lime.
Except for clods larger than 1 inch, mixed material must have a color reaction with sprayed
phenolphthalein alcohol indicator solution.
Complete all the mixing work within 7 days of the initial application of lime.

24-1.03E Compaction
Begin compacting immediately after final mixing, but not less than 36 hours after the beginning
of initial mixing.
Compact by using sheepsfoot or segmented wheel rollers immediately followed by steel drum or
pneumatic-tired rollers. Do not use vibratory rollers.
If you request and the Engineer approves, you may compact mixed material in layers greater
than 0.50 foot.
If the specified thickness is 0.50 foot or less, compact in one layer. If the specified thickness is
more than 0.50 foot, compact in 2 or more layers of approximately equal thickness. The
maximum compacted thickness of any one layer must not exceed 0.50 foot unless you first
demonstrate your equipment and methods provide uniform distribution of lime and achieve the
specified compaction.
Use other compaction methods in areas inaccessible to rollers.
Compact the lime stabilized soil to at least 95 percent relative compaction determined under
California Test 216 as modified under "Mixed Material." The relative compaction is determined
on a wet weight basis.

24-1.03F Finish Grading

Maintain the moisture content of the lime stabilized soil through the entire finish grading
operation at a minimum of 3 percent above optimum moisture content.
The finished surface of the lime stabilized soil must not vary more than 0.08 foot above or below
the grade established by the Engineer unless the lime stabilized soil is to be covered by material
paid for by the cubic yard, in which case the finished surface may not vary above the grade
established by the Engineer.
If lime stabilized soil is above the allowable tolerance, trim, remove, and dispose of the excess
material. Do not leave loose material on the finished surface. If finish rolling cannot be
completed within 2 hours of trimming, defer trimming.
If lime stabilized soil is below the allowable tolerance, you may use trimmed material to fill low
areas only if final grading and final compaction occurs within 48 hours of beginning initial

April 11,2011 4-53

compaction. Before placing trimmed material, scarify the surface of the area to be filled at least
2 inches deep.
Finish rolling of trimmed surfaces must be performed with at least 1 complete coverage with
steel drum or pneumatic-tired rollers.

24-1.03G Curing
General
Choose the method of curing.
Apply the chosen cure method within 48 hours of completing the sheepsfoot or segmented
wheel compaction. Apply the chosen cure method within the same day of any trimming and
finish grading.

Water Cure
Water may be used to cure the finished surface before you place a moist material blanket, or
apply curing seal. Keep the surface above the optimum moisture content of the lime stabilized
soil. Use this method for no more than 3 days, after which you must place a curing seal or
moist material blanket.

Curing Seal
Curing seal equipment must have a gage indicating the volume of curing seal in the storage
tank.
If curing seal is used, apply it:

1. To the finished surface of lime stabilized soil under Section 94-1.06, "Applying," of the
Standard Specifications
2. At a rate from 0.10 to 0.20 gallon per square yard. The Engineer determines the exact
rate
3. When the lime stabilized soil is at optimum moisture
4. When the ambient temperature is above 40 °F and rising

Repair damaged curing seal the same day the damage occurs.

Moist Material Blanket

Moist material blanket consists of moist structural material. Moist material blanket may be a
temporary or permanent layer of material of sufficient thickness to prevent drying of the lime
stabilized soil. You may use moist material blanket if the lime stabilized soil can bear the weight
of construction equipment. Maintain the moist material blanket above the optimum moisture
content, as appropriate, until the next structural layer is placed.

April 11,2011 4-54

24-1.04 MEASUREMENT AND PAYMENT

Lime stabilized soil is measured by the square yard determined from horizontal measurements
of the planned surface of the lime stabilized soil.
Curing seal is measured under Section 94, "Asphaltic Emulsions." The amount of curing seal
used is determined from the gauge specified for the curing equipment.
The contract item prices for the work involved with lime stabilized soil are paid:

1. Per square yard for lime stabilized soil

2. Per ton for lime
3. Per ton for asphaltic emulsion (curing seal)

Payment for the contract items involved with lime stabilized soil includes full compensation for
furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work
involved in constructing the lime stabilized soil, complete in place, as shown on the plans, as
specified in these specifications and the special provisions, and as directed by the Engineer.
The Department does not adjust payment for lime.
Quantities of lime wasted or disposed of in a manner not specified, or remaining on hand after
completion of the work, will not be paid for. If you use a partial load of lime, weigh the truck and
the remaining lime on a scale under Section 9-1.01, "Measurement of Quantities," and submit a
weighmaster certificate to the Engineer.
Full compensation for preparing soil to be stabilized is included in the contract price paid per
square yard for lime stabilized soil, and no separate payment is made therefor, except removing
and disposing of rocks and solids larger 1/3 of the layer thickness and larger than 4 inches from
native soil or embankment other than imported borrow is paid for as extra work as provided in
Section 4-1.03D, "Extra Work." Removing and disposing of rocks and solids larger than 1/3 of
the lift thickness and larger than 4 inches from imported borrow is at your expense.
Full compensation for mixing, compacting, and maintaining the moisture content of the lime
stabilized soil is included in the contract price paid per square yard for lime stabilized soil, and
no separate payment is made therefor.
Full compensation for applying lime is included in the contract price paid per ton for lime, and no
additional compensation is allowed therefor.
If the dispute resolution ITP determines the Engineer's test results are correct, the Engineer
deducts the ITP's testing costs from payments. If the ITP determines your test results are
correct, the State pays the ITP testing costs.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-55

SECTION 25 AGGREGATE SUBBASES

(Issued 02-16-07)

In Section 25-1.02A replace the 1st paragraph with:

Aggregate must be clean and free from organic matter and other deleterious substances.
Aggregate must consist of any combination of:

1. Broken stone
2. Crushed gravel
3. Natural rough surfaced gravel
4. Sand
5. Up to 100 percent of any combination of processed:

5.1. Asphalt concrete

5.2. Portland cement concrete
5.3. Lean concrete base
5.4. Cement treated base

Replace Section 25-1.02B with:

25-1.02B Class 4 Aggregate Subbase
Aggregate must be clean and free from organic matter and other deleterious substances.
Aggregate must consist of any combination of:

1. Broken stone
2. Crushed gravel
3. Natural rough surfaced gravel
4. Sand
5. Up to 100 percent of any combination of processed:

5.1. Asphalt concrete

5.2. Portland cement concrete
5.3. Lean concrete base
5.4. Cement treated base

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-56

SECTION 26 AGGREGATE BASES

(Issued 02-16-07)

In Section 26-1.02A replace the 1st paragraph with:

Aggregate must be clean and free from organic matter and other deleterious substances.
Aggregate must consist of any combination of:

1. Broken stone
2. Crushed gravel
3. Natural rough surfaced gravel
4. Sand
5. Up to 100 percent of any combination of processed:

5.1. Asphalt concrete

5.2. Portland cement concrete
5.3. Lean concrete base
5.4. Cement treated base

In Section 26-1.02B replace the 1st paragraph with:

Aggregate must be clean and free from organic matter and other deleterious substances.
Aggregate must consist of any combination of:

1. Broken stone
2. Crushed gravel
3. Natural rough surfaced gravel
4. Sand
5. Up to 100 percent of any combination of processed:

5.1. Asphalt concrete

5.2. Portland cement concrete
5.3. Lean concrete base
5.4. Cement treated base

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-57

SECTION 27 CEMENT TREATED BASES

(Issued 07-31-07)

In Section 27-1.02 replace the 1st paragraph with:

Cement shall be Type II portland cement conforming to the provisions in Section 90-2.01A,
"Cement."

In Section 27-1.02 replace the 3rd paragraph with:

Aggregate for use in Class A cement treated base shall be of such quality that when mixed with
cement in an amount not to exceed 5 percent by weight of the dry aggregate and compacted at
optimum moisture content, the compressive strength of a sample of the compacted mixture shall
not be less than 750 pounds per square inch at 7 days, when tested by California Test 312.

In Section 27-1.02 replace the 4th paragraph with:

Aggregate for use in Class B cement treated base shall have a Resistance (R-value) of not less
than 60 before mixing with cement and a Resistance (R-value) of not less than 80 after mixing
with cement in an amount not to exceed 2.5 percent by weight of the dry aggregate.

In Section 27-1.07 replace the 9th paragraph with:

When surfacing material is hot mix asphalt, the low areas shall be filled with hot mix asphalt
conforming to the requirements for the lowest layer of hot mix asphalt to be placed as surfacing.
This filling shall be done as a separate operation prior to placing the lowest layer of surfacing,
and full compensation for this filling will be considered as included in the contract price paid for
cement treated base and no additional compensation will be allowed therefor.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 28 LEAN CONCRETE BASE

(Issued 05-15-09)

In Section 28-1.02 replace the 1st paragraph with:

Cement shall be Type II portland cement conforming to the provisions in Section 90-2.01A,
"Cement."

April 11,2011 4-58

In Section 28-1.02 replace the 6th paragraph with:

Aggregate shall be of such quality that, when mixed with cement in an amount not to exceed
300 pounds per cubic yard, and tested in conformance with the requirements in California Test
548, the compressive strength of a sample will be not less than 700 pounds per square inch at 7
days.

Replace Section 28-1.05 with:

Placing of lean concrete base shall conform to the provisions for placing concrete pavement in
Section 40-3.04, "Placing Concrete," except that the third paragraph in Section 40-3.04A,
"General," shall not apply.
Unless otherwise required by the plans or the special provisions, lean concrete base shall be
constructed in not less than 12-foot widths separated by construction joints. Lean concrete
base constructed monolithically in widths greater than 26 feet shall be constructed with a
longitudinal contraction joint offset not more than 3 feet from the centerline of the width being
constructed.
Longitudinal contraction joints in lean concrete base shall be constructed in conformance with
the provisions in Section 40-3.08E, "Sawing Method."
When concrete pavement is to be placed over lean concrete base, longitudinal construction
joints and longitudinal contraction joints in the lean concrete base shall not be within one foot of
planned longitudinal contraction joints nor longitudinal construction joints in the concrete
pavement.
Lean concrete base shall not be mixed nor placed while the atmospheric temperature is below
35 °F, and shall not be placed on frozen ground.

In Section 28-1.06 replace the 1st and 2nd paragraphs with:

Lean concrete base shall be spread, compacted, and shaped in conformance with the
provisions in Section 40-3.04D, "Stationary Side Form Construction," and Section 40-3.04E,
"Slip-Form Construction."
In advance of curing operations, lean concrete base to be surfaced with hot mix asphalt shall be
textured with a drag strip of burlap, a broom or a spring steel tine device which will produce
scoring in the finished surface. The scoring shall be parallel with the centerline or transverse
thereto. The operation shall be performed at a time and in a manner to produce the coarsest
texture practical for the method used.

In Section 28-1.08 replace the 2nd paragraph with:

Hardened lean concrete base with a surface lower than 0.05 foot below the grade established
by the Engineer shall be removed and replaced with lean concrete base which complies with
these specifications, or if permitted by the Engineer, the low areas shall be filled with pavement
material as follows:

1. When pavement material is hot mix asphalt, the low areas shall be filled with hot mix
asphalt conforming to the requirements for the lowest layer of hot mix asphalt to be

April 11,2011 4-59

placed as pavement. This shall be done as a separate operation prior to placing the lowest
layer of pavement, and full compensation for this filling will be considered as included in
the contract price paid per cubic yard for lean concrete base and no additional
compensation will be allowed therefor.
2. When pavement material is portland cement concrete, the low areas shall be filled with
pavement concrete at the time and in the same operation that the pavement is placed.
Full compensation for this filling will be considered as included in the contract price paid
per cubic yard for lean concrete base and no additional compensation will be allowed
therefor.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 29 TREATED PERMEABLE BASES

(Issued 05-15-09)

In Section 29-1.02B replace the 2nd paragraph with:

Cement shall be Type II portland cement conforming to the provisions in Section 90-2.01A,
"Cement."

In Section 29-1.04A replace the 1st paragraph with:

Aggregates and asphalt for asphalt treated permeable base shall be stored, proportioned and
mixed in the same manner provided for storing, proportioning and mixing aggregates and
asphalt for hot mix asphalt in Section 39-1.08, "Production," except as follows:

1. The aggregate need not be separated into sizes.

2. The temperature of the aggregate before adding the asphalt binder shall be not less than
275° F nor more than 325° F.
3. Asphalt treated permeable base stored in excess of 2 hours shall not be used in the work.
4. The aggregate shall be combined with 2.5 percent paving asphalt by weight of the dry
aggregate. After testing samples of the Contractor's proposed aggregate supply, the
Engineer may order an increase or decrease in the asphalt content. If an increase or
decrease is ordered, and the increase or decrease exceeds the specified amount by more
than 0.1 percent by weight of the dry aggregate, the compensation payable to the
Contractor for the asphalt treated permeable base will be increased or decreased on the
basis of the total increase or decrease in asphalt.
5. The asphalt content of the asphalt mixture will be determined, at the option of the
Engineer, by extraction tests in conformance with the requirements in California Test 310
or 362, or will be determined in conformance with the requirements in California Test

April 11,2011 4-60

379. The bitumen ratio pounds of asphalt per 100 pounds of dry aggregate shall not vary
by more than 0.5 pound of asphalt above or 0.5 pound of asphalt below the amount
designated by the Engineer. Compliance with this requirement will be determined either
by taking samples from trucks at the plant or from the mat behind the paver before
rolling. If the sample is taken from the mat behind the paver, the bitumen ratio shall be
not less than the amount designated by the Engineer, less 0.7 pound of asphalt per 100
pounds of dry aggregate.

In Section 29-1.04B replace the 2nd paragraph with:

Cement treated permeable base shall contain not less than 287 pounds of cement per cubic
yard.

In Section 29-1.05 replace the 1st paragraph with:

Asphalt treated permeable base shall be spread and compacted as specified for hot mix asphalt
under the "Method" construction process in Section 39, "Hot Mix Asphalt," and these
specifications.

In Section 29-1.05 in the 8th paragraph, replace the 2nd sentence with:
The filter fabric shall conform to the provisions in Section 88-1.02, "Filtration," and shall be
placed in conformance with the provisions for placing filter fabric for edge drains in Section 68-
3.03, "Installation."

In Section 29-1.06 replace the 1st and 2nd paragraphs with:

Cement treated base shall be placed, spread, compacted, and shaped in conformance with the
provisions in Section 40-3.04D, "Stationary Side Form Construction," and Section 40-3.04E,
"Slip-Form Construction," except that vibrators shall not be used and the third paragraph in
Section 40-3.04A, "General," shall not apply.

In Section 29-1.06 in the 9th paragraph, replace the 2nd sentence with:
The filter fabric shall conform to the provisions in Section 88-1.02, "Filtration," and shall be
placed in conformance with the provisions for placing filter fabric for edge drains in Section 68-
3.03, "Installation."

In Section 29-1.07 replace the 2nd paragraph with:

Hardened treated permeable base with a surface lower than 0.05 foot below the grade
established by the Engineer shall be removed and replaced with treated permeable base which

April 11,2011 4-61

complies with these specifications, or if permitted by the Engineer, the low areas shall be filled
with pavement material as follows:

1. When pavement material is hot mix asphalt, the low areas shall be filled with hot mix
asphalt conforming to the requirements for the lowest layer of hot mix asphalt to be
placed as pavement. This shall be done as a separate operation prior to placing the lowest
layer of pavement.
2. When pavement material is portland cement concrete, the low areas shall be filled with
pavement concrete at the time and in the same operation in which the pavement is placed.
3. Full compensation for filling low areas will be considered as included in the contract
price paid per cubic yard for treated permeable base and no additional compensation will
be allowed therefor.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 37 BITUMINOUS SEALS

(Issued 06-05-09)

In Section 37-1.03 replace the 4th through 6th paragraphs with:

On 2-lane two-way roadways, W8-7 "LOOSE GRAVEL" signs and W13-1 (35) speed advisory
signs shall be furnished and placed adjacent to both sides of the traveled way where screenings
are being spread on a traffic lane. The first W8-7 sign in each direction shall be placed where
traffic first encounters loose screenings, regardless of which lane the screenings are being
spread on. The W13-1 (35) signs need not be placed in those areas with posted speed limits of
less than 40 MPH. The signs shall be placed at maximum 2,000-foot intervals along each side
of the traveled way and at public roads or streets entering the seal coat area as directed by the
Engineer.
On multilane roadways (freeways, expressways and multilane conventional highways) where
screenings are being spread on a traffic lane, W8-7 "LOOSE GRAVEL" signs and W13-1 (35)
speed advisory signs shall be furnished and placed adjacent to the outside edge of the traveled
way nearest to the lane being worked on. The first W8-7 sign shall be placed where the
screenings begin with respect to the direction of travel on that lane. The W13-1 (35) signs need
not be placed in those areas with posted speed limits of less than 40 MPH. The signs shall be
placed at maximum 2,000-foot intervals along the edge of traveled way and at on-ramps, public
roads or streets entering the seal coat area as directed by the Engineer.
The W8-7 and W13-1 signs shall be maintained in place at each location until final brooming of
the seal coat surface at that location is completed. The W8-7 and W13-1 signs shall conform to
the provisions for construction area signs in Section 12, "Construction Area Traffic Control
Devices." The signs may be set on temporary portable supports with the W13-1 below the W8-
7 or on barricades with the W13-1 sign alternating with the W8-7 sign.

April 11,2011 4-62

In Section 37-1.07 replace the 2nd paragraph with:

Rollers shall be oscillating type pneumatic-tired rollers. A minimum of 2 pneumatic-tired rollers
conforming to the provisions in Section 39-3.03 "Spreading and Compacting Equipment," shall
be furnished.

In Section 37-1.09 replace the 2nd paragraph with:

The above prices and payments shall include full compensation for furnishing all labor,
materials, tools, equipment and incidentals, and for doing all the work involved in applying seal
coat, complete in place, including furnishing, placing, maintaining, and removing W8-7 and
W13-1 signs, when required, and temporary supports or barricades for the signs, as shown on
the plans, and as specified in these specifications and the special provisions, and as directed by
the Engineer.

In Section 37-2.05 replace the 6th paragraph with:

In addition to conforming to the provisions in Section 5-1.10, "Equipment," the identifying
number of mixer-spreader trucks shall be at least 2 inches in height, located on the front and
rear of the vehicle.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 39 ASPHALT CONCRETE

(Issued 06-05-09)

Replace Section 39 with:

SECTION 39 HOT MIX ASPHALT

39-1 GENERAL

39-1.01 DESCRIPTION
Section 39 includes specifications for producing and placing hot mix asphalt (HMA) by mixing
aggregate and asphalt binder at a mixing plant and spreading and compacting the HMA mixture.
The special provisions specify one or more type of HMA, including:

April 11,2011 4-63

1. Type A
2. Type B
3. Open graded friction course (OGFC). OGFC includes hot mix asphalt (open graded),
rubberized hot mix asphalt (open graded) (RHMA-O) and rubberized hot mix asphalt
(open graded high binder) (RHMA-O-HB)
4. Rubberized hot mix asphalt (gap graded) (RHMA-G)

The special provisions specify the HMA construction process, including:

1. Standard
2. Method
3. Quality Control / Quality Assurance (QC / QA)

39-1.02 MATERIALS
39-1.02A Geosynthetic Pavement Interlayer
Geosynthetic pavement interlayer must comply with the specifications for pavement fabric or
paving mat in Section 88-1.07, "Pavement Interlayer."

39-1.02B Tack Coat

Tack coat must comply with the specifications for asphaltic emulsion in Section 94, "Asphaltic
Emulsion," or asphalt binder in Section 92, "Asphalts." Choose the type and grade.
Notify the Engineer if you dilute asphaltic emulsion with water. The weight ratio of added water
to asphaltic emulsion must not exceed 1 to 1.
Measure added water either by weight or volume in compliance with the specifications for
weighing, measuring, and metering devices under Section 9-1.01, "Measurement of Quantities,"
or you may use water meters from water districts, cities, or counties. If you measure water by
volume, apply a conversion factor to determine the correct weight.
With each dilution, submit in writing:

1. The weight ratio of water to bituminous material in the original asphaltic emulsion
2. The weight of asphaltic emulsion before diluting
3. The weight of added water
4. The final dilution weight ratio of water to asphaltic emulsion

39-1.02C Asphalt Binder

Asphalt binder in HMA must comply with Section 92, "Asphalts," or Section 39-1.02D, "Asphalt
Rubber Binder." The special provisions specify the grade.
Asphalt binder for geosynthetic pavement interlayer must comply with Section 92, "Asphalts."
Choose from Grades PG 64-10, PG 64-16, or PG 70-10.

April 11,2011 4-64

39-1.02D Asphalt Rubber Binder

General
Use asphalt rubber binder in RHMA-G, RHMA-O, and RHMA-O-HB. Asphalt rubber binder
must be a combination of:

1. Asphalt binder
2. Asphalt modifier
3. Crumb rubber modifier (CRM)

The combined asphalt binder and asphalt modifier must be 80.0 ± 2.0 percent by weight of the
asphalt rubber binder.

Asphalt Modifier
Asphalt modifier must be a resinous, high flash point, and aromatic hydrocarbon, and comply
with:

Asphalt Modifier for Asphalt Rubber Binder

Quality Characteristic ASTM Specification
2 -6
Viscosity, m /s (x 10 ) at 100 °C D 445 X ± 3a
Flash Point, CL.O.C., °C D 92 207 minimum
Molecular Analysis
Asphaltenes, percent by mass D 2007 0.1 maximum
Aromatics, percent by mass D 2007 55 minimum
Note:
a
The symbol "X" is the proposed asphalt modifier viscosity. "X" must be between 19 and 36. A change in "X"
requires a new asphalt rubber binder design.

Asphalt modifier must be from 2.0 percent to 6.0 percent by weight of the asphalt binder in the
asphalt rubber binder.

Crumb Rubber Modifier

CRM consists of a ground or granulated combination of scrap tire CRM and high natural CRM.
CRM must be 75.0 ± 2.0 percent scrap tire CRM and 25.0 ± 2.0 percent high natural CRM by
total weight of CRM. Scrap tire CRM must be from any combination of automobile tires, truck
tires, or tire buffings.
Sample and test scrap tire CRM and high natural CRM separately. CRM must comply with:

April 11,2011 4-65

Crumb Rubber Modifier for Asphalt Rubber Binder

Quality Characteristic Test Method Specification
Scrap tire CRM gradation LP-10 100
(% passing No. 8 sieve)
High natural CRM gradation LP-10 100
(% passing No. 10 sieve)
Wire in CRM (% max.) LP-10 0.01
Fabric in CRM (% max.) LP-10 0.05
CRM particle length (inch max.) a -- 3/16
CRM specific gravity a CT 208 1.1 – 1.2
Natural rubber content in high natural CRM (%) a ASTM D 297 40.0 – 48.0
Note:
a
Test at mix design and for Certificate of Compliance.

Only use CRM ground and granulated at ambient temperature. If steel and fiber are
cryogenically separated, it must occur before grinding and granulating. Only use cryogenically
produced CRM particles that can be ground or granulated and not pass through the grinder or
granulator.
CRM must be dry, free-flowing particles that do not stick together. CRM must not cause
foaming when combined with the asphalt binder and asphalt modifier. You may add calcium
carbonate or talc up to 3 percent by weight of CRM.

Asphalt Rubber Binder Design and Profile

Submit in writing an asphalt rubber binder design and profile that complies with the asphalt
rubber binder specifications. In the design, designate the asphalt, asphalt modifier, and CRM
and their proportions. The profile must include the same component sources for the asphalt
rubber binder used.
Design the asphalt rubber binder from testing you perform for each quality characteristic and for
the reaction temperatures expected during production. The 24-hour (1,440-minute) interaction
period determines the design profile. At a minimum, mix asphalt rubber binder components,
take samples, and perform and record the following tests:

Asphalt Rubber Binder Reaction Design Profile

Test Minutes of Reaction a Limits
45 60 90 120 240 360 1440
Cone penetration @ 77 °F, 0.10-mm (ASTM D 217) Xb X X 25 - 70
Resilience @ 77 °F, percent rebound (ASTM D 5329) X X X 18 min.
Field softening point, °F (ASTM D 36) X X X 125 - 165
Viscosity, centipoises (LP-11) X X X X X X X 1,500 - 4,000
Notes:
a
Six hours (360 minutes) after CRM addition, reduce the oven temperature to 275 °F for a period of 16 hours. After the
16-hour (1320 minutes) cool-down after CRM addition, reheat the binder to the reaction temperature expected during
production for sampling and testing at 24 hours (1440 minutes).
b
"X" denotes required testing

Asphalt Rubber Binder

After interacting for a minimum of 45 minutes, asphalt rubber binder must comply with:

April 11,2011 4-66

Asphalt Rubber Binder

Quality Characteristic Test for Quality Test Method Specification
Control or Acceptance Minimum Maximum
Cone penetration @ 77 °F, 0.10-mm Acceptance ASTM D 217 25 70
Resilience @ 77 °F, percent rebound Acceptance ASTM D 5329 18 --
Field softening point, °F Acceptance ASTM D 36 125 165
Viscosity @ 375 °F, centipoises Quality Control LP-11 1,500 4,000

39-1.02E Aggregate
Aggregate must be clean and free from deleterious substances. Aggregate:

1. Retained on the No. 4 sieve is coarse

2. Passing the No. 4 sieve is fine
3. Added and passing the No. 30 sieve is supplemental fine, including:

3.1. Hydrated lime

3.2. Portland cement
3.3. Fines from dust collectors

The special provisions specify the aggregate gradation for each HMA type.
The specified aggregate gradation is before the addition of asphalt binder and includes
supplemental fines. The Engineer tests for aggregate grading under California Test 202,
modified by California Test 105 if there is a difference in specific gravity of 0.2 or more between
the coarse and fine parts of different aggregate blends.
Choose a sieve size target value (TV) within each target value limit presented in the aggregate
gradation tables.

April 11,2011 4-67

Aggregate Gradation
(Percentage Passing)
HMA Types A and B

3/4–inch HMA Types A and B

Sieve Sizes Target Value Limits Allowable Tolerance
1" 100 —
3/4" 90 - 100 TV ±5
1/2" 70 - 90 TV ±6
No. 4 45 - 55 TV ±7
No. 8 32 - 40 TV ±5
No. 30 12 - 21 TV ±4
No. 200 2-7 TV ±2

1/2–inch HMA Types A and B

Sieve Sizes Target Value Limits Allowable Tolerance
3/4" 100 —
1/2" 95 - 99 TV ±6
3/8" 75 - 95 TV ±6
No. 4 55 - 66 TV ±7
No. 8 38 - 49 TV ±5
No. 30 15 - 27 TV ±4
No. 200 2-8 TV ±2

3/8–inch HMA Types A and B

Sieve Sizes Target Value Limits Allowable Tolerance
1/2" 100 —
3/8" 95 - 100 TV ±6
No. 4 58 - 72 TV ±7
No. 8 34 - 48 TV ±6
No. 30 18 - 32 TV ±5
No. 200 2-9 TV ±2

No. 4 HMA Types A and B

Sieve Sizes Target Value Limits Allowable Tolerance
3/8" 100 —
No. 4 95 - 100 TV ±7
No. 8 72 - 77 TV ±7
No. 30 37 - 43 TV ±7
No. 200 2 - 12 TV ±4

April 11,2011 4-68

Rubberized Hot Mix Asphalt - Gap Graded (RHMA-G)

3/4–inch RHMA-G
Sieve Sizes Target Value Limits Allowable Tolerance
1" 100 —
3/4" 95 - 100 TV ±5
1/2" 83 - 87 TV ±6
3/8" 65 - 70 TV ±6
No. 4 28 - 42 TV ±7
No. 8 14 - 22 TV ±5
No. 200 0-6 TV ±2

1/2–inch RHMA-G
Sieve Sizes Target Value Limits Allowable Tolerance
3/4" 100 —
1/2" 90 - 100 TV ±6
3/8" 83 - 87 TV ±6
No. 4 28 - 42 TV ±7
No. 8 14 - 22 TV ±5
No. 200 0-6 TV ±2

Open Graded Friction Course (OGFC)

1–inch OGFC
Sieve Sizes Target Value Limits Allowable Tolerance
1 1/2" 100 —
1" 99 - 100 TV ±5
3/4" 85 - 96 TV ±5
1/2" 55 - 71 TV ±6
No. 4 10 - 25 TV ±7
No. 8 6 - 16 TV ±5
No. 200 1-6 TV ±2

1/2–inch OGFC
Sieve Sizes Target Value Limits Allowable Tolerance
3/4" 100 —
1/2" 95 - 100 TV ±6
3/8" 78 - 89 TV ±6
No. 4 28 - 37 TV ±7
No. 8 7 - 18 TV ±5
No. 30 0 - 10 TV ±4
No. 200 0-3 TV ±2

3/8–inch OGFC
Sieve Sizes Target Value Limits Allowable Tolerance
1/2" 100 —
3/8" 90 - 100 TV ±6
No. 4 29 - 36 TV ±7
No. 8 7 - 18 TV ±6
No. 30 0 - 10 TV ±5
No. 200 0-3 TV ±2

April 11,2011 4-69

Before the addition of asphalt binder and lime treatment, aggregate must comply with:

Aggregate Quality
Quality Characteristic Test Method HMA Type
A B RHMA-G OGFC
Percent of crushed particles CT 205
Coarse aggregate (% min.)
One fractured face 90 25 -- 90
Two fractured faces 75 -- 90 75
Fine aggregate (% min)
(Passing No. 4 sieve
and retained on No. 8 sieve.)
One fractured face 70 20 70 90
Los Angeles Rattler (% max.) CT 211
Loss at 100 Rev. 12 -- 12 12
Loss at 500 Rev. 45 50 40 40
Sand equivalent (min.) a CT 217 47 42 47 --
Fine aggregate angularity (% min.) b AASHTO T
304 Method 45 45 45 --
A
Flat and elongated particles (% max. ASTM D
by weight @ 5:1) 4791 10 10 10 10
Notes:
a
Reported value must be the average of 3 tests from a single sample.
b
The Engineer waives this specification if HMA contains less than 10 percent of nonmanufactured sand by weight
of total aggregate. Manufactured sand is fine aggregate produced by crushing rock or gravel.

39-1.02F Reclaimed Asphalt Pavement

You may produce HMA using reclaimed asphalt pavement (RAP). HMA produced using RAP
must comply with the specifications for HMA except aggregate quality specifications do not
apply to RAP. You may substitute RAP aggregate for a part of the virgin aggregate in HMA in a
quantity not exceeding 15.0 percent of the aggregate blend. Do not use RAP in OGFC and
RHMA-G.
Assign the substitution rate of RAP aggregate for virgin aggregate with the job mix formula
(JMF) submittal. The JMF must include the percent of RAP used. If you change your assigned
RAP aggregate substitution rate by more than 5 percent (within the 15.0 percent limit), submit a
new JMF.
Process RAP from asphalt concrete. You may process and stockpile RAP throughout the
project's life. Prevent material contamination and segregation. Store RAP in stockpiles on
smooth surfaces free of debris and organic material. Processed RAP stockpiles must consist
only of homogeneous RAP.

39-1.03 HOT MIX ASPHALT MIX DESIGN REQUIREMENTS

39-1.03A General
A mix design consists of performing California Test 367 and laboratory procedures on
combinations of aggregate gradations and asphalt binder contents to determine the optimum

April 11,2011 4-70

binder content (OBC) and HMA mixture qualities. If RAP is used, use Laboratory Procedure LP-
9. The result of the mix design becomes the proposed JMF.
Use Form CEM-3512 to document aggregate quality and mix design data. Use Form CEM-
3511 to present the JMF.
Laboratories testing aggregate qualities and preparing the mix design and JMF must be
qualified under the Department's Independent Assurance Program. Take samples under
California Test 125.
The Engineer reviews the aggregate qualities, mix design, and JMF and verifies and accepts
the JMF.
You may change the JMF during production. Do not use the changed JMF until the Engineer
accepts it. Except when adjusting the JMF in compliance with Section 39-1.03E, "Job Mix
Formula Verification," perform a new mix design and submit in writing a new JMF submittal for
changing any of the following:

1. Target asphalt binder percentage

2. Asphalt binder supplier
3. Asphalt rubber binder supplier
4. Component materials used in asphalt rubber binder or percentage of any component
materials
5. Combined aggregate gradation
6. Aggregate sources
7. Substitution rate for RAP aggregate of more than 5 percent
8. Any material in the JMF

For OGFC, submit in writing a complete JMF submittal except asphalt binder content. The
Engineer determines the asphalt binder content under California Test 368 within 20 days of your
complete JMF submittal and provides you a Form CEM-3513.

39-1.03B Hot Mix Asphalt Mix Design

Perform a mix design that produces HMA in compliance with:

April 11,2011 4-71

Hot Mix Asphalt Mix Design Requirements

Quality Characteristic Test Method HMA Type
A B RHMA-G
Air voids content (%) CT 367a 4.0 4.0 Special
Provisions
Voids in mineral aggregate (% min.) LP-2
No. 4 grading 17.0 17.0 --
3/8" grading 15.0 15.0 --
1/2" grading 14.0 14.0 18.0 – 23.0b
3/4" grading 13.0 13.0 18.0 – 23.0b
Voids filled with asphalt (%) LP-3
No. 4 grading 76.0 – 80.0 76.0 – 80.0 Note d
3/8" grading 73.0 – 76.0 73.0 – 76.0
1/2" grading 65.0 – 75.0 65.0 – 75.0
3/4" grading 65.0 – 75.0 65.0 – 75.0
Dust proportion LP-4
No. 4 and 3/8" gradings 0.9 – 2.0 0.9 – 2.0 Note d
1/2" and 3/4" gradings 0.6 – 1.3 0.6 – 1.3
Stabilometer value (min.) c CT 366
No. 4 and 3/8" gradings 30 30 --
1/2" and 3/4" gradings 37 35 23
Notes:
a
Calculate the air voids content of each specimen using California Test 309 and Lab Procedure LP-1. Modify
California Test 367, Paragraph C5, to use the exact air voids content specified in the selection of OBC.
b
Voids in mineral aggregate for RHMA-G must be within this range.
c
Modify California Test 304, Part 2.B.2.c: "After compaction in the compactor, cool to 140 °± 5 °F by allowing
the briquettes to cool at room temperature for 0.5-hour, then place the briquettes in the oven at 140 °F for a
minimum of 2 hours and not more than 3 hours."
d
Report this value in the JMF submittal.

For stability and air voids content, prepare 3 briquettes at the OBC and test for compliance.
Report the average of 3 tests. Prepare new briquettes and test if the range of stability for the 3
briquettes is more than 8 points. The average air void content may vary from the specified air
void content by ±0.5 percent.
You may use the briquettes used for stability testing to determine bulk specific gravity under CT
308. If you use the same briquettes and tests using bulk specific gravity fail, you may prepare 3
new briquettes and determine a new bulk specific gravity.

39-1.03C Job Mix Formula Submittal

Each JMF submittal must consist of:

1. Proposed JMF on Form CEM-3511

2. Mix design documentation on Form CEM-3512 dated within 12 months of submittal
3. JMF verification on Form CEM-3513, if applicable
4. JMF renewal on Form CEM-3514, if applicable
5. Materials Safety Data Sheets (MSDS) for:

5.1. Asphalt binder

April 11,2011 4-72

5.2. Base asphalt binder used in asphalt rubber binder

5.3. CRM and asphalt modifier used in asphalt rubber binder
5.4. Blended asphalt rubber binder mixture
5.5. Supplemental fine aggregate except fines from dust collectors
5.6. Antistrip additives

If the Engineer requests in writing, sample the following materials in the presence of the
Engineer and place in labeled containers weighing no more than 50 pounds each:

1. Coarse, fine, and supplemental fine aggregate from stockpiles, cold feed belts, or hot
bins. Samples must include at least 120 pounds for each coarse aggregate, 80 pounds for
each fine aggregate, and 10 pounds for each type of supplemental fines. The Department
combines these aggregate samples to comply with the JMF target values submitted on
Form CEM-3511.
2. RAP from stockpiles or RAP system. Samples must be at least 60 pounds.
3. Asphalt binder from the binder supplier. Samples must be in two 1-quart cylindrical
shaped cans with open top and friction lids.
4. Asphalt rubber binder with the components blended in the proportions to be used.
Samples must be in four 1-quart cylindrical shaped cans with open top and friction lids.

Notify the Engineer in writing at least 2 business days before sampling materials. For aggregate
and RAP, split the samples into at least 4 parts. Submit 3 parts to the Engineer and use 1 part
for your testing.

39-1.03D Job Mix Formula Review

The Engineer reviews each mix design and proposed JMF within 5 business days from the
complete JMF submittal. The review consists of reviewing the mix design procedures and
comparing the proposed JMF with the specifications.
The Engineer may verify aggregate qualities during this review period.

39-1.03E Job Mix Formula Verification

If you cannot submit a Department-verified JMF on Form CEM-3513 dated within 12 months
before HMA production, the Engineer verifies the JMF.
Based on your testing and production experience, you may submit on Form CEM-3511 an
adjusted JMF before the Engineer's verification testing. JMF adjustments may include a change
in the:

1. Asphalt binder content target value up to ±0.6 percent from the optimum binder content
value submitted on Form CEM-3512 except do not adjust the target value for asphalt
rubber binder for RHMA-G below 7.0 percent
2. Aggregate gradation target values within the target value limits specified in the aggregate
gradation tables

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For HMA Type A, Type B, and RHMA-G, the Engineer verifies the JMF from samples taken
from HMA produced by the plant to be used. Notify the Engineer in writing at least 2 business
days before sampling materials.
In the Engineer's presence and from the same production run, take samples of:

1. Aggregate
2. Asphalt binder
3. RAP
4. HMA

Sample aggregate from cold feed belts or hot bins. Sample RAP from the RAP system.
Sample HMA under California Test 125 except if you request in writing and the Engineer
approves, you may sample from any of the following locations:

1. The plant
2. A truck
3. A windrow
4. The paver hopper
5. The mat behind the paver

You may sample from a different project including a non-Department project if you make
arrangements for the Engineer to be present during sampling.
For aggregate, RAP, and HMA, split the samples into at least 4 parts and label their containers.
Submit 3 split parts to the Engineer and use 1 part for your testing.
The Engineer verifies each proposed JMF within 20 days of receiving verification samples. If
you request in writing, the Engineer verifies RHMA-G quality requirements within 3 business
days of sampling. Verification is testing for compliance with the specifications for:

1. Aggregate quality
2. Aggregate gradation (JMF TV ± tolerance)
3. Asphalt binder content (JMF TV ± tolerance)
4. HMA quality specified in the table Hot Mix Asphalt Mix Design Requirements except:

4.1. Air voids content (design value ± 2.0 percent)

4.2. Voids filled with asphalt (report only if an adjustment for asphalt binder content
target value is less than or equal to ± 0.3 percent from OBC)
4.3. Dust proportion (report only if an adjustment for asphalt binder content target value
is less than or equal to ± 0.3 percent from OBC)

The Engineer prepares 3 briquettes from a single split sample. To verify the JMF for stability
and air voids content, the Engineer tests the 3 briquettes and reports the average of 3 tests.

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The Engineer prepares new briquettes if the range of stability for the 3 briquettes is more than 8
points.
The Engineer may use the briquettes used for stability testing to determine bulk specific gravity
under CT 308. If the Engineer uses the same briquettes and the tests using bulk specific gravity
fail, the Engineer prepares 3 new briquettes and determines a new bulk specific gravity.
If the Engineer verifies the JMF, the Engineer provides you a Form CEM-3513.
If the Engineer's tests on plant-produced samples do not verify the JMF, the Engineer notifies
you in writing and you must submit a new JMF submittal or submit an adjusted JMF based on
your testing. JMF adjustments may include a change in the:

You may adjust the JMF only once due to a failed verification test. An adjusted JMF requires a
new Form CEM-3511 and verification of a plant-produced sample.
The Engineer reverifies the JMF if HMA production has stopped for longer than 30 days and the
verified JMF is older than 12 months.
For each HMA type and aggregate size specified, the Engineer verifies at the State's expense
up to 2 proposed JMF including a JMF adjusted after verification failure. The Engineer deducts
$3,000 from payments for each verification exceeding this limit. This deduction does not apply
to verifications initiated by the Engineer or if a JMF expires while HMA production is stopped
longer than 30 days.

39-1.03F Job Mix Formula Renewal

You may request a JMF renewal by submitting the following:

1. Proposed JMF on Form CEM-3511

2. A previously verified JMF documented on Form CEM-3513 dated within 12 months
3. Mix design documentation on Form CEM-3512 used for the previously verified JMF

If the Engineer requests in writing, sample the following materials in the presence of the
Engineer and place in labeled containers weighing no more than 50 pounds each:

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2. RAP from stockpiles or RAP system. Samples must be at least 60 pounds.

3. Asphalt binder from the binder supplier. Samples must be in two 1-quart cylindrical
shaped cans with open top and friction lids.
4. Asphalt rubber binder with the components blended in the proportions to be used.
Samples must be in four 1-quart cylindrical shaped cans with open top and friction lids.

Notify the Engineer in writing at least 2 business days before sampling materials. For aggregate
and RAP, split samples into at least 4 parts. Submit 3 parts to the Engineer and use 1 part for
your testing.
The Engineer reviews each complete JMF renewal submittal within 5 business days.
The Engineer may verify aggregate qualities during this review period.
Notify the Engineer in writing at least 2 business days before sampling materials. For
aggregate, RAP, and HMA, split the samples into at least 4 parts. Submit 3 parts to the
Engineer and use 1 part for your testing.
The Engineer verifies the JMF renewal submittal under Section 39-1.03E, "Job Mix Formula
Verification," except:

1. The Engineer retains samples until you provide test results for your part on Form CEM-
3514.
2. The Engineer tests samples of materials obtained from the HMA production unit after
you submit test results that comply with the specifications for the quality characteristics
under Section 39-1.03E, "Job Mix Formula Verification."
3. The Engineer verifies each proposed JMF within 30 days of receiving verification
samples.
4. You may not adjust the JMF due to a failed verification.
5. For each HMA type and aggregate gradation specified, the Engineer verifies at the State's
expense 1 proposed JMF.

If the Engineer verifies the JMF renewal, the Engineer provides you a Form CEM-3513.

39-1.03G Job Mix Formula Acceptance

You may start HMA production if:

1. The Engineer's review of the JMF shows compliance with the specifications.
2. The Department has verified the JMF within 12 months before HMA production.
3. The Engineer accepts the verified JMF.

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39-1.04 CONTRACTOR QUALITY CONTROL

39-1.04A General
Establish, maintain, and change a quality control system to ensure materials and work comply
with the specifications. Submit quality control test results to the Engineer within 3 days of a
request except when QC / QA is specified.
You must identify the HMA sampling location in your Quality Control Plan. During production,
take samples under California Test 125 except if you request in writing and the Engineer
approves, you may sample HMA from:

1. The plant
2. The truck
3. A windrow
4. The paver hopper
5. The mat behind the paver

39-1.04B Prepaving Conference

Meet with the Engineer at a prepaving conference at a mutually agreed time and place. Discuss
methods of performing the production and paving work.

39-1.04C Asphalt Rubber Binder

Take asphalt rubber binder samples from the feed line connecting the asphalt rubber binder
tank to the HMA plant. Sample and test asphalt rubber binder under Laboratory Procedure LP-
11.
Test asphalt rubber binder for compliance with the viscosity specifications in Section 39-1.02,
"Materials." During asphalt rubber binder production and HMA production using asphalt rubber
binder, measure viscosity every hour with not less than 1 reading for each asphalt rubber binder
batch. Log measurements with corresponding time and asphalt rubber binder temperature.
Submit the log daily in writing.
Submit a Certificate of Compliance under Section 6-1.07, "Certificates of Compliance." With the
Certificate of Compliance, submit test results in writing for CRM and asphalt modifier with each
truckload delivered to the HMA plant. A Certificate of Compliance for asphalt modifier must not
represent more than 5,000 pounds. Use an AASHTO-certified laboratory for testing.
Sample and test gradation and wire and fabric content of CRM once per 10,000 pounds of scrap
tire CRM and once per 3,400 pounds of high natural CRM. Sample and test scrap tire CRM and
high natural CRM separately.
Submit certified weight slips in writing for the CRM and asphalt modifier furnished.

39-1.04D Aggregate
Determine the aggregate moisture content and RAP moisture content in continuous mixing
plants at least twice a day during production and adjust the plant controller. Determine the RAP
moisture content in batch mixing plants at least twice a day during production and adjust the
plant controller.

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39-1.04E Reclaimed Asphalt Pavement

Perform RAP quality control testing each day.
Sample RAP once daily and determine the RAP aggregate gradation under Laboratory
Procedure LP-9 and submit the results to the Engineer in writing with the combined aggregate
gradation.

39-1.04F Density Cores

To determine density for Standard and QC / QA projects, take 4-inch or 6-inch diameter density
cores at least once every 5 business days. Take 1 density core for every 250 tons of HMA from
random locations the Engineer designates. Take density cores in the Engineer's presence and
backfill and compact holes with material authorized by the Engineer. Before submitting a
density core to the Engineer, mark it with the density core's location and place it in a protective
container.
If a density core is damaged, replace it with a density core taken within 1 foot longitudinally from
the original density core. Relocate any density core located within 1 foot of a rumble strip to 1
foot transversely away from the rumble strip.

39-1.04G Briquettes
Prepare 3 briquettes for each stability and air voids content determination. Report the average
of 3 tests. Prepare new briquettes and test if the range of stability for the 3 briquettes is more
than 12 points.
You may use the briquettes used for stability testing to determine bulk specific gravity under CT
308. If you use these briquettes and tests using bulk specific gravity fail, you may prepare 3
new briquettes and determine a new bulk specific gravity.

39-1.05 ENGINEER'S ACCEPTANCE

The Engineer's acceptance of HMA is specified in the sections for each HMA construction
process.
The Engineer samples materials for testing under California Test 125 and the applicable test
method except samples may be taken from:

1. The plant from:

1.1. A truck
1.2. An automatic sampling device

2. The mat behind the paver

Sampling must be independent of Contractor quality control, statistically-based, and random.

If you request, the Engineer splits samples and provides you with a part.

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The Engineer accepts HMA based on:

1. Accepted JMF
2. Accepted QCP for Standard and QC / QA
3. Compliance with the HMA Acceptance tables
4. Acceptance of a lot for QC / QA
5. Visual inspection

The Engineer prepares 3 briquettes for each stability and air voids content determination. The
Engineer reports the average of 3 tests. The Engineer prepares new briquettes and test if the
range of stability for the 3 briquettes is more than 8 points.
The Engineer may use the briquettes used for stability testing to determine bulk specific gravity
under CT 308. If the Engineer uses the same briquettes and the tests using bulk specific gravity
fail, the Engineer prepares 3 new briquettes and determines a new bulk specific gravity.

39-1.06 DISPUTE RESOLUTION

You and the Engineer must work together to avoid potential conflicts and to resolve disputes
regarding test result discrepancies. Notify the Engineer in writing within 5 days of receiving a
test result if you dispute the test result.
If you or the Engineer dispute each other's test results, submit written quality control test results
and copies of paperwork including worksheets used to determine the disputed test results to the
Engineer. An Independent Third Party (ITP) performs referee testing. Before the ITP
participates in a dispute resolution, the ITP must be accredited under the Department's
Independent Assurance Program. The ITP must be independent of the project. By mutual
agreement, the ITP is chosen from:

If split quality control or acceptance samples are not available, the ITP uses any available
material representing the disputed HMA for evaluation.

39-1.07 PRODUCTION START-UP EVALUATION

The Engineer evaluates HMA production and placement at production start-up.
Within the first 750 tons produced on the first day of HMA production, in the Engineer's
presence and from the same production run, take samples of:

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1. Aggregate
2. Asphalt binder
3. RAP
4. HMA

Sample aggregate from cold feed belts or hot bins. Take RAP samples from the RAP system.
Sample HMA under California Test 125 except if you request in writing and the Engineer
approves, you may sample HMA from:

1. The plant
2. The truck
3. A windrow
4. The paver hopper
5. The mat behind the paver

For aggregate, RAP, and HMA, split the samples into at least 4 parts and label their containers.
Submit 3 split parts to the Engineer and keep 1 part.
For Standard and QC / QA projects, you and the Engineer must test the split samples and
report test results in writing within 3 business days of sampling. If you proceed before receipt of
the test results, the Engineer may consider the HMA placed to be represented by these test
results.
For Standard and QC / QA projects, take 4-inch or 6-inch diameter density cores within the first
750 tons on the first day of HMA production. For each density core, the Engineer reports the
bulk specific gravity determined under California Test 308, Method A in addition to the percent
of maximum theoretical density. You may test for in-place density at the density core locations
and include them in your production tests for percent of maximum theoretical density.

39-1.08 PRODUCTION
39-1.08A General
Produce HMA in a batch mixing plant or a continuous mixing plant. Proportion aggregate by hot
or cold feed control.
HMA plants must be Department-qualified. Before production, the HMA plant must have a
current qualification under the Department's Materials Plant Quality Program.
During production, you may adjust:

1. Hot or cold feed proportion controls for virgin aggregate and RAP
2. The set point for asphalt binder content

39-1.08B Mixing
Mix HMA ingredients into a homogeneous mixture of coated aggregates.
Asphalt binder must be between 275 °F and 375 °F when mixed with aggregate.
Asphalt rubber binder must be between 375 °F and 425 °F when mixed with aggregate.

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When mixed with asphalt binder, aggregate must not be more than 325 °F except aggregate for
OGFC with unmodified asphalt binder must be not more than 275 °F. Aggregate temperature
specifications do not apply when you use RAP.
HMA with or without RAP must not be more than 325 °F.

39-1.08C Asphalt Rubber Binder

Deliver scrap tire CRM and high natural CRM in separate bags.
Either proportion and mix asphalt binder, asphalt modifier, and CRM simultaneously or premix
the asphalt binder and asphalt modifier before adding CRM. If you premix asphalt binder and
asphalt modifier, mix them for at least 20 minutes. When you add CRM, the asphalt binder and
asphalt modifier must be between 375 °F and 440 °F.
Do not use asphalt rubber binder during the first 45 minutes of the reaction period. During this
period, the asphalt rubber binder mixture must be between 350 °F and the lower of 425 °F or 25
°F below the asphalt binder's flash point indicated in the MSDS.
If any asphalt rubber binder is not used within 4 hours after the reaction period, discontinue
heating. If the asphalt rubber binder drops below 375 °F, reheat before use. If you add more
scrap tire CRM to the reheated asphalt rubber binder, the binder must undergo a 45-minute
reaction period. The added scrap tire CRM must not exceed 10 percent of the total asphalt
rubber binder weight. Reheated and reacted asphalt rubber binder must comply with the
viscosity specifications for asphalt rubber binder in Section 39-1.02, "Materials." Do not reheat
asphalt rubber binder more than twice.

39-1.09 SUBGRADE, TACK COAT, AND GEOSYNTHETIC PAVEMENT

INTERLAYER
39-1.09A General
Prepare subgrade or apply tack coat to surfaces receiving HMA. If specified, place geosynthetic
pavement interlayer over a coat of asphalt binder.

39-1.09B Subgrade
Subgrade to receive HMA must comply with the compaction and elevation tolerance
specifications in the sections for the material involved. Subgrade must be free of loose and
extraneous material. If HMA is paved on existing base or pavement, remove loose paving
particles, dirt, and other extraneous material by any means including flushing and sweeping.

39-1.09C Tack Coat

Apply tack coat:

1. To existing pavement including planed surfaces

2. Between HMA layers
3. To vertical surfaces of:

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3.1. Curbs
3.2. Gutters
3.3. Construction joints

Before placing HMA, apply tack coat in 1 application at the minimum residual rate specified for
the condition of the underlying surface:

Tack Coat Application Rates for HMA Type A, Type B, and RHMA-G
Minimum Residual Rates (gallons per square yard)
CSS1/CSS1h, CRS1/CRS2, Asphalt Binder and
SS1/SS1h and RS1/RS2 and PMRS2/PMCRS2
HMA over:
QS1h/CQS1h QS1/CQS1 and
Asphaltic Asphaltic PMRS2h/PMCRS2h
Emulsion Emulsion Asphaltic Emulsion
New HMA (between layers) 0.02 0.03 0.02
Existing AC and PCC pavement 0.03 0.04 0.03
Planed pavement 0.05 0.06 0.04

Tack Coat Application Rates for OGFC

Minimum Residual Rates (gallons per square yard)
CSS1/CSS1h, CRS1/CRS2, Asphalt Binder and
SS1/SS1h and RS1/RS2 and PMRS2/PMCRS2
OGFC over:
QS1h/CQS1h QS1/CQS1 and
Asphaltic Asphaltic PMRS2h/PMCRS2h
Emulsion Emulsion Asphaltic Emulsion
New HMA 0.03 0.04 0.03
Existing AC and PCC pavement 0.05 0.06 0.04
Planed pavement 0.06 0.07 0.05

If you dilute asphaltic emulsion, mix until homogeneous before application.

Apply to vertical surfaces with a residual tack coat rate that will thoroughly coat the vertical face
without running off.
If you request in writing and the Engineer authorizes, you may:

1. Change tack coat rates

2. Omit tack coat between layers of new HMA during the same work shift if:

2.1. No dust, dirt, or extraneous material is present

2.2. The surface is at least 140 °F

Immediately in advance of placing HMA, apply additional tack coat to damaged areas or where
loose or extraneous material is removed.
Close areas receiving tack coat to traffic. Do not track tack coat onto pavement surfaces
beyond the job site.
Asphalt binder tack coat must be between 285 °F and 350 °F when applied.

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39-1.09D Geosynthetic Pavement Interlayer

Place geosynthetic pavement interlayer in compliance with the manufacturer's
recommendations.
Before placing the geosynthetic pavement interlayer and asphalt binder:

1. Repair cracks 1/4 inch and wider, spalls, and holes in the pavement. The State pays for
this repair work under Section 4-1.03D, "Extra Work."
2. Clean the pavement of loose and extraneous material.

Immediately before placing the interlayer, apply 0.25 gallon ± 0.03 gallon of asphalt binder per
square yard of interlayer or until the fabric is saturated. Apply asphalt binder the width of the
geosynthetic pavement interlayer plus 3 inches on each side. At interlayer overlaps, apply
asphalt binder on the lower interlayer the same overlap distance as the upper interlayer.
Align and place the interlayer with no overlapping wrinkles, except a wrinkle that overlaps may
remain if it is less than 1/2 inch thick. If the overlapping wrinkle is more than 1/2 inch thick, cut
the wrinkle out and overlap the interlayer no more than 2 inches.
The minimum HMA thickness over the interlayer must be 0.12 foot thick including conform
tapers. Do not place the interlayer on a wet or frozen surface.
Overlap the interlayer borders between 2 inches and 4 inches. In the direction of paving,
overlap the following roll with the preceding roll at any break.
You may use rolling equipment to correct distortions or wrinkles in the interlayer.
If asphalt binder tracked onto the interlayer or brought to the surface by construction equipment
causes interlayer displacement, cover it with a small quantity of HMA.
Before placing HMA on the interlayer, do not expose the interlayer to:

1. Traffic except for crossings under traffic control and only after you place a small HMA
quantity
2. Sharp turns from construction equipment
3. Damaging elements

Pave HMA on the interlayer during the same work shift.

39-1.10 SPREADING AND COMPACTING EQUIPMENT

Paving equipment for spreading must be:

1. Self-propelled
2. Mechanical
3. Equipped with a screed or strike-off assembly that can distribute HMA the full width of a
traffic lane

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4. Equipped with a full-width compacting device

5. Equipped with automatic screed controls and sensing devices that control the thickness,
longitudinal grade, and transverse screed slope

Install and maintain grade and slope references.

The screed must produce a uniform HMA surface texture without tearing, shoving, or gouging.
The paver must not leave marks such as ridges and indentations unless you can eliminate them
by rolling.
Rollers must be equipped with a system that prevents HMA from sticking to the wheels. You
may use a parting agent that does not damage the HMA or impede the bonding of layers.
In areas inaccessible to spreading and compacting equipment:

1. Spread the HMA by any means to obtain the specified lines, grades and cross sections.
2. Use a pneumatic tamper, plate compactor, or equivalent to achieve thorough compaction.

39-1.11 TRANSPORTING, SPREADING, AND COMPACTING

Do not pave HMA on a wet pavement or frozen surface.
You may deposit HMA in a windrow and load it in the paver if:

1. Paver is equipped with a hopper that automatically feeds the screed

2. Loading equipment can pick up the windrowed material and deposit it in the paver
hopper without damaging base material
3. Activities for deposit, pick-up, loading, and paving are continuous
4. HMA temperature in the windrow does not fall below 260 °F

You may pave HMA in 1 or more layers on areas less than 5 feet wide and outside the traveled
way including shoulders. You may use mechanical equipment other than a paver for these
areas. The equipment must produce a uniform smoothness and texture.
HMA handled, spread, or windrowed must not stain the finished surface of any improvement
including pavement.
Do not use petroleum products such as kerosene or diesel fuel to release HMA from trucks,
spreaders, or compactors.
HMA must be free of:

1. Segregation
2. Coarse or fine aggregate pockets
3. Hardened lumps

Longitudinal joints in the top layer must match specified lane edges. Alternate longitudinal joint
offsets in lower layers at least 0.5 foot from each side of the specified lane edges. You may
request in writing other longitudinal joint placement patterns.

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Until the adjoining through lane's top layer has been paved, do not pave the top layer of:

1. Shoulders
2. Tapers
3. Transitions
4. Road connections
5. Driveways
6. Curve widenings
7. Chain control lanes
8. Turnouts
9. Turn pockets

If the number of lanes change, pave each through lane's top layer before paving a tapering
lane's top layer. Simultaneous to paving a through lane's top layer, you may pave an adjoining
area's top layer including shoulders. Do not operate spreading equipment on any area's top
layer until completing final compaction.
If HMA (leveling) is specified, fill and level irregularities and ruts with HMA before spreading
HMA over base, existing surfaces, or bridge decks. You may use mechanical equipment other
than a paver for these areas. The equipment must produce a uniform smoothness and texture.
HMA used to change an existing surface's cross slope or profile is not HMA (leveling).
If placing HMA against the edge of existing pavement, sawcut or grind the pavement straight
and vertical along the joint and remove extraneous material without damaging the surface
remaining in place. If placing HMA against the edge of a longitudinal or transverse construction
joint and the joint is damaged or not placed to a neat line, sawcut or grind the pavement straight
and vertical along the joint and remove extraneous material without damaging the surface
remaining in place. Repair or remove and replace damaged pavement at your expense.
Rolling must leave the completed surface compacted and smooth without tearing, cracking, or
shoving. Complete finish rolling activities before the pavement surface temperature is:

1. Below 150 °F for HMA with unmodified binder

2. Below 140 °F for HMA with modified binder
3. Below 200 °F for RHMA-G

If a vibratory roller is used as a finish roller, turn the vibrator off.

Do not use a pneumatic tired roller to compact RHMA-G.
For Standard and QC/QA, if a 3/4-inch aggregate grading is specified, you may use a 1/2-inch
aggregate grading if the specified paved thickness is from 0.15 foot to 0.20 foot thick.
Spread and compact HMA under Section 39-3.03, "Spreading and Compacting Equipment," and
Section 39-3.04, "Transporting, Spreading, and Compacting," for any of the following:

1. Specified paved thickness is less than 0.15 foot.

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2. Specified paved thickness is less than 0.20 foot and a 3/4-inch aggregate grading is
specified and used.
3. You spread and compact at:

3.1. Asphalt concrete surfacing replacement areas

3.2. Leveling courses
3.3. Areas the Engineer determines conventional compaction and compaction
measurement methods are impeded

Do not allow traffic on new HMA pavement until its mid-depth temperature is below 160 °F.
If you request in writing and the Engineer authorizes, you may cool HMA Type A and Type B
with water when rolling activities are complete. Apply water under Section 17, "Watering."
Spread sand at a rate between 1 pound and 2 pounds per square yard on new RHMA-G,
RHMA-O, and RHMA-O-HB pavement when finish rolling is complete. Sand must be free of
clay or organic matter. Sand must comply with Section 90-3.03, "Fine Aggregate Grading."
Keep traffic off the pavement until spreading sand is complete.

39-1.12 SMOOTHNESS
39-1.12A General
Determine HMA smoothness with a profilograph and a straightedge.
Smoothness specifications do not apply to OGFC placed on existing pavement not constructed
under the same project.
If portland cement concrete is placed on HMA:

1. Cold plane the HMA finished surface to within specified tolerances if it is higher than the
grade specified by the Engineer.
2. Remove and replace HMA if the finished surface is lower than 0.05 foot below the grade
specified by the Engineer.

39-1.12B Straightedge
The HMA pavement top layer must not vary from the lower edge of a 12-foot long straightedge:

1. More than 0.01 foot when the straight edge is laid parallel with the centerline
2. More than 0.02 foot when the straightedge is laid perpendicular to the centerline and
extends from edge to edge of a traffic lane
3. More than 0.02 foot when the straightedge is laid within 24 feet of a pavement conform

39-1.12C Profilograph
Under California Test 526, determine the zero (null) blanking band Profile Index (PI0) and must-
grinds on the top layer of HMA Type A, Type B, and RHMA-G pavement. Take 2 profiles within
each traffic lane, 3 feet from and parallel with the edge of each lane.

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A must-grind is a deviation of 0.3 inch or more in a length of 25 feet. You must correct must-
grinds.
For OGFC, only determine must-grinds when placed over HMA constructed under the same
project. The top layer of the underlying HMA must comply with the smoothness specifications
before placing OGFC.
Profile pavement in the Engineer's presence. Choose the time of profiling.
On tangents and horizontal curves with a centerline radius of curvature 2,000 feet or more, the
PI0 must be at most 3 inches per 0.1-mile section.
On horizontal curves with a centerline radius of curvature between 1,000 feet and 2,000 feet
including pavement within the superelevation transitions, the PI0 must be at most 6 inches per
0.1-mile section.
Before the Engineer accepts HMA pavement for smoothness, submit written final profilograms.
Submit 1 electronic copy of profile information in Microsoft Excel and 1 electronic copy of
longitudinal pavement profiles in ".erd" format or other ProVAL compatible format to the
Engineer and to:

Smoothness@dot.ca.gov

The following HMA pavement areas do not require a PI0. You must measure these areas with a
12-foot straightedge and determine must-grinds with a profilograph:

1. New HMA with a total thickness less than or equal to 0.25 foot
2. HMA sections of city or county streets and roads, turn lanes and collector lanes that are
less than 1,500 feet in length

The following HMA pavement areas do not require a PI0. You must measure these areas with a
12-foot straightedge:

1. Horizontal curves with a centerline radius of curvature less than 1,000 feet including
pavement within the superelevation transitions of those curves
2. Within 12 feet of a transverse joint separating the pavement from:

2.1. Existing pavement not constructed under the same project

2.2. A bridge deck or approach slab

3. Exit ramp termini, truck weigh stations, and weigh-in-motion areas

4. If steep grades and superelevation rates greater than 6 percent are present on:

4.1. Ramps
4.2. Connectors

5. Turn lanes

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6. Areas within 15 feet of manholes or drainage transitions

7. Acceleration and deceleration lanes for at-grade intersections
8. Shoulders and miscellaneous areas
9. HMA pavement within 3 feet from and parallel to the construction joints formed between
curbs, gutters, or existing pavement

39-1.12D Smoothness Correction

If the top layer of HMA Type A, Type B, or RHMA-G pavement does not comply with the
smoothness specifications, grind the pavement to within tolerances, remove and replace it, or
place a layer of HMA. The Engineer must authorize your choice of correction before the work
begins.
Remove and replace the areas of OGFC not in compliance with the must-grind and straightedge
specifications, except you may grind OGFC for correcting smoothness:

1. At a transverse joint separating the pavement from pavement not constructed under the
same project
2. Within 12 feet of a transverse joint separating the pavement from a bridge deck or
approach slab

Corrected HMA pavement areas must be uniform rectangles with edges:

1. Parallel to the nearest HMA pavement edge or lane line

2. Perpendicular to the pavement centerline

Measure the corrected HMA pavement surface with a profilograph and a 12-foot straightedge
and correct the pavement to within specified tolerances. If a must-grind area or straightedged
pavement cannot be corrected to within specified tolerances, remove and replace the
pavement.
On ground areas not overlaid with OGFC, apply fog seal coat under Section 37-1, "Seal Coats."

39-1.13 MISCELLANEOUS AREAS AND DIKES

Miscellaneous areas are outside the traveled way and include:

1. Median areas not including inside shoulders

2. Island areas
3. Sidewalks
4. Gutters
5. Gutter flares
6. Ditches
7. Overside drains
8. Aprons at the ends of drainage structures

April 11,2011 4-88

Spread miscellaneous areas in 1 layer and compact to the specified lines and grades.
For miscellaneous areas and dikes:

1. Do not submit a JMF.

2. Choose the 3/8-inch or 1/2-inch HMA Type A and Type B aggregate gradations.
3. Minimum asphalt binder content must be 6.8 percent for 3/8-inch aggregate and 6.0
percent for 1/2-inch aggregate. If you request in writing and the Engineer authorizes, you
may reduce the minimum asphalt binder content.
4. Choose asphalt binder Grade PG 70-10 or the same grade specified for HMA.

39-2 STANDARD
39-2.01 DESCRIPTION
If HMA is specified as Standard, construct it under Section 39-1, "General," this Section 39-2,
"Standard," and Section 39-5, "Measurement and Payment."

39-2.02 CONTRACTOR QUALITY CONTROL

39-2.02A Quality Control Plan
Establish, implement, and maintain a Quality Control Plan (QCP) for HMA. The QCP must
describe the organization and procedures you will use to:

1. Control the quality characteristics

2. Determine when corrective actions are needed (action limits)
3. Implement corrective actions

When you submit the proposed JMF, submit the written QCP. You and the Engineer must
discuss the QCP during the prepaving conference.
The QCP must address the elements affecting HMA quality including:

1. Aggregate
2. Asphalt binder
3. Additives
4. Production
5. Paving

The Engineer reviews each QCP within 5 business days from the submittal. Hold HMA
production until the Engineer accepts the QCP in writing. The Engineer's QCP acceptance
does not mean your compliance with the QCP will result in acceptable HMA. Section 39-1.05,
"Engineer's Acceptance," specifies HMA acceptance.

39-2.02B Quality Control Testing

Perform sampling and testing at the specified frequency for the following quality characteristics:

April 11,2011 4-89

April 11,2011 4-90

Minimum Quality Control – Standard

Quality Test Minimum HMA Type
Characteristic Method Sampling
and A B RHMA-G OGFC
Testing
Frequency
Aggregate gradationa CT 202 JMF ± JMF ± JMF ± JMF ±
1 per 750
Tolerance b Tolerance b Tolerance b Tolerance b
tons and
Sand equivalent CT 217 47 42 47 --
any
(min.) c
remaining
Asphalt binder CT 379 or part JMF ± 0.45 JMF ± 0.45 JMF ± 0.50 JMF ± 0.50
content (%) 382
HMA moisture CT 226 or 1 per 1.0 1.0 1.0 1.0
content (%, max.) CT 370 2,500 tons
but not
less than 1
per paving
day
Percent of maximum Quality 2 per 91 - 97 91 - 97 91 - 97 --
theoretical density control business
(%) d, e plan day (min.)
Stabilometer value CT 366 One per
(min.) c, f 4,000 tons
No. 4 and 3/8" or 2 per 5 30 30 -- --
gradings business
1/2" and 3/4" days, 37 35 23 --
gradings which-
Air voids content CT 367 ever is 4±2 4±2 Specification --
(%) c, g more ±2
Aggregate moisture CT 226 or
content at CT 370
continuous mixing
2 per day
plants and RAP
during -- -- -- --
moisture content at
production
continuous mixing
plants and batch
mixing plants h
Percent of crushed CT 205
particles coarse
aggregate (%, min.)
One fractured 90 25 -- 90
As
face
necessary
Two fractured 75 -- 90 75
and
faces
designat-
Fine aggregate (%,
ed in the
min)
QCP. At
(Passing No. 4
least once
sieve and
per project
retained on No.
8 sieve.)
One fractured 70 20 70 90
face

April 11,2011 4-91

Los Angeles Rattler CT 211

(%, max.)
Loss at 100 rev. 12 -- 12 12
Loss at 500 rev. 45 50 40 40
Flat and elongated ASTM D Report only Report only Report only Report only
particles (%, max. 4791
by weight @ 5:1)
Fine aggregate AASHTO
angularity (%, min.) T 304, 45 45 45 --
Method A
Voids filled with LP-3
asphalt (%) i
No. 4 grading 76.0 – 80.0 76.0 – 80.0 Report only
--
3/8" grading 73.0 – 76.0 73.0 – 76.0
1/2" grading 65.0 – 75.0 65.0 – 75.0
3/4" grading 65.0 – 75.0 65.0 – 75.0
Voids in mineral LP-2
aggregate (% min.) i
No. 4 grading 17.0 17.0 --
--
3/8" grading 15.0 15.0 --
1/2" grading 14.0 14.0 18.0 – 23.0 j
3/4" grading 13.0 13.0 18.0 – 23.0 j
Dust proportion i LP-4
No. 4 and 3/8"
gradings 0.9 – 2.0 0.9 – 2.0 Report only --
1/2" and 3/4"
gradings 0.6 – 1.3 0.6 – 1.3
Smoothness Section 12-foot 12-foot 12-foot 12-foot
39-1.12 straightedge, straightedge, straightedge, straightedge
--
must-grind, must-grind, must-grind, and must-
and PI0 and PI0 and PI0 grind
Asphalt rubber Section
Section
binder viscosity @ 39-1.02D -- -- 1,500 – 4,000 1,500 – 4,000
39-1.04C
350 °F, centipoises
Asphalt modifier Section Section Section 39- Section 39-
-- --
39-1.02D 39-1.04C 1.02D 1.02D
Crumb rubber Section Section -- -- Section 39- Section 39-
modifier 39-1.02D 39-1.04C 1.02D 1.02D
Notes:
a
Determine combined aggregate gradation containing RAP under Laboratory Procedure LP-9.
b
The tolerances must comply with the allowable tolerances in Section 39-1.02E, "Aggregate."
c
Report the average of 3 tests from a single split sample.
d
Required for HMA Type A, Type B, and RHMA-G if the specified paved thickness is at least 0.15 foot.
e
Determine maximum theoretical density (California Test 309) at the frequency specified for Test Maximum
Density under California Test 375, Part 5.D.
f
Modify California Test 304, Part 2.B.2.c: "After compaction in the mechanical compactor, cool to 140 °F ± 5 °F
by allowing the briquettes to cool at room temperature for 0.5 hour, then place the briquettes in the oven at 140 °F
for a minimum of 2 hours and not more than 3 hours."
g
Determine the bulk specific gravity of each lab-compacted briquette under California Test 308, Method A, and
theoretical maximum specific gravity under California Test 309.
h
For adjusting the plant controller at the HMA plant.
i
Report only if the adjustment for asphalt binder content target value is less than or equal to ± 0.3 percent from
OBC.
j
Voids in mineral aggregate for RHMA-G must be within this range.

April 11,2011 4-92

For any single quality characteristic except smoothness, if 2 consecutive quality control test
results do not comply with the action limits or specifications:

1. Stop production.
2. Notify the Engineer in writing.
3. Take corrective action.
4. Demonstrate compliance with the specifications before resuming production and
placement on the State highway.

39-2.03 ENGINEER'S ACCEPTANCE

39-2.03A Testing
The Engineer samples for acceptance testing and tests for:

April 11,2011 4-93

HMA Acceptance - Standard

Quality Characteristic Test HMA Type
Method A B RHMA-G OGFC
Aggregate gradation a CT 202 JMF ± JMF ± JMF ± JMF ±
Sieve 3/4" 1/2" 3/8" Tolerance c Tolerance c Tolerance c Tolerance c
1/2" Xb
3/8" X
No. 4 X
No. 8 X X X
No. 200 X X X
Sand equivalent (min.) d CT 217 47 42 47 --
Asphalt binder content (%) CT 379 or JMF ± 0.45 JMF ± 0.45 JMF ± 0.50 JMF ± 0.50
382
HMA moisture content (%, CT 226 or 1.0 1.0 1.0 1.0
max.) CT 370
Percent of maximum CT 375 91 – 97 91 – 97 91 – 97 --
theoretical density (%) e, f
Stabilometer value (min.) d, g CT 366
No. 4 and 3/8" gradings 30 30 -- --
1/2" and 3/4" gradings 37 35 23 --
Air voids content (%) d, h CT 367 4±2 4±2 Specification ± --
2
Percent of crushed particles CT 205
Coarse aggregate (%, min.)
One fractured face 90 25 -- 90
Two fractured faces 75 -- 90 75
Fine aggregate (%, min)
(Passing No. 4 sieve and
retained on No. 8 sieve.)
One fractured face 70 20 70 90
Percent of crushed particles CT 205
Coarse aggregate (%, min.)
One fractured face 90 25 -- 90
Two fractured faces 75 -- 90 75

Los Angeles Rattler (%, CT 211

max.) 12 -- 12 12
Loss at 100 rev. 45 50 40 40
Loss at 500 rev.
Fine aggregate angularity (%, AASHTO
min.) T 304, 45 45 45 --
Method A
Flat and elongated particles ASTM D Report only Report only Report only Report only
(%, max. by weight @ 5:1) 4791
Voids filled with asphalt (%) i LP-3
No. 4 grading 76.0 – 80.0 76.0 – 80.0 Report only
3/8" grading 73.0 – 76.0 73.0 – 76.0 --
1/2" grading 65.0 – 75.0 65.0 – 75.0
3/4" grading 65.0 – 75.0 65.0 – 75.0
Voids in mineral aggregate LP-2
(% min.) i
--
No. 4 grading 17.0 17.0 --
3/8" grading 15.0 15.0 --

April 11,2011 4-94

1/2" grading 14.0 14.0 18.0 – 23.0 j

3/4" grading 13.0 13.0 18.0 – 23.0 j
Dust proportion i LP-4
No. 4 and 3/8" gradings 0.9 – 2.0 0.9 – 2.0 Report only --
1/2" and 3/4" gradings 0.6 – 1.3 0.6 – 1.3
Smoothness Section 12-foot 12-foot 12-foot 12-foot
39-1.12 straightedge, straightedge, straightedge, straightedge
must-grind, must-grind, and must-grind, and and must-grind
and PI0 PI0 PI0
Asphalt binder Various Section 92 Section 92 Section 92 Section 92
Asphalt rubber binder Various -- -- Section 92- Section 92-
1.02(C) and 1.02(C) and
Section 39- Section 39-
1.02D 1.02D
Asphalt modifier Various -- -- Section 39- Section 39-
1.02D 1.02D
Crumb rubber modifier Various -- -- Section 39- Section 39-
1.02D 1.02D
a
The Engineer determines combined aggregate gradations containing RAP under Laboratory Procedure LP-9.
b
"X" denotes the sieves the Engineer considers for the specified aggregate gradation.
c
The tolerances must comply with the allowable tolerances in Section 39-1.02E, "Aggregate."
d
The Engineer reports the average of 3 tests from a single split sample.
e
The Engineer determines percent of maximum theoretical density if the specified paved thickness is at least 0.15
foot under California Test 375 except the Engineer uses:
1. California Test 308, Method A, to determine in-place density of each density core instead of using the
nuclear gauge in Part 4, "Determining In-Place Density By The Nuclear Density Device."
2. California Test 309 to determine maximum theoretical density instead of calculating test maximum density
in Part 5, "Determining Test Maximum Density."
f
The Engineer determines maximum theoretical density (California Test 309) at the frequency specified for Test
Maximum Density under California Test 375, Part 5.D.
g
Modify California Test 304, Part 2.B.2.c: "After compaction in the mechanical compactor, cool to 140 °F ±5 °F
by allowing the briquettes to cool at room temperature for 0.5 hour, then place the briquettes in the oven at 140 °F
for a minimum of 2 hours and not more than 3 hours."
h
The Engineer determines the bulk specific gravity of each lab-compacted briquette under California Test 308,
Method A, and theoretical maximum specific gravity under California Test 309.
i
Report only if the adjustment for asphalt binder content target value is less than or equal to ± 0.3 percent from
OBC.
j
Voids in mineral aggregate for RHMA-G must be within this range.

No single test result may represent more than the smaller of 750 tons or 1 day's production.
For any single quality characteristic except smoothness, if 2 consecutive acceptance test results
do not comply with the specifications:

1. Stop production.
2. Take corrective action.
3. In the Engineer's presence, take samples and split each sample into 4 parts. Test 1 part
for compliance with the specifications and submit 3 parts to the Engineer. The Engineer
tests 1 part for compliance with the specifications and reserves and stores 2 parts.

April 11,2011 4-95

4. Demonstrate compliance with the specifications before resuming production and

placement on the State highway.

The Engineer tests the density core you take from each 250 tons of HMA production. The
Engineer determines the percent of maximum theoretical density for each density core by
determining the density core's density and dividing by the maximum theoretical density.
If the specified total paved thickness is at least 0.15 foot and any layer is less than 0.15 foot, the
Engineer determines the percent of maximum theoretical density from density cores taken from
the final layer measured the full depth of the total paved HMA thickness.
For percent of maximum theoretical density, the Engineer determines a deduction for each test
result outside the specifications in compliance with:

April 11,2011 4-96

Reduced Payment Factors for Percent of Maximum Theoretical Density

HMA Type A and B Reduced Payment HMA Type A and B Reduced Payment
and RHMA-G Factor and RHMA-G Factor
Percent of Maximum Percent of Maximum
Theoretical Density Theoretical Density
91.0 0.0000 97.0 0.0000
90.9 0.0125 97.1 0.0125
90.8 0.0250 97.2 0.0250
90.7 0.0375 97.3 0.0375
90.6 0.0500 97.4 0.0500
90.5 0.0625 97.5 0.0625
90.4 0.0750 97.6 0.0750
90.3 0.0875 97.7 0.0875
90.2 0.1000 97.8 0.1000
90.1 0.1125 97.9 0.1125
90.0 0.1250 98.0 0.1250
89.9 0.1375 98.1 0.1375
89.8 0.1500 98.2 0.1500
89.7 0.1625 98.3 0.1625
89.6 0.1750 98.4 0.1750
89.5 0.1875 98.5 0.1875
89.4 0.2000 98.6 0.2000
89.3 0.2125 98.7 0.2125
89.2 0.2250 98.8 0.2250
89.1 0.2375 98.9 0.2375
89.0 0.2500 99.0 0.2500
< 89.0 Remove and Replace > 99.0 Remove and Replace

39-2.04 TRANSPORTING, SPREADING, AND COMPACTING

Determine the number of rollers needed to obtain the specified density and surface finish.

39-3 METHOD
39-3.01 DESCRIPTION
If HMA is specified as Method, construct it under Section 39-1, "General," this Section 39-3,
"Method," and Section 39-5, "Measurement and Payment."

April 11,2011 4-97

39-3.02 ENGINEER'S ACCEPTANCE

39-3.02A Testing
The Engineer samples for acceptance testing and tests for:

April 11,2011 4-98

HMA Acceptance - Method

Quality Characteristic Test HMA Type
Method A B RHMA-G OGFC
Aggregate gradation a CT 202 JMF ± JMF ± JMF ± JMF ±
Tolerance b Tolerance b Tolerance b Tolerance b
Sand equivalent (min.) c CT 217 47 42 47 --
Asphalt binder content (%) CT 379 or JMF ± 0.45 JMF ± 0.45 JMF ± 0.50 JMF ± 0.50
382
HMA moisture content (%, CT 226 or 1.0 1.0 1.0 1.0
max.) CT 370
Stabilometer value (min.) c, CT 366
d

No. 4 and 3/8" 30 30 -- --

gradings
1/2" and 3/4" gradings 37 35 23 --
Percent of crushed CT 205
particles
Coarse aggregate (% min.)
One fractured face 90 25 -- 90
Two fractured faces 75 -- 90 75
Fine aggregate (% min)
(Passing No. 4 sieve
and retained on No. 8
sieve.)
One fractured face 70 20 70 90
Los Angeles Rattler (% CT 211
max.)
Loss at 100 rev. 12 -- 12 12
Loss at 500 rev. 45 50 40 40
Air voids content (%) c, e CT 367 4±2 4±2 Specification ± --
2
Fine aggregate angularity AASHTO
(% min.) T 304, 45 45 45 --
Method A
Flat and elongated particles ASTM D
(% max. by weight @ 5:1) 4791 Report only Report only Report only Report only
Voids filled with asphalt LP-3
(%) f Report only
No. 4 grading 76.0 – 80.0 76.0 – 80.0
--
3/8" grading 73.0 – 76.0 73.0 – 76.0
1/2" grading 65.0 – 75.0 65.0 – 75.0
3/4" grading 65.0 – 75.0 65.0 – 75.0
Voids in mineral aggregate LP-2
(% min.) f
No. 4 grading 17.0 17.0 --
--
3/8" grading 15.0 15.0 --
1/2" grading 14.0 14.0 18.0 – 23.0 g
3/4" grading 13.0 13.0 18.0 – 23.0 g
Dust proportion f LP-4
No. 4 and 3/8" 0.9 – 2.0 0.9 – 2.0 Report only
--
gradings 0.6 – 1.3 0.6 – 1.3
1/2" and 3/4" gradings
Smoothness Section 12-foot 12-foot 12-foot 12-foot
39-1.12 straightedge straightedge straightedge straightedge

April 11,2011 4-99

and must-grind and must-grind and must-grind and must-grind

Asphalt binder Various Section 92 Section 92 Section 92 Section 92
Asphalt rubber binder Various -- -- Section 92- Section 92-
1.02(C) and 1.02(C) and
Section 39- Section 39-
1.02D 1.02D
Asphalt modifier Various -- -- Section 39- Section 39-
1.02D 1.02D
Crumb rubber modifier Various -- -- Section 39- Section 39-
1.02D 1.02D
a
The Engineer determines combined aggregate gradations containing RAP under Laboratory Procedure LP-9.
b
The tolerances must comply with the allowable tolerances in Section 39-1.02E, "Aggregate."
c
The Engineer reports the average of 3 tests from a single split sample.
d
Modify California Test 304, Part 2.B.2.c: "After compaction in the mechanical compactor, cool to 140 °F ±5 °F by
allowing the briquettes to cool at room temperature for 0.5 hour, then place the briquettes in the oven at 140 °F for a
minimum of 2 hours and not more than 3 hours."
e
The Engineer determines the bulk specific gravity of each lab-compacted briquette under California Test 308,
Method A, and theoretical maximum specific gravity under California Test 309.
f
Report only if the adjustment for asphalt binder content target value is less than or equal to ± 0.3 percent from
OBC.
g
Voids in mineral aggregate for RHMA-G must be within this range.

39-3.03 SPREADING AND COMPACTING EQUIPMENT

Each paver spreading HMA Type A and Type B must be followed by 3 rollers:

1. One vibratory roller specifically designed to compact HMA. The roller must be capable
of at least 2,500 vibrations per minute and must be equipped with amplitude and
frequency controls. The roller's gross static weight must be at least 7.5 tons.
2. One oscillating type pneumatic-tired roller at least 4 feet wide. Pneumatic tires must be
of equal size, diameter, type, and ply. The tires must be inflated to 60 psi minimum and
maintained so that the air pressure does not vary more than 5 psi.
3. One steel-tired, 2-axle tandem roller. The roller's gross static weight must be at least 7.5
tons.

April 11,2011 4-100

Each roller must have a separate operator. Rollers must be self-propelled and reversible.
Compact RHMA-G under the specifications for compacting HMA Type A and Type B except do
not use pneumatic-tired rollers.
Compact OGFC with steel-tired, 2-axle tandem rollers. If placing over 300 tons of OGFC per
hour, use at least 3 rollers for each paver. If placing less than 300 tons of OGFC per hour, use
at least 2 rollers for each paver. Each roller must weigh between 126 pounds to 172 pounds
per linear inch of drum width. Turn the vibrator off.

39-3.04 TRANSPORTING, SPREADING, AND COMPACTING

Pave HMA in maximum 0.25-foot thick compacted layers.
If the surface to be paved is both in sunlight and shade, pavement surface temperatures are
taken in the shade.
Spread HMA Type A and Type B only if atmospheric and surface temperatures are:

Minimum Atmospheric and Surface Temperatures

Compacted Layer
Thickness, feet Atmospheric,° F Surface,° F
Unmodified Asphalt Modified Asphalt Unmodified Asphalt Modified Asphalt
Binder Bindera Binder Binder a
< 0.15 55 50 60 55
0.15 – 0.25 45 45 50 50
Note:
a
Except asphalt rubber binder.

If the asphalt binder for HMA Type A and Type B is:

1. Unmodified asphalt binder, complete:

1.1. First coverage of breakdown compaction before the surface temperature drops
below 250 °F
1.2. Breakdown and intermediate compaction before the surface temperature drops
below 200 °F
1.3. Finish compaction before the surface temperature drops below 150 °F

2. Modified asphalt binder, complete:

2.1. First coverage of breakdown compaction before the surface temperature drops
below 240 °F
2.2. Breakdown and intermediate compaction before the surface temperature drops
below 180 °F
2.3. Finish compaction before the surface temperature drops below 140 °F

For RHMA-G:

April 11,2011 4-101

1. Only spread and compact if the atmospheric temperature is at least 55 °F and the surface
temperature is at least 60 °F.
2. Complete the first coverage of breakdown compaction before the surface temperature
drops below 280 °F.
3. Complete breakdown and intermediate compaction before the surface temperature drops
below 250 °F.
4. Complete finish compaction before the surface temperature drops below 200 °F.
5. If the atmospheric temperature is below 70 °F, cover loads in trucks with tarpaulins. The
tarpaulins must completely cover the exposed load until you transfer the mixture to the
paver's hopper or to the pavement surface.

For OGFC with unmodified asphalt binder:

1. Only spread and compact if the atmospheric temperature is at least 55 °F and the surface
temperature is at least 60 °F.
2. Complete first coverage using 2 rollers before the surface temperature drops below 240
°F.
3. Complete all compaction before the surface temperature drops below 200 °F.
4. If the atmospheric temperature is below 70 °F, cover loads in trucks with tarpaulins. The
tarpaulins must completely cover the exposed load until you transfer the mixture to the
paver's hopper or to the pavement surface.

For OGFC with modified asphalt binder except asphalt rubber binder:

1. Only spread and compact if the atmospheric temperature is at least 50 °F and the surface
temperature is at least 50 °F.
2. Complete first coverage using 2 rollers before the surface temperature drops below 240
°F.
3. Complete all compaction before the surface temperature drops below 180 °F.
4. If the atmospheric temperature is below 70 °F, cover loads in trucks with tarpaulins. The
tarpaulins must completely cover the exposed load until you transfer the mixture to the
paver's hopper or to the pavement surface.

For RHMA-O and RHMA-O-HB:

1. Only spread and compact if the atmospheric temperature is at least 55 °F and surface
temperature is at least 60 °F.
2 Complete the 1st coverage using 2 rollers before the surface temperature drops below 280
°F.
3. Complete compaction before the surface temperature drops below 250 °F.

April 11,2011 4-102

4. If the atmospheric temperature is below 70 °F, cover loads in trucks with tarpaulins. The
tarpaulins must completely cover the exposed load until the mixture is transferred to the
paver's hopper or to the pavement surface.

For RHMA-G and OGFC, tarpaulins are not required if the time from discharge to truck until
transfer to the paver's hopper or the pavement surface is less than 30 minutes.
HMA compaction coverage is the number of passes needed to cover the paving width. A pass
is 1 roller's movement parallel to the paving in either direction. Overlapping passes are part of
the coverage being made and are not a subsequent coverage. Do not start a coverage until
completing the prior coverage.
Start rolling at the lower edge and progress toward the highest part.
Perform breakdown compaction of each layer of HMA Type A, Type B, and RHMA-G with 3
coverages using a vibratory roller. The speed of the vibratory roller in miles per hour must not
exceed the vibrations per minute divided by 1,000. If the HMA layer thickness is less than 0.08
foot, turn the vibrator off. The Engineer may order fewer coverages if the HMA layer thickness
is less than 0.15 foot.
Perform intermediate compaction of each layer of HMA Type A and Type B with 3 coverages
using a pneumatic-tired roller at a speed not to exceed 5 mph.
Perform finish compaction of HMA Type A, Type B, and RHMA-G with 1 coverage using a steel-
tired roller.
Compact OGFC with 2 coverages using steel-tired rollers.

39-4 QUALITY CONTROL / QUALITY ASSURANCE

39-4.01 DESCRIPTION
If HMA is specified as Quality Control / Quality Assurance, construct it under Section 39-1,
"General," this Section 39-4, "Quality Control / Quality Assurance," and Section 39-5,
"Measurement and Payment."

39-4.02 GENERAL
The QC / QA construction process consists of:

1. Establishing, maintaining, and changing if needed a quality control system providing

assurance the HMA complies with the specifications
2. Sampling and testing at specified intervals, or sublots, to demonstrate compliance and to
control process
3. The Engineer sampling and testing at specified intervals to verify testing process and
HMA quality
4. The Engineer using test results, statistical evaluation of verified quality control tests, and
inspection to accept HMA for payment

A lot is a quantity of HMA. The Engineer designates a new lot when:

April 11,2011 4-103

1. 20 sublots are complete

2. The JMF changes
3. Production stops for more than 30 days

Each lot consists of no more than 20 sublots. A sublot is 750 tons except HMA paved at day's
end greater than 250 tons is a sublot. If HMA paved at day's end is less than 250 tons, you may
either make this quantity a sublot or include it in the previous sublot's test results for statistical
evaluation.

39-4.03 CONTRACTOR QUALITY CONTROL

39-4.03A General
Use a composite quality factor, QFC, and individual quality factors, QFQCi, to control your
process and evaluate your quality control program. For quality characteristics without quality
factors, use your quality control plan's action limits to control process.
Control HMA quality including:

1. Materials
2. Proportioning
3. Spreading and compacting
4. Finished roadway surface

Develop, implement, and maintain a quality control program that includes:

1. Inspection
2. Sampling
3. Testing

39-4.03B Quality Control Plan

With the JMF submittal, submit a written Quality Control Plan (QCP). The QCP must comply
with the Department's Quality Control Manual for Hot Mix Asphalt Production and Placement.
Discuss the QCP with the Engineer during the prepaving conference.
The Engineer reviews each QCP within 5 business days from the submittal. Hold HMA
production until the Engineer accepts the QCP in writing. The Engineer's QCP acceptance
does not mean your compliance with the QCP will result in acceptable HMA. Section 39-1.05,
"Engineer's Acceptance," specifies HMA acceptance.
The QCP must include the name and qualifications of a Quality Control Manager. The Quality
Control Manager administers the QCP and during paving must be at the job site within 3 hours
of receiving notice. The Quality Control Manager must not be any of the following on the
project:

April 11,2011 4-104

1. Foreman
2. Production or paving crewmember
3. Inspector
4. Tester

The QCP must include action limits and details of corrective action you will take if a test result
for any quality characteristic falls outside an action limit.
As work progresses, you must submit a written QCP supplement to change quality control
procedures, personnel, tester qualification status, or laboratory accreditation status.

39-4.03C Quality Control Inspection, Sampling, And Testing

Sample, test, inspect, and manage HMA quality control.
Provide a roadway inspector while HMA paving activities are in progress. Provide a plant
inspector during HMA production.
Inspectors must comply with the Department's Quality Control Manual for Hot Mix Asphalt
Production and Placement.
Provide a testing laboratory and personnel for quality control testing. Provide the Engineer
unrestricted access to the quality control activities. Before providing services for the project, the
Engineer reviews, accredits, and qualifies the testing laboratory and personnel under the
Department's Independent Assurance Program.
The minimum random sampling and testing for quality control is:

April 11,2011 4-105

Minimum Quality Control – QC / QA

Quality Test Min- HMA Type Location Max.
Characteristic Method imum of Report-
Sampl- Sampling ing Time
ing and Allow-
Testing ance
Frequen A B RHMA-G
-cy
Aggregate JMF ± JMF ± JMF ±
CT 202 CT 125
gradation a Tolerance b Tolerance b Tolerance b
Loose
Mix
Asphalt binder CT 379 or Behind
1 per JMF ±0.45 JMF ±0.45 JMF ±0.5
content (%) 382 Paver 24 hours
750 tons
See CT
125
Percent of maximum
theoretical density QC Plan 92 - 96 92 - 96 91 - 96 QC Plan
(%) c, d
Aggregate moisture
content at continuous
mixing plants and 2 per
Stock-
RAP moisture day
CT 226 or piles or
content at continuous during -- -- -- --
CT 370 cold feed
mixing plants and produc-
belts
batch mixing plants e tion

Sand equivalent 1 per

CT 217 47 42 47 CT 125 24 hours
(min.) f 750 tons
1 per
2,500
tons but
HMA moisture CT 226 or not less
1.0 1.0 1.0 24 hours
content (%,max.) CT 370 than 1
per
Loose
paving
Mix
day
Behind
Stabilometer 1 per
Paver
Value (min.) f, g 4,000
See CT
No. 4 and 3/8" tons or 30 30 --
CT 366 125
gradings 2 per 5
1/2" and 3/4" bus- 37 35 23
48 hours
gradings iness
days,
Air voids content which- Specifica-
CT 367 4±2 4±2
(%)f, h ever is tion ± 2
more

April 11,2011 4-106

Percent of crushed
particles coarse
aggregate (% min.)
One fractured
face 90 25 --
Two fractured
faces 75 -- 90
Fine aggregate (% CT 205 CT 125
min)
(Passing No. 4
sieve and
retained on No.
8 sieve.)
One fractured 70 20 70
face
Los Angeles Rattler
(% max.)
CT 211 As CT 125
Loss at 100 rev. 12 -- 12
Loss at 500 rev. neces- 45 50 40
sary and
AASHTO
Fine aggregate designat
T 304, 45 45 45 CT 125
angularity (% min.) -ed in
Method A
QCP.
Flat and elongated Report Report Report
ASTM D At least
particle (% max. by only only only CT 125
4791 once per 48 hours
weight @ 5:1)
project.
Voids filled with
asphalt (%) i
No. 4 grading 76.0 – 80.0 76.0 – 80.0 Report only
LP-3 LP-3
3/8" grading 73.0 – 76.0 73.0 – 76.0
1/2" grading 65.0 – 75.0 65.0 – 75.0
3/4" grading 65.0 – 75.0 65.0 – 75.0
Voids in mineral
aggregate (% min.) i
No. 4 grading 17.0 17.0 --
LP-2 LP-2
3/8" grading 15.0 15.0 --
1/2" grading 14.0 14.0 18.0 – 23.0j
3/4" grading 13.0 13.0 18.0 – 23.0j
Dust proportion i
No. 4 and 3/8" 0.9 – 2.0 0.9 – 2.0 Report only
gradings LP-4 0.6 – 1.3 0.6 – 1.3 LP-4
1/2" and 3/4"
gradings
Smoothness 12-foot
12-foot 12-foot
straight-
straight- straight-
Section edge,
-- edge, must- edge, must- --
39-1.12 must-
grind, and grind, and
grind, and
PI0 PI0
PI0
Asphalt rubber
Section 1,500 – Section
binder viscosity @ -- -- -- 24 hours
39-1.02D 4,000 39-1.02D
350 °F, centipoises
Crumb rubber Section -- -- -- Section 39- Section 48 hours
modifier 39-1.02D 1.02D 39-1.02D
Notes:

April 11,2011 4-107

a
Determine combined aggregate gradation containing RAP under Laboratory Procedure LP-9.
b
The tolerances must comply with the allowable tolerances in Section 39-1.02E, "Aggregate."
c
Required for HMA Type A, Type B, and RHMA-G if the specified paved thickness is at least 0.15 foot.
d
Determine maximum theoretical density (California Test 309) at the frequency specified for test maximum
density under California Test 375, Part 5 D.
e
For adjusting the plant controller at the HMA plant.
f
Report the average of 3 tests from a single split sample.
g
Modify California Test 304, Part 2.B.2.c: "After compaction in the mechanical compactor, cool to 140 °F ± 5 °F
by allowing the briquettes to cool at room temperature for 0.5 hour, then place the briquettes in the oven at 140 °F
for a minimum of 2 hours and not more than 3 hours."
h
Determine the bulk specific gravity of each lab-compacted briquette under California Test 308, Method A, and
theoretical maximum specific gravity under California Test 309.
i
Report only if the adjustment for asphalt binder content target value is less than or equal to ± 0.3 percent from
OBC.
j
Voids in mineral aggregate for RHMA-G must be within this range.

Within the specified reporting time, submit written test results including:

1. Sampling location, quantity, and time

2. Testing results
3. Supporting data and calculations

If test results for any quality characteristic are beyond the action limits in the QCP, take
corrective actions. Document the corrective actions taken in the inspection records under
Section 39-4.03E, "Records of Inspection and Testing."
Stop production, notify the Engineer in writing, take corrective action, and demonstrate
compliance with the specifications before resuming production and placement on the State
highway if:

1. A lot's composite quality factor, QFC, or an individual quality factor, QFQCi for i = 3, 4, or
5, is below 0.90 determined under Section 39-4.03F, "Statistical Evaluation"
2. An individual quality factor, QFQCi for i = 1 or 2, is below 0.75
3. Quality characteristics for which a quality factor, QFQCi, is not determined has 2
consecutive acceptance or quality control tests not in compliance with the specifications

39-4.03D Charts And Records

Record sampling and testing results for quality control on forms provided in the "Quality Control
Manual for Hot Mix Asphalt," or on forms you submit with the QCP. The QCP must also include
form posting locations and submittal times.
Submit quality control test results using the Department's statistical evaluation program,
HMAPay, available at

www.dot.ca.gov/hq/construc/hma/index.htm

April 11,2011 4-108

39-4.03E Records Of Inspection And Testing

During HMA production, submit in writing a daily:

1. HMA Construction Daily Record of Inspection. Also make this record available at the
HMA plant and job site each day.
2. HMA Inspection and Testing Summary. Include in the summary:

2.1. Test forms with the testers' signatures and Quality Control Manager's initials.
2.2. Inspection forms with the inspectors' signatures and Quality Control Manager's
initials.
2.3. A list and explanation of deviations from the specifications or regular practices.
2.4. A signed statement by the Quality Control Manager that says:

"It is hereby certified that the information contained in this record is accurate, and
that information, tests, or calculations documented herein comply with the
specifications of the contract and the standards set forth in the testing procedures.
Exceptions to this certification are documented as part of this record."

Retain for inspection the records generated as part of quality control including inspection,
sampling, and testing for at least 3 years after final acceptance.

39-4.03F Statistical Evaluation

General
Determine a lot's composite quality factor, QFC, and the individual quality factors, QFQCi.
Perform statistical evaluation calculations to determine these quality factors based on quality
control test results for:

1. Aggregate gradation
2. Asphalt binder content
3. Percent of maximum theoretical density

The Engineer grants a waiver and you must use 1.0 as the individual quality factor for percent of
maximum theoretical density, QFQC5, for HMA paved in:

1. Areas where the specified paved thickness is less than 0.15 foot
2. Areas where the specified paved thickness is less than 0.20 foot and a 3/4-inch grading is
specified and used
3. Dig outs
4. Leveling courses
5. Areas where, in the opinion of the Engineer, compaction or compaction measurement by
conventional methods is impeded

April 11,2011 4-109

Statistical Evaluation Calculations

Use the Variability-Unknown / Standard Deviation Method to determine the percentage of a lot
not in compliance with the specifications. The number of significant figures used in the
calculations must comply with AASHTO R-11, Absolute Method.
Determine the percentage of work not in compliance with the specification limits for each quality
characteristic as follows:

1. Calculate the arithmetic mean ( X ) of the test values

Σx
X= n

where:
x = individual test values
n = number of test values

2. Calculate the standard deviation

n (Σx2 )-(Σx) 2
s= n(n-1)

where:
∑(x2) = sum of the squares of individual test values
(∑x)2 = sum of the individual test values squared
n = number of test values

3. Calculate the upper quality index (Qu)

USL - X
Qu = s

where:
USL = target value plus the production tolerance or upper specification limit
s= standard deviation
X = arithmetic mean

4. Calculate the lower quality index (QL);

X - LSL
QL = s

where:
LSL = target value minus production tolerance or lower specification limit
s= standard deviation
X = arithmetic mean

April 11,2011 4-110

5. From the table, Upper Quality Index QU or Lower Quality Index QL, of this Section 39-
4.03F, "Statistical Evaluation", determine PU ;

where:
PU = the estimated percentage of work outside the USL.
PU = 0, when USL is not specified.

6. From the table, Upper Quality Index QU or Lower Quality Index QL, of this Section 39-
4.03F, "Statistical Evaluation," determine PL;

where:
PL = the estimated percentage of work outside the LSL.
PL = 0, when LSL is not specified.

7. Calculate the total estimated percentage of work outside the USL and LSL, percent
defective

Percent defective = PU + PL

PU and PL are determined from:

April 11,2011 4-111

PU Upper Quality Index QU or Lower Quality Index QL

or Sample Size (n)
PL 5 6 7 8 9 10-11 12-14 15-17 18-22 23-29 30-42 43-66 >66
0 1.72 1.88 1.99 2.07 2.13 2.20 2.28 2.34 2.39 2.44 2.48 2.51 2.56
1 1.64 1.75 1.82 1.88 1.91 1.96 2.01 2.04 2.07 2.09 2.12 2.14 2.16
2 1.58 1.66 1.72 1.75 1.78 1.81 1.84 1.87 1.89 1.91 1.93 1.94 1.95
3 1.52 1.59 1.63 1.66 1.68 1.71 1.73 1.75 1.76 1.78 1.79 1.80 1.81
4 1.47 1.52 1.56 1.58 1.60 1.62 1.64 1.65 1.66 1.67 1.68 1.69 1.70
5 1.42 1.47 1.49 1.51 1.52 1.54 1.55 1.56 1.57 1.58 1.59 1.59 1.60
6 1.38 1.41 1.43 1.45 1.46 1.47 1.48 1.49 1.50 1.50 1.51 1.51 1.52
7 1.33 1.36 1.38 1.39 1.40 1.41 1.41 1.42 1.43 1.43 1.44 1.44 1.44
8 1.29 1.31 1.33 1.33 1.34 1.35 1.35 1.36 1.36 1.37 1.37 1.37 1.38
9 1.25 1.27 1.28 1.28 1.29 1.29 1.30 1.30 1.30 1.31 1.31 1.31 1.31
10 1.21 1.23 1.23 1.24 1.24 1.24 1.25 1.25 1.25 1.25 1.25 1.26 1.26
11 1.18 1.18 1.19 1.19 1.19 1.19 1.20 1.20 1.20 1.20 1.20 1.20 1.20
12 1.14 1.14 1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.15
13 1.10 1.10 1.10 1.10 1.10 1.10 1.11 1.11 1.11 1.11 1.11 1.11 1.11
14 1.07 1.07 1.07 1.06 1.06 1.06 1.06 1.06 1.06 1.06 1.06 1.06 1.06
15 1.03 1.03 1.03 1.03 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02
16 1.00 0.99 0.99 0.99 0.99 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98
17 0.97 0.96 0.95 0.95 0.95 0.95 0.94 0.94 0.94 0.94 0.94 0.94 0.94
18 0.93 0.92 0.92 0.92 0.91 0.91 0.91 0.91 0.90 0.90 0.90 0.90 0.90
19 0.90 0.89 0.88 0.88 0.88 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87
20 0.87 0.86 0.85 0.85 0.84 0.84 0.84 0.83 0.83 0.83 0.83 0.83 0.83
21 0.84 0.82 0.82 0.81 0.81 0.81 0.80 0.80 0.80 0.80 0.80 0.80 0.79
22 0.81 0.79 0.79 0.78 0.78 0.77 0.77 0.77 0.76 0.76 0.76 0.76 0.76
23 0.77 0.76 0.75 0.75 0.74 0.74 0.74 0.73 0.73 0.73 0.73 0.73 0.73
24 0.74 0.73 0.72 0.72 0.71 0.71 0.70 0.70 0.70 0.70 0.70 0.70 0.70
25 0.71 0.70 0.69 0.69 0.68 0.68 0.67 0.67 0.67 0.67 0.67 0.67 0.66
26 0.68 0.67 0.67 0.65 0.65 0.65 0.64 0.64 0.64 0.64 0.64 0.64 0.63
27 0.65 0.64 0.63 0.62 0.62 0.62 0.61 0.61 0.61 0.61 0.61 0.61 0.60
28 0.62 0.61 0.60 0.59 0.59 0.59 0.58 0.58 0.58 0.58 0.58 0.58 0.57
29 0.59 0.58 0.57 0.57 0.56 0.56 0.55 0.55 0.55 0.55 0.55 0.55 0.54
30 0.56 0.55 0.54 0.54 0.53 0.53 0.52 0.52 0.52 0.52 0.52 0.52 0.52
31 0.53 0.52 0.51 0.51 0.50 0.50 0.50 0.49 0.49 0.49 0.49 0.49 0.49
32 0.50 0.49 0.48 0.48 0.48 0.47 0.47 0.47 0.46 0.46 0.46 0.46 0.46
33 0.47 0.48 0.45 0.45 0.45 0.44 0.44 0.44 0.44 0.43 0.43 0.43 0.43
34 0.45 0.43 0.43 0.42 0.42 0.42 0.41 0.41 0.41 0.41 0.41 0.41 0.40
35 0.42 0.40 0.40 0.39 0.39 0.39 0.38 0.38 0.38 0.38 0.38 0.38 0.38
36 0.39 0.38 0.37 0.37 0.36 0.36 0.36 0.36 0.36 0.36 0.36 0.36 0.36
37 0.36 0.35 0.34 0.34 0.34 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.32
38 0.33 0.32 0.32 0.31 0.31 0.31 0.30 0.30 0.30 0.30 0.30 0.30 0.30
39 0.30 0.30 0.29 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
40 0.28 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25
41 0.25 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23
42 0.23 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
43 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18
44 0.16 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15
45 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13
46 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10
47 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08
48 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
49 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03
50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

April 11,2011 4-112

1. If the value of QU or QL does not correspond to a value in the table, use the next lower value.
2. If QU or QL are negative values, PU or PL is equal to 100 minus the table value for PU or PL.

Quality Factor Determination

Determine individual quality factors, QFQCi, using percent defective = PU + PL and:

Quality Factors
Maximum Allowable Percent Defective (PU + PL)
Quality Sample Size (n)
Factor 5 6 7 8 9 10-11 12-14 15-17 18-22 23-29 30-42 43-66 >66
1.05 0 0 0 0 0 0 0 0 0 0
1.04 0 1 3 5 4 4 4 3 3 3 3
1.03 0 2 4 6 8 7 7 6 5 5 4 4
1.02 1 3 6 9 11 10 9 8 7 7 6 6
1.01 0 2 5 8 11 13 12 11 10 9 8 8 7
1.00 22 20 18 17 16 15 14 13 12 11 10 9 8
0.99 24 22 20 19 18 17 16 15 14 13 11 10 9
0.98 26 24 22 21 20 19 18 16 15 14 13 12 10
0.97 28 26 24 23 22 21 19 18 17 16 14 13 12
0.96 30 28 26 25 24 22 21 19 18 17 16 14 13
0.95 32 29 28 26 25 24 22 21 20 18 17 16 14
0.94 33 31 29 28 27 25 24 22 21 20 18 17 15
0.93 35 33 31 29 28 27 25 24 22 21 20 18 16
0.92 37 34 32 31 30 28 27 25 24 22 21 19 18
0.91 38 36 34 32 31 30 28 26 25 24 22 21 19
0.90 39 37 35 34 33 31 29 28 26 25 23 22 20
0.89 41 38 37 35 34 32 31 29 28 26 25 23 21
0.88 42 40 38 36 35 34 32 30 29 27 26 24 22
0.87 43 41 39 38 37 35 33 32 30 29 27 25 23
0.86 45 42 41 39 38 36 34 33 31 30 28 26 24
0.85 46 44 42 40 39 38 36 34 33 31 29 28 25
0.84 47 45 43 42 40 39 37 35 34 32 30 29 27
0.83 49 46 44 43 42 40 38 36 35 33 31 30 28
0.82 50 47 46 44 43 41 39 38 36 34 33 31 29
0.81 51 49 47 45 44 42 41 39 37 36 34 32 30
0.80 52 50 48 46 45 44 42 40 38 37 35 33 31
0.79 54 51 49 48 46 45 43 41 39 38 36 34 32
0.78 55 52 50 49 48 46 44 42 41 39 37 35 33
0.77 56 54 52 50 49 47 45 43 42 40 38 36 34
0.76 57 55 53 51 50 48 46 44 43 41 39 37 35
0.75 58 56 54 52 51 49 47 46 44 42 40 38 36
60 57 55 53 52 51 48 47 45 43 41 40 37
61 58 56 55 53 52 50 48 46 44 43 41 38
Reject 62 59 57 56 54 53 51 49 47 45 44 42 39
63 61 58 57 55 54 52 50 48 47 45 43 40
64 62 60 58 57 55 53 51 49 48 46 44 41
Reject Values Greater Than Those Shown Above
Notes:
1. To obtain a quality factor when the estimated percent outside specification limits from table, "Upper Quality
Index QU or Lower Quality Index QL," does not correspond to a value in the table, use the next larger value.

April 11,2011 4-113

Compute the composite of single quality factors, QFC, for a lot using:
5
QFC = ∑w i QF QCi
i=1

where:
QFC = the composite quality factor for the lot rounded to 2 decimal places.
QFQCi = the quality factor for the individual quality characteristic.
w= the weighting factor listed in the table HMA Acceptance – QC / QA.
i= the quality characteristic index number in the table HMA Acceptance –
QC / QA.

39-4.04 ENGINEER'S QUALITY ASSURANCE

39-4.04A General
The Engineer assures quality by:

1. Reviewing mix designs and proposed JMF

2. Inspecting procedures
3. Conducting oversight of quality control inspection and records
4. Verification sampling and testing during production and paving

39-4.04B Verification Sampling And Testing

General
The Engineer samples:

1. Aggregate to verify gradation

2. HMA to verify asphalt binder content

Verification
For aggregate gradation and asphalt binder content, the ratio of verification testing frequency to
the minimum quality control testing frequency is 1:5. The Engineer performs at least 3
verification tests per lot.
Using the t-test, the Engineer compares quality control tests results for aggregate gradation and
asphalt binder content with corresponding verification test results. The Engineer uses the
average and standard deviation of up to 20 sequential sublots for the comparison. The
Engineer uses production start-up evaluation tests to represent the first sublot. When there are
less than 20 sequential sublots, the Engineer uses the maximum number of sequential sublots
available. The 21st sublot becomes the 1st sublot (n = 1) in the next lot.
The t-value for a group of test data is computed as follows:

April 11,2011 4-114

Xc − Xv
t= and Sc2 (nc - 1) + Sv2 (nv - 1)
1 1 Sp2 =
Sp + nc + nv - 2
nc nv

where:
nc = Number of quality control tests (2 minimum, 20 maximum).
nv = Number of verification tests (minimum of 1 required).
Xc Mean of quality control tests.
=
Xv Mean of verification tests.
=
Sp = Pooled standard deviation (When nv = 1, Sp = Sc).
Sc = Standard deviation of quality control tests.
Sv = Standard deviation of verification tests (when nv > 1).

The comparison of quality control test results and the verification test results is at a level of
significance of α = 0.025. The Engineer computes t and compares it to the critical t-value, tcrit,
from:

Critical T-Value
Degrees of freedom tcrit Degrees of freedom tcrit
(nc+nv-2) (for α = 0.025) (nc+nv-2) (for α = 0.025)
1 24.452 18 2.445
2 6.205 19 2.433
3 4.177 20 2.423
4 3.495 21 2.414
5 3.163 22 2.405
6 2.969 23 2.398
7 2.841 24 2.391
8 2.752 25 2.385
9 2.685 26 2.379
10 2.634 27 2.373
11 2.593 28 2.368
12 2.560 29 2.364
13 2.533 30 2.360
14 2.510 40 2.329
15 2.490 60 2.299
16 2.473 120 2.270
17 2.458 ∞ 2.241

If the t-value computed is less than or equal to tcrit, quality control test results are verified.
If the t-value computed is greater than tcrit and both X v and X c comply with acceptance
specifications, the quality control tests are verified. You may continue to produce and place
HMA with the following allowable differences:

April 11,2011 4-115

1. X v − X c ≤ 1.0 percent for any grading

2. X v − X c ≤ 0.1 percent for asphalt binder content

If the t-value computed is greater than tcrit and the X v − X c for grading and asphalt binder
content are greater than the allowable differences, quality control test results are not verified
and:

1. The Engineer notifies you in writing.

2. You and the Engineer must investigate why the difference exist.
3. If the reason for the difference cannot be found and corrected, the Engineer's test results
are used for acceptance and pay.

39-4.05 ENGINEER'S ACCEPTANCE

39-4.05A Testing
The Engineer samples for acceptance testing and tests for:

April 11,2011 4-116

HMA Acceptance – QC / QA
Index Quality Characteristic Weight Test HMA Type
(i) -ing Method
Factor
(w)
A B RHMA-G
a
Aggregate gradation

Sieve 3/4" 1/2" 3/8"

1 1/2" Xb -- -- 0.05
CT 202 JMF ± Tolerance c
1 3/8" -- X -- 0.05
1 No. 4 -- -- X 0.05
2 No. 8 X X X 0.10
3 No. 200 X X X 0.15
4 Asphalt binder content (%) 0.30 CT 379 or JMF ± 0.45 JMF ± 0.45 JMF ± 0.5
382
5 Percent of maximum theoretical 0.40 CT 375 92 – 96 92 – 96 91 – 96
density (%) d, e
Sand equivalent (min.) f CT 217 47 42 47
Stabilometer value (min.) f,, g CT 366
No. 4 and 3/8" gradings 30 30 --
1/2" and 3/4" gradings 37 35 23
Air voids content (%)f, h CT 367 4±2 4±2 Specifica-
tion ± 2
Percent of crushed particles coarse CT 205
aggregate (% min.)
One fractured face 90 25 --
Two fractured faces 70 -- 90
Fine aggregate (% min)
(Passing No. 4 sieve and retained
on No. 8 sieve.)
One fractured face 70 20 70
HMA moisture content (%, max.) CT 226 or 1.0 1.0 1.0
CT 370
Los Angeles Rattler (% max.) CT 211
Loss at 100 rev. 12 -- 12
Loss at 500 rev. 45 50 45
Fine aggregate angularity (% min.) AASHTO 45 45 45
T 304,
Method A
Flat and elongated particle (% max. ASTM D Report Report Report
by weight @ 5:1) 4791 only only only
Voids in mineral aggregate (% min.) i (Note j)
No. 4 grading 17.0 17.0 --
3/8" grading LP-2 15.0 15.0 --
1/2" grading 14.0 14.0 18.0 - 23.0
3/4" grading 13.0 13.0 18.0 - 23.0
Voids filled with asphalt (%) i
No. 4 grading LP-3 76.0 - 80.0 76.0 - 80.0 Report
3/8" grading 73.0 - 76.0 73.0 - 76.0 only
1/2" grading 65.0 - 75.0 65.0 - 75.0
3/4" grading 65.0 - 75.0 65.0 - 75.0

April 11,2011 4-117

Dust proportion i LP-4

No. 4 and 3/8" gradings 0.9 - 2.0 0.9 – 2.0 Report
1/2" and 3/4" gradings 0.6 - 1.3 0.6 – 1.3 only
Smoothness Section 12-foot 12-foot 12-foot
39-1.12 straight- straight- straight-
edge, must- edge, must- edge,
grind, and grind, and must-
PI0 PI0 grind, and
PI0
Asphalt binder Various Section 92 Section 92 Section 92
Section
92-
1.02(C)
Asphalt rubber binder Various -- --
and
Section
39-1.02D
Section
Asphalt modifier Various -- --
39-1.02D
Section
Crumb rubber modifier Various -- --
39-1.02D
Notes:
a
The Engineer determines combined aggregate gradations containing RAP under Laboratory Procedure LP-9.
b
"X" denotes the sieves the Engineer considers for the specified aggregate gradation.
c
The tolerances must comply with the allowable tolerances in Section 39-1.02E, "Aggregate."
d
The Engineer determines percent of maximum theoretical density if the specified paved thickness is at least 0.15
foot under California Test 375 except the Engineer uses:
1. California Test 308, Method A, to determine in-place density of each density core instead of using the
nuclear gauge in Part 4, "Determining In-Place Density By The Nuclear Density Device."
2. California Test 309 to determine maximum theoretical density instead of calculating test maximum
density in Part 5, "Determining Test Maximum Density."
e
The Engineer determines maximum theoretical density (California Test 309) at the frequency specified for Test
Maximum Density under California Test 375, Part 5.D.
f
The Engineer reports the average of 3 tests from a single split sample.
g
Modify California Test 304, Part 2.B.2.c: "After compaction in the mechanical compactor, cool to 140 °F ± 5
°F by allowing the briquettes to cool at room temperature for 0.5 hour, then place the briquettes in the oven at 140
°F for a minimum of 2 hours and not more than 3 hours."
h
The Engineer determines the bulk specific gravity of each lab-compacted briquette under California Test 308,
Method A, and theoretical maximum specific gravity under California Test 309.
i
Report only if the adjustment for asphalt binder content target value is less than or equal to ± 0.3 percent from
OBC.
j
Voids in mineral aggregate for RHMA-G must be within this range.

The Engineer determines the percent of maximum theoretical density from the average density
of 3 density cores you take from every 750 tons of production or part thereof divided by the
maximum theoretical density.
If the specified total paved thickness is at least 0.15 foot and any layer is less than 0.15 foot, the
Engineer determines the percent of maximum theoretical density from density cores taken from
the final layer measured the full depth of the total paved HMA thickness.
The Engineer stops production and terminates a lot if:

April 11,2011 4-118

1. The lot's composite quality factor, QFC, or an individual quality factor, QFQCi for i = 3, 4,
or 5, is below 0.90 determined under Section 39-4.03F, "Statistical Evaluation"
2. An individual quality factor, QFQCi for i = 1 or 2, is below 0.75
3. Quality characteristics for which a quality factor, QFQCi, is not determined has 2
consecutive acceptance or quality control tests not in compliance with the specifications

For any single quality characteristic for which a quality factor, QFQCi, is not determined, except
smoothness, if 2 consecutive acceptance test results do not comply with specifications:

39-4.05B Statistical Evaluation, Determination Of Quality Factors And Acceptance

Statistical Evaluation and Determination of Quality Factors
To determine the individual quality factor, QFQCi, for any quality factor i = 1 through 5 or a lot's
composite quality factor, QFC, for acceptance and payment adjustment, the Engineer uses the
evaluation specifications under Section 39-4.03F, "Statistical Evaluation," and:

1. Verified quality control test results for aggregate gradation

2. Verified quality control test results for asphalt binder content
3. The Engineer's test results for percent of maximum theoretical density

Lot Acceptance Based on Quality Factors

The Engineer accepts a lot based on the quality factors determined for aggregate gradation and
asphalt binder content, QFQCi for i = 1 through 4, using the total number of verified quality control
test result values and the total percent defective (PU + PL).
The Engineer accepts a lot based on the quality factor determined for maximum theoretical
density, QFQC5, using the total number of test result values from density cores and the total
percent defective (PU + PL).
The Engineer calculates the quality factor for the lot, QFC, which is a composite of weighted
individual quality factors, QFQCi, determined for each quality characteristic in the HMA
Acceptance – QC / QA table in Section 39-4.05A, "Testing."
The Engineer accepts a lot based on quality factors if:

1. The current composite quality factor, QFC, is 0.90 or greater

2. Each individual quality factor, QFQCi for i = 3, 4, and 5, is 0.90 or greater
3. Each individual quality factor, QFQCi for i = 1 and 2, is 0.75 or greater

April 11,2011 4-119

No single quality characteristic test may represent more than the smaller of 750 tons or 1 day's
production.

Payment Adjustment
If a lot is accepted, the Engineer adjusts payment with the following formula:

n
PA = ∑ HMACP * wi * [QFQCi * ( HMATT − WHMATTi) + WHMATTi] −(HMACP * HMATT )
i =1

where:
PA = Payment adjustment rounded to 2 decimal places.
HMACP = HMA contract price.
HMATT = HMA total tons represented in the lot.
WHMATTi = Total tons of waived quality characteristic HMA.
QFQCi = Running quality factor for the individual quality characteristic.
QFQCi for i = 1 through 4 must be from verified Contractor's QC
results. QFQC5 must be determined from the Engineer's results on
density cores taken for percent of maximum theoretical density
determination.
w= Weighting factor listed in the HMA acceptance table.
i= Quality characteristic index number in the HMA acceptance table.

If the payment adjustment is a negative value, the Engineer deducts this amount from payment.
If the payment adjustment is a positive value, the Engineer adds this amount to payment.
The 21st sublot becomes the 1st sublot (n = 1) in the next lot. When the 21st sequential sublot
becomes the 1st sublot, the previous 20 sequential sublots become a lot for which the Engineer
determines a quality factor. The Engineer uses this quality factor to pay for the HMA in the lot.
If the next lot consists of less than 8 sublots, these sublots must be added to the previous lot for
quality factor determination using 21 to 27 sublots.

39-4.05C Dispute Resolution

For a lot, if you or the Engineer dispute any quality factor, QFQCi, or verification test result, every
sublot in that lot must be retested.
Referee tests must be performed under the specifications for acceptance testing.
Any quality factor, QFQCi, must be determined using the referee tests.
For any quality factor, QFQCi, for i = 1 through 5, dispute resolution:

1. If the difference between the quality factors for QFQCi using the referee test result and the
disputed test result is less than or equal to 0.01, the original test result is correct.

April 11,2011 4-120

2. If the difference between the quality factor for QFQCi using the referee test result and the
disputed test result is more than 0.01, the quality factor determined from the referee tests
supersedes the previously determined quality factor.

39-5 MEASUREMENT AND PAYMENT

39-5.01 MEASUREMENT
The contract item for HMA is measured by weight. The weight of each HMA mixture designated
in the Engineer's Estimate must be the combined mixture weight.
If tack coat, asphalt binder, and asphaltic emulsion are paid with separate contract items, their
contract items are measured under Section 92, "Asphalts," or Section 94, "Asphaltic
Emulsions," as the case may be.
If recorded batch weights are printed automatically, the contract item for HMA is measured by
using the printed batch weights, provided:

1. Total aggregate and supplemental fine aggregate weight per batch is printed. If
supplemental fine aggregate is weighed cumulatively with the aggregate, the total
aggregate batch weight must include the supplemental fine aggregate weight.
2. Total asphalt binder weight per batch is printed.
3. Each truckload's zero tolerance weight is printed before weighing the first batch and after
weighing the last batch.
4. Time, date, mix number, load number and truck identification is correlated with a load
slip.
5. A copy of the recorded batch weights is certified by a licensed weighmaster and
submitted to the Engineer.

The contract item for placing HMA dike is measured by the linear foot along the completed
length. The contract item for placing HMA in miscellaneous areas is measured as the in-place
compacted area in square yards. In addition to the quantities measured on a linear foot or
square yard basis, the HMA for dike and miscellaneous areas are measured by weight.
The contract item for geosynthetic pavement interlayer is measured by the square yard for the
actual pavement area covered.

39-5.02 PAYMENT
The contract prices paid per ton for hot mix asphalt as designated in the Engineer's Estimate
include full compensation for furnishing all labor, materials, tools, equipment, and incidentals for
doing all the work involved in constructing hot mix asphalt, complete in place, as shown on the
plans, as specified in these specifications and the special provisions, and as directed by the
Engineer.
If HMA is specified to comply with Section 39-4, "Quality Control / Quality Assurance," the
Engineer adjusts payment under that section.
Full compensation for the Quality Control Plan and prepaving conference is included in the
contract prices paid per ton for hot mix asphalt as designated in the Engineer's Estimate and no
additional compensation will be allowed therefor.

April 11,2011 4-121

Full compensation for performing and submitting mix designs and for Contractor sampling,
testing, inspection, testing facilities, and preparation and submittal of results is included in the
contract prices paid per ton for HMA as designated in the Engineer's Estimate and no additional
compensation will be allowed therefor.
Full compensation for reclaimed asphalt pavement is included in the contract prices paid per ton
for HMA as designated in the Engineer's Estimate and no additional compensation will be
allowed therefor.
The contract price paid per ton for hot mix asphalt (leveling) includes full compensation for
furnishing all labor, materials, tools, equipment, and incidentals for doing all the work involved in
hot mix asphalt (leveling), complete in place, as shown on the plans, as specified in these
specifications and the special provisions, and as directed by the Engineer.
The State pays for HMA dike at the contract price per linear foot for place HMA dike and by the
ton for HMA. The contract prices paid per linear foot for place hot mix asphalt dike as
designated in the Engineer's Estimate include full compensation for furnishing all labor, tools,
equipment, and incidentals, and for doing all the work involved in placing HMA dike, complete in
place, including excavation, backfill, and preparation of the area to receive the dike, as shown
on the plans, as specified in these specifications and the special provisions, and as directed by
the Engineer.
The State pays for HMA specified to be a miscellaneous area at the contract price per square
yard for place hot mix asphalt (miscellaneous area) and per ton for hot mix asphalt. The
contract price paid per square yard for place hot mix asphalt (miscellaneous area) includes full
compensation for furnishing all labor, tools, equipment, and incidentals, and for doing all the
work involved in placing HMA (miscellaneous area) complete in place, including excavation,
backfill, and preparation of the area to receive HMA (miscellaneous area), as shown on the
plans, as specified in these specifications and the special provisions, and as directed by the
Engineer.
If the Quality Control / Quality Assurance construction process is specified, HMA placed in dikes
and miscellaneous areas is paid for at the contract price per ton for hot mix asphalt under
Section 39-4, "Quality Control / Quality Assurance." Section 39-4.05B, "Statistical Evaluation,
Determination of Quality Factors and Acceptance," does not apply to HMA placed in dikes and
miscellaneous areas.
If there are no contract items for place hot mix asphalt dike and place hot mix asphalt
(miscellaneous area) and the work is specified, full compensation for constructing HMA dikes
and HMA (miscellaneous areas) including excavation, backfill, and preparation of the area to
receive HMA dike or HMA (miscellaneous area) is included in the contract price paid per ton for
the hot mix asphalt designated in the Engineer's Estimate and no separate payment will be
made therefor.
The contract price paid per square yard for geosynthetic pavement interlayer includes full
compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing
all the work involved in placing geosynthetic pavement interlayer, complete in place, as shown
on the plans, as specified in these specifications and the special provisions, and as directed by
the Engineer.
The contract price paid per ton for paving asphalt (binder, geosynthetic pavement interlayer)
includes full compensation for furnishing all labor, materials, tools, equipment, and incidentals,
and for doing all the work involved in applying paving asphalt (binder, geosynthetic pavement
interlayer), complete in place, including spreading sand to cover exposed binder material, as

April 11,2011 4-122

shown on the plans, as specified in these specifications and the special provisions, and as
directed by the Engineer.
Full compensation for small quantities of HMA placed on geosynthetic pavement interlayer to
prevent displacement during construction is included in the contract price paid per ton for the
HMA being paved over the interlayer and no separate payment will be made therefor.
The contract price paid per ton for tack coat includes full compensation for furnishing all labor,
materials, tools, equipment, and incidentals, and for doing all the work involved in applying tack
coat, complete in place, as shown on the plans, as specified in these specifications and the
special provisions, and as directed by the Engineer.
The Engineer does not adjust payment for increases or decreases in the quantities for tack coat,
regardless of the reason for the increase or decrease. Section 4-1.03B, "Increased or
Decreased Quantities," does not apply to the items for tack coat.
Full compensation for performing smoothness testing, submitting written and electronic copies
of tests, and performing corrective work including applying fog seal coat is included in the
contract price paid per ton for the HMA designated in the Engineer's Estimate and no separate
payment will be made therefor.
Full compensation for spreading sand on RHMA-G, RHMA-O, and RHMA-O-HB surfaces and
for sweeping and removing excess sand is included in the contract price paid per ton for
rubberized hot mix asphalt as designated in the Engineer's Estimate and no separate payment
will be made therefor.
If the Engineer fails to comply with a specification within a specified time, and if, in the opinion of
the Engineer, work completion is delayed because of the failure, the Engineer adjusts payment
and contract time under Section 8-1.09, "Right of Way Delays."
If the dispute resolution ITP determines the Engineer's test results are correct, the Engineer
deducts the ITP's testing costs from payments. If the ITP determines your test results are
correct, the State pays the ITP's testing costs. If, in the Engineer's opinion, work completion is
delayed because of incorrect Engineer test results, the Engineer adjusts payment and contract
time under Section 8-1.09, "Right of Way Delays."

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 40 PORTLAND CEMENT CONCRETE PAVEMENT

(Issued 06-05-09)

Replace Section 40 with:

SECTION 40 CONCRETE PAVEMENT

April 11,2011 4-123

40-1 GENERAL
40-1.01 SUMMARY
Section 40 includes specifications for constructing concrete pavement on a prepared subgrade.

40-1.02 SUBMITTALS
40-1.02A Certificates of Compliance
Submit Certificates of Compliance under Section 6-1.07, "Certificates of Compliance." Include a
test result report for any specified test with certification that test was performed within 12
months before the tested material's use.
Submit Certificates of Compliance for:

1. Tie bars
2. Threaded tie bar splice couplers
3. Dowel bars
4. Tie bar baskets
5. Dowel bar baskets
6. Chemical adhesive (drill and bond)
7. Silicone joint sealant
8. Asphalt rubber joint sealant
9. Preformed compression seal
10. Backer rods. Include the manufacturer's statement of compatibility with the sealant to be
used.
11. Joint filler material
12. Curing compound. For each delivery to the job site, submit a copy of the Certificate of
Compliance to the Engineer and the Transportation Laboratory. Each Certificate of
Compliance must not represent more than 10,000 gallons and must include a test result
report for:

12.1. Moisture loss at 24 hours under California Test 534

12.2. Reflectance under ASTM E 1347
12.3. Viscosity under ASTM D 2196
12.4. Nonvolatile content under ASTM D 3723
12.5. Pigment content under ASTM D 3723

13. Epoxy powder coating

40-1.02B Curing Compound Samples

Submit split curing compound samples to the Transportation Laboratory.

40-1.02C Drilled Corings

Submit each core taken for Engineer's acceptance in a plastic bag. Mark each core with a
location description.

April 11,2011 4-124

40-1.02D Independent Third Party Air Content Testing Laboratory

Before testing, submit for the Engineer's approval the name of a laboratory that will test drilled
core specimens for air content in cases of dispute.

40-1.02E Dowel Bars

Before placing dowel bars, submit a procedure for identifying transverse contraction joint
locations relative to the dowel bars' longitudinal center and a procedure for consolidating
concrete around the dowel bars.

40-1.02F Concrete Field Qualification

Submit field qualification data and test reports including:

1. Mixing date
2. Mixing equipment and procedures used
3. Batch volume in cubic yards
4. Type and source of ingredients used
5. Penetration of the concrete
6. Air content of the plastic concrete
7. Age and strength at time of concrete beam testing

Field qualification test reports must be certified with a signature by an official in responsible
charge of the laboratory performing the tests.

40-1.02G Frequency Measuring Device (Tachometer)

Submit calibration documentation and operational guidelines for frequency measuring devices
for concrete consolidation vibrators.

40-1.02H Manufacturer's Recommendations and Instructions

If used and at least 15 days before delivery to the job site, submit manufacturer's
recommendations and instructions for storage and installation of:

1. Threaded tie bar splice couplers

2. Chemical adhesive (drill and bond)
3. Silicone liquid sealant
4. Asphalt rubber liquid sealant
5. Preformed compression seals
6. Joint filler material

April 11,2011 4-125

40-1.02I Mix Proportions

At least 15 days before starting testing for mix proportions under California Test 559, submit a
copy of the AASHTO accreditation for your laboratory determining the mix proportions. At least
30 days before starting field qualification, submit under California Test 559 the proposed
concrete mix proportions, the corresponding mix identifications, and laboratory test reports
including the modulus of rupture for each trial mixture at 10, 21, 28, and 42 days.

40-1.02J Preformed Compression Seal

Submit the manufacturer's data sheet used to develop the recommended preformed
compression seal based on the joint dimensions.

40-1.02K Concrete Pavement Early Age Crack Mitigation System

At least 24 hours before each paving shift, submit:

1. Early age stress and strength predictions

2. Scheduled sawing and curing activities
3. Contingency plan if volunteer cracking occurs

At least 24 hours before paving, meet with the Engineer to review the submittals for the early
age crack mitigation system.
During paving, update the system with current weather data obtained from a portable weather
station. Before paving concrete pavement with these updates, submit new stress and strength
predictions and curing and sawing activity schedules.

40-1.02L Profilograms
Submit profilograms within 5 business days of initial profiling and within 2 business days of
profiling corrected sections.
Submit 1 electronic copy of profile information in ".erd" format or other ProVAL compatible
format to the Engineer and to:

Smoothness@dot.ca.gov

Submit the original of final profilograms before the Engineer accepts the contract.
Submitted profilograms become the Department's property.

40-1.02M Protecting Concrete Pavement During Cold Weather

Submit a plan for protecting concrete pavement when the average ambient daily temperature is
below 40 °F and daytime ambient temperature is less than 50 °F during the initial 72 hours after
paving.

April 11,2011 4-126

40-1.02N Quality Control Charts

Submit updated quality control charts each paving day.

40-1.02O Quality Control Plan

At least 30 days before the start of field qualification, submit a concrete pavement quality control
plan (QCP).

40-1.03 QUALITY CONTROL AND ASSURANCE

40-1.03A Contractor Quality Control Plan
Establish, implement, and maintain a QCP for concrete pavement. The QCP must describe the
organization and procedures you use to:

1. Control the production process

2. Determine if changes to the production process are needed
3. Implement changes

The QCP must address the elements affecting concrete pavement quality including:

1. Mix proportions
2. Aggregate gradation
3. Materials quality
4. Stockpile management
5. Line and grade control
6. Proportioning
7. Mixing and transportation
8. Placing and consolidation
9. Contraction and construction joints
10. Dowel bar placement, alignment, and anchorage
11. Tie bar placement
12. Modulus of rupture
13. Finishing and curing
14. Surface smoothness
15. Joint sealant and compression seal installation

The QCP must include details of corrective action to be taken if any process is out of control.
As a minimum, a process is out of control if any of the following occurs:

1. For fine and coarse aggregate gradation, 2 consecutive running averages of 4 tests are
outside the specification limits

April 11,2011 4-127

2. For fine and coarse aggregates, the moisture content of either aggregate changes by more
than 0.5 percentage point from any reading
3. For individual penetration or air content measurements:

3.1. One point falls outside the suspension limit line

3.2. Two points in a row fall outside the action limit line

Stop production and take corrective action for out of control processes except fine and coarse
aggregate moisture content or the Engineer rejects subsequent material.

40-1.03B Quality Control Testing

Select random locations and perform sampling and testing in compliance with:

Quality Control Testing

Test Frequency Test Method
Cleanness value 2 per day CT 227
Sand equivalent 2 per day CT 217
Aggregate gradation 2 per day CT 202
Air content (freeze thaw) a 1 per hour CT 504
Air content (non-freeze thaw) 1 per 4 hours CT 504
Density 1 per 4 hours CT 518
Penetration 1 per 4 hours CT 533
Calibration of moisture meter b, c 1 per day CT 223 or CT 226
Notes:
a
If air entrainment is specified, make at least 1 air content measurement per hour. If air entrainment is not
specified, make at least 1 air content measurement per 4 hours.
b
Make at least 1 measurement of moisture content per week to check the calibration of an electronically actuated
moisture meter.
c
Random location sampling and testing is not applicable.

If air entrainment is specified, the testing laboratory and tester must be qualified under the
Department's Independent Assurance Manual. The manual is available from the Transportation
Laboratory.

40-1.03C Control Charts

Maintain control charts to identify potential problems and assignable causes. Post a copy of
each control chart at a location determined by the Engineer.
Individual measurement control charts must use the target values in the mix proportions as
indicators of central tendency.
Develop linear control charts for:

1. Cleanness value
2. Sand equivalent
3. Fine and coarse aggregate gradation

April 11,2011 4-128

4. Air content
5. Penetration

Control charts must include:

1. Contract number
2. Mix proportions
3. Test number
4. Each test parameter
5. Action and suspension limits
6. Specification limits
7. Quality control test results

For fine and coarse aggregate gradation control charts, record the running average of the
previous 4 consecutive gradation tests for each sieve and superimpose the specification limits.
For penetration and air content control charts, record the individual measurements and
superimpose the following action and suspension limits:

Penetration and Air Content Action and Suspension Limits

Individual Measurements
Control Parameter Action Limit Suspension Limit
Penetration, CT 533 1 inch 1-1/2 inch
Air content, CT 504 ±1.0 percent ±1.5 percent

40-1.03D Contractor's Laboratory

Use a laboratory that complies with ASTM C 1077 to determine the mix proportions for concrete
pavement. The laboratory must have a current AASHTO accreditation for:

1. AASHTO T 97 or ASTM C 78
2. ASTM C 192/C 192M

40-1.03E Joint Sealant and Compression Seal Installation Training

Before installing joint sealant or compression seals, arrange for a representative from the joint
sealant or compression seal manufacturer to provide training on the cleaning and preparation of
the joint and installing the sealant or seal. Until your personnel and the Department's personnel
have been trained, do not install joint sealant or compression seals.

40-1.03F Frequency Measuring Device (Tachometer)

Before each day's concrete pavement placement and at intervals not to exceed 4 hours of
production, test and record vibration frequency and amplitude for concrete consolidation
vibrators.

April 11,2011 4-129

40-1.03G Early Age Concrete Pavement Crack Mitigation System

Develop and implement a system for predicting concrete pavement stresses and strength during
the initial 72 hours after paving. The system must include:

1. Subscribing to a weather service to obtain forecasts for wind speed, ambient

temperatures, humidity, and cloud cover
2. Portable weather station with anemometer, temperature and humidity sensors, located at
the paving site
3. Early age concrete pavement stress and strength prediction computer program
4. Analyzing, monitoring, updating, and reporting the system's predictions

40-1.03H Curing Compound

Sample curing compound from shipping containers at the manufacturer's source of supply. Split
the samples.

40-1.03I Concrete Pavement Smoothness

Within 10 days after paving, measure the Profile Index (PI0) of the concrete pavement surface
using a zero (null) blanking band under California Test 526.
For the following concrete pavement areas, the Engineer does not require a profilograph and
you must test and correct high points determined by a 12-foot straightedge placed parallel with
and perpendicular to the centerline:

1. Horizontal curves with a centerline radius of curvature less than 1,000 feet including
concrete pavement within the superelevation transitions of those curves.
2. Exit ramp termini, truck weigh stations, and weigh-in-motion areas
3. Where steep grades and superelevation rates greater than 6 percent are present on:

3.1. Ramps
3.2. Connectors

4. Turn lanes and areas around manholes or drainage transitions

5. Acceleration and deceleration lanes for at-grade intersections
6. Shoulders and miscellaneous gore areas

Use a California Profilograph or equivalent to determine the concrete pavement profile. If the
profilograph uses a mechanical recorder, use an electronic scanner to reduce the profilogram.
The profilograph operator must be qualified under the Department's Independent Assurance
Manual. The manual is available from the Transportation Laboratory.

April 11,2011 4-130

40-1.03J Profilograph Test Procedure

Notify the Engineer at least 2 business days before performing profilograph testing. Each day
before performing profilograph testing, notify the Engineer of the start location. Perform
profilograph testing in the Engineer's presence.
Before starting profilograph testing, remove foreign objects from the concrete pavement surface.
Before starting profilograph testing, calibrate the profilograph in the Engineer's presence. If the
Engineer chooses not to be present during profilograph testing, you may perform the testing
with the Engineer's written approval. Note the Engineer's absence on the profilogram.
Determine PI0 values for the final concrete pavement surface of each 0.1-mile section of a traffic
lane. Take 2 profiles within each traffic lane, 3 feet from and parallel with the edge of each lane.
Each section's PI0 is the average of the PI0 values for the measurements within that traffic lane.
A section that is less than 0.01 mile and is the result of an interruption to continuous concrete
pavement surface must comply with the PI0 specifications for a full section. Adjust the PI0 for a
partial section to reflect a full section.
Use stationing to locate vertical deviations greater than 0.3 inches. The profilogram stationing
must be the same as the project stationing. Note 0.1-mile segments on the profilogram.
Label the profilogram with:

1. Contract number
2. County and route number
3. Stationing
4. Operator's name
5. Test date
6. Test number
7. Traffic direction
8. Traffic lane (numbered from left to right in direction of travel)
9. Test wheel path (left or right in direction of travel)
10. Test direction
11. Paving direction

40-1.03K Smoothness Corrective Action

Correct concrete pavement not complying with the Engineer's acceptance specifications for
smoothness by grinding under Section 42-2, "Grinding."
Do not grind before:

1. Ten days after concrete pavement placement

2. The concrete has developed a modulus of rupture of at least 550 psi

Grind the entire lane width. When completed, the lane width must be uniform in texture and
appearance. Square the corrected area's start and end normal to the paved surface's
centerline.
Retest sections where corrections were made.

April 11,2011 4-131

40-1.03L Engineer's Acceptance

General
The Engineer accepts concrete pavement based on the Department's testing for the following
concrete pavement quality characteristics. A single test represents no more than the quantity
specified:

Concrete Pavement Acceptance

Quality Characteristic Quantity Test
28-day modulus of rupture 1,000 cubic yards CT 523
Thickness 1,200 square yards for primary area CT 531
measurements
Dowel bar placement 700 square yards Measurement
Tie bar placement 4,000 square yards Measurement
Coefficient of friction One day's paving CT 342
Air content (freeze-thaw) a One day's paving CT 504
Note:
a
Air content tests must be performed under California Test 504 if air entrainment is
specified.

At the Department's option, the Engineer also accepts concrete pavement based on your or the
Department's testing for smoothness. A single test represents no more than 0.1 mile.
The Engineer considers other concrete pavement quality characteristics in determining final
acceptance. The Engineer's acceptance of modulus of rupture, thickness, dowel bar and tie bar
placement, coefficient of friction, smoothness, and air content does not constitute final concrete
pavement acceptance.

Modulus of Rupture
The Engineer accepts concrete pavement for modulus of rupture on a lot basis. The minimum
modulus of rupture for each lot is 570 psi at 28 days.
For each lot of concrete for concrete pavement:

1. Quantity must not exceed 1,000 cubic yards.

2. Department determines the modulus of rupture of test beams aged 10 days and 28 days.
3. Department calculates the modulus of rupture by averaging the individual test results of 2
beams aged for 28 days.
4. Difference in the individual test results of beams aged 28 days must not exceed 12
percent when tested by Method 1, or 16 percent when tested by Method 2. The Engineer
calculates the difference relative to the average of the 2 test results.

The Department provides molds and machines for modulus of rupture acceptance testing.
Provide material and labor the Engineer may require.

April 11,2011 4-132

Concrete Pavement Smoothness

If the Department tests for smoothness, the tests are performed under Section 40-1.03I,
"Concrete Pavement Smoothness."
The Engineer accepts concrete pavement for smoothness in compliance with the following:

1. For tangents and horizontal curves having a centerline radius of curvature 2,000 feet or
more, the PI0 must be at most 3 inches per 0.1-mile section.
2. For horizontal curves having a centerline radius of curvature from 1,000 to 2,000 feet
including concrete pavement within the superelevation transitions of those curves, the PI0
must be at most 6 inches per 0.1-mile section.
3. If using a profilograph to measure smoothness, the surface must not have individual high
points greater than 0.3 inch.
4. If using a straightedge to measure smoothness, the surface must be within 0.02 foot of the
straightedge's lower edge.

Profile index specifications apply to existing pavement within 50 feet of the transverse joint
separating new concrete pavement and the existing pavement.
If the Department's profilograph test results do not match yours, the Engineer may order you to
recalibrate your profilograph equipment and perform a retest. If your test results are inaccurate
due to operator error, the Engineer may disqualify your profilograph operator. If the Engineer
determines your test results are inaccurate, the Engineer does not make adjustments to
payment or contract time for recalibrating, retesting, and delays.

Concrete Pavement Thickness

The Engineer accepts concrete pavement for thickness based on coring in the primary area,
which is the area placed in 1 day for each thickness. Concrete pavement thickness must not be
deficient by more than 0.05 foot.
After corrective grinding has been completed, core concrete pavement in the primary area
under Section 40-3.16, "Obtaining Drilled Cores," at locations determined by the Engineer and
in the Engineer's presence. The core specimen diameter must be 4 inches. To identify the
limits of concrete pavement deficient in thickness by more than 0.05 foot, you may divide
primary areas into secondary areas. Specifications that may affect concrete pavement
thickness such as allowable tolerances for subgrade construction do not change the thickness
specified for concrete pavement.
In each primary area, the Engineer measures concrete pavement thickness every 1,200 square
yards and any remaining area. The Engineer measures cores under California Test 531 to the
nearest 0.01 foot. Core at least 1 foot from existing, contiguous, and parallel concrete
pavement not constructed as part of this contract.
You may request the Engineer make additional thickness measurements and use them to
determine the average thickness variation. The Engineer determines the locations with random
sampling methods.

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If each thickness measurement in a primary area is less than 0.05 foot deficient, the Engineer
calculates the average thickness deficiency in that primary area. The Engineer uses 0.02 foot
for a thickness difference more than 0.02 foot over the specified thickness.
For each thickness measurement in a primary area deficient by more than 0.05 foot, the
Engineer determines a secondary area where the thickness deficiency is more than 0.05 foot.
The Engineer determines this secondary area by measuring the thickness of each concrete
pavement slab adjacent to the measurement found to be more than 0.05 foot deficient. The
Engineer continues to measure the thickness until an area that is bound by slabs with thickness
deficient by 0.05 foot or less is determined.
Slabs without bar reinforcement are defined as the areas bound by longitudinal and transverse
joints and concrete pavement edges. Slabs with bar reinforcement are defined as the areas
bound by longitudinal joints and concrete pavement edges and 15-foot lengths. Secondary area
thickness measurements in a slab determine that entire slab's thickness.
The Engineer measures the remaining primary area thickness after removing the secondary
areas from consideration for determining the average thickness deficiency.
The Engineer determines the slabs to remove and replace.

Required Use of Air-Entraining Admixtures

If air-entraining admixtures are specified, the Engineer may choose to accept concrete
pavement for air content based on your air content quality control tests. The Engineer decides
to use your air content quality control tests based on a t-test that determines the difference in
the means of your test and the Engineer's verification tests. The Engineer calculates the t-value
of the test data as follows:

Xc − Xv
t= and Sc2 (nc - 1) + Sv2 (nv - 1)
1 1 Sp2 =
Sp + nc + nv - 2
nc nv

where:

nc = Number of your quality control tests (minimum of 2 required)

nv = Number of verification tests (minimum of 1 required)
Xc = Mean of your quality control tests
Xv = Mean of the verification tests
Sp = Pooled standard deviation
(When nv = 1, Sp = Sc)
Sc = Standard deviation of your quality control tests
Sv = Standard deviation of the verification tests (when nv > 1)

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The Engineer compares your quality control test results with the Department's verification test
results at a level of significance of α = 0.01. The Engineer compares the t-value to tcrit,
determined from:

tcrit
degrees of freedom tcrit
(nc+nv-2) (for α = 0.01)
1 63.657
2 9.925
3 5.841
4 4.604
5 4.032
6 3.707
7 3.499
8 3.355
9 3.250
10 3.169

If the t-value calculated is less than or equal to tcrit, your quality control test results are verified.
If the t-value calculated is greater than tcrit, quality control test results are not verified.
If your quality control test results are not verified, core at least 3 specimens from concrete
pavement under Section 40-3.16, "Obtaining Drilled Cores." The Engineer selects the core
locations. Your approved third party independent testing laboratory must test these specimens
for air content under ASTM C 457. The Engineer compares these test results with your quality
control test results using the t-test method. If your quality control test results are verified based
on this comparison, the Engineer uses the quality control test results for acceptance of concrete
pavement for air content. If your quality control test results are not verified based on this
comparison, the Engineer uses the air content of core specimens determined under ASTM C
457 for acceptance.

Dowel Bar and Tie Bar Placement

The Engineer uses core specimens to evaluate and accept concrete pavement for:

1. Dowel bar placement

2. Tie bar placement
3. Concrete consolidation

Obtain cores under Section 40-3.16, "Obtaining Drilled Cores." The Engineer determines the
core locations. Each core must have a nominal diameter of 4 inches. Core each day's paving
within 2 business days in compliance with:

1. One test for every 700 square yards of doweled concrete pavement or remaining fraction
of that area. Each dowel bar test consists of 2 cores, 1 on each dowel bar end to expose
both ends and allow measurement.

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2. One test for every 4,000 square yards of concrete pavement with tie bars or remaining
fraction of that area

If the tests indicate dowel or tie bars are not placed within the specified tolerances or if there are
air voids around the dowel or tie bars, core additional specimens to determine the limits of
unacceptable work.
The Engineer determines the slabs to remove and replace.
If the Engineer approves your request, slabs may remain in place with an adjustment in
payment for:

1. Dowel bars with centers from ±2 inches to ±3 inches from the saw cut of a transverse
contraction joint or with deficient concrete consolidation around the dowel bars
2. Tie bars placed outside their specified placement and position or with deficient concrete
consolidation around the tie bars

Bar Reinforcing Steel

The Engineer accepts concrete pavement for bar reinforcing steel based on inspection before
concrete placement.

Curing Compound
The Engineer accepts curing compound based on test results submitted with the Certificate of
Compliance for moisture loss, reflectance, viscosity, nonvolatile content, and pigment content.
Curing compound sampled from shipping containers from the manufacturer's supply source or
from the job site must match these test results within the specified tolerances listed in the
precision and bias statements for the test methods.

40-2 MATERIALS
40-2.01 CONCRETE
40-2.01A General
Concrete must comply with Section 90, "Portland Cement Concrete."

40-2.01B Aggregate
The specifications for reduction in Operating Range and Contract Compliance for cleanness
value and sand equivalent specified under Section 90-2.02A, "Coarse Aggregate," and Section
90-2.02B, "Fine Aggregate," do not apply to concrete pavement.
Combined aggregate gradings must comply with Section 90-3, "Aggregate Gradings," and the
difference between the percent passing the 3/8-inch sieve and the percent passing the No. 8
sieve must not be less than 16 percent of the total aggregate.

April 11,2011 4-136

40-2.01C Cementitious Material

Concrete for concrete pavement must contain from 505 pounds to 675 pounds cementitious
material per cubic yard. The specifications for reducing cementitious material content in Section
90-4.05, "Optional Use of Chemical Admixtures," do not apply to concrete pavement.

40-2.01D Mix Proportions

Your laboratory determining mix proportions must determine the minimum cementitious
materials content or the maximum water to cementitious materials ratio under California Test
559 and:

1. You must make trial mixtures no more than 24 months before field qualification.
2. Modulus of rupture used to determine the minimum cementitious materials content or
maximum water to cementitious materials ratio must be 570 psi at 28 days age and 650
psi at 42 days age.
3. Your laboratory must determine an increase in the cementitious materials content or a
decrease in the water to cementitious materials ratio from the trial mixtures to ensure
concrete pavement complies with the specifications.

If changing an aggregate supply source or the mix proportions, produce a trial batch and field-
qualify the new concrete. The Engineer does not adjust contract time for performing sampling,
testing, and qualifying new mix proportions or changing an aggregate supply source.

40-2.01E Field Qualification

Proposed mix proportions must be field qualified before you place concrete pavement. Use an
American Concrete Institute (ACI) certified "Concrete Laboratory Technician, Grade I" to
perform field qualification tests and calculations.
The Engineer accepts field qualification if five beams made and tested under California Test 523
comply with the following:

1. At a minimum, beams are tested at 10, 21, and 28 days of age

2. At your choice of age not later than 28 days, no single beam's modulus of rupture is less
than 550 psi and the average modulus of rupture is at least 570 psi

40-2.02 TIE BARS

Unless specified as smooth, tie bars must be deformed.
Deformed tie bars must be:

1. Deformed steel reinforcing bars under any of the following:

1.1. ASTM A 615/A 615M, Grade 40 or 60

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1.2. ASTM A 996/A 996M

1.3. ASTM A 706/A 706M

2. Epoxy-coated under Section 52-1.02B, "Epoxy-coated Reinforcement," and the

following:

2.1. Epoxy-coated tie bars must comply with either ASTM A 775/ A 775M or ASTM A
934/ A 934 M.
2.2. Epoxy coating under ASTM A 934/ A 934M must be purple or gray.

Smooth tie bars must be:

1. Plain, round, and smooth steel under ASTM A 615/A 615M, Grade 40 or 60
2. Epoxy-coated under Section 52-1.02B, "Epoxy-coated Reinforcement," and the
following:

2.1. Epoxy-coated smooth tie bars must comply with ASTM A 884/A 884M, Class A,
Type 1 or Type 2.
2.2. Epoxy coating under ASTM A 884/A 884 M, Class A, Type 2 must be purple or
gray.
2.3. Bend test does not apply.

Fabricate, sample, and handle epoxy-coated smooth and deformed tie bars at the job site under
ASTM D 3963/D 3963M and Section 52-1.02B, "Epoxy-coated Reinforcement."

Do not bend epoxy-coated tie bars.

40-2.03 DOWEL BARS

40-2.03A General
Dowel bars must be:

1. Plain, round, and smooth steel under ASTM A 615/A 615M, Grade 40 or 60
2. Epoxy-coated under Section 52-1.02B, "Epoxy-coated Reinforcement," and the
following:

2.1 Epoxy-coated dowel bars must comply with ASTM A 884/A 884M, Class A, Type
1 or Type 2.
2.2. Epoxy coating under ASTM A 884/ A 884M, Class A, Type 2 must be purple or
gray.
2.3. Specifications for bend test do not apply.

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Fabricate, sample, and handle epoxy-coated dowel bars at the job site under ASTM D 3963/D
3963M and Section 52-1.02B, "Epoxy-coated Reinforcement," except each sample must be 18
inches long. Sample each load delivered to the job site.

40-2.03B Dowel Bar Lubricant

Dowel bar lubricant must be petroleum paraffin-based or curing compound. Paraffin-based
lubricant must be Dayton Superior DSC BB-Coat or Valvoline Tectyl 506 or an approved equal
and must be factory-applied. Curing compound must be curing compound (3) under Section 90-
7.01B, "Curing Compound Method," of the Standard Specifications.

40-2.04 CURING COMPOUND

Curing compound must be curing compound (1) or (2) with white pigment under Section 90-
7.01B, "Curing Compound Method."
Reflectance must be at least 60 percent when tested under ASTM E 1347.

40-2.05 CHEMICAL ADHESIVE (DRILL AND BOND)

Chemical adhesive for drilling and bonding dowels and tie bars must be prequalified. A list of
prequalified chemical adhesives is available on the Department's Materials Engineering and
Testing Services website. The prequalified list indicates the appropriate chemical adhesive
system for the concrete temperature and installation conditions.
Each chemical adhesive system must clearly and permanently show the manufacturer's name,
model number of the system, manufacturing date, lot number, shelf life or expiration date, and
current International Conference of Building Officials (ICBO) Evaluation Report number. Each
chemical adhesive carton must include the manufacturer's recommended installation
procedures and warning or precautions required by State or Federal laws and regulations.

40-2.06 DOWEL AND TIE BAR BASKETS

Dowel and tie bar baskets must be:

1. Minimum W10 wire size number under ASTM A 82/A 82M

2. Either U-frame or A-frame shape
3. Welded under Section 7.4 of ASTM A 185/A 185M

You may epoxy-coat dowel and tie bar baskets under Section 52-1.02B, "Epoxy-coated
Reinforcement," and the following:

1. Epoxy-coated dowel and tie bar baskets must comply with ASTM A 884/A 884M, Class
A, Type 1 or Type 2.
2. Epoxy-coating under ASTM A 884/ A 884M, Class A, Type 2 must be purple or gray.

Handle epoxy-coated dowel and tie-bar baskets at the manufacturing plant and job site under
ASTM D 3963/D 3963M and Section 52-1.02B, "Epoxy-coated Reinforcement."

April 11,2011 4-139

Fasteners must be driven fasteners under ASTM F 1667. Fasteners on lean concrete base or
asphalt concrete must have a minimum shank diameter of 3/16 inch and a minimum shank
length of 2 1/2 inches. For asphalt treated permeable base or cement treated permeable base,
the shank diameter must be at least 3/16 inch and the shank length must be at least 5 inches.
Fasteners, clips, and washers must have a minimum 0.2-mil thick zinc coating applied either by
electroplating or galvanizing.

40-2.07 BACKER RODS

Backer rods must be Type 1 under ASTM D 5249. Backer rod diameter must be at least 25
percent greater than the sawcut joint width. Backer rod material must be expanded,
crosslinked, closed-cell polyethylene foam. No bond or adverse reaction may occur between
the backer rod and sealant.

40-2.08 JOINT FILLER MATERIAL

Joint filler for isolation joints must be preformed expansion joint filler for concrete (bituminous
type) under ASTM D 994.

40-2.09 HYDRAULIC CEMENT GROUT (NON-SHRINK)

Hydraulic cement grout (non-shrink) must comply with ASTM C 1107/ C 1107M. Use clean,
uniform, rounded aggregate filler to extend the grout. Aggregate filler must not exceed 60
percent of the grout mass or the maximum recommended by the manufacturer, whichever is
less. Aggregate filler moisture content must not exceed 0.5 percent. Aggregate filler must
comply with:

Aggregate Filler Grading

Sieve Size Percentage Passing
1/2-inch 100
3/8-inch 85 - 100
No. 4 10 - 30
No. 8 0 - 10
No. 16 0-5

40-2.10 BAR REINFORCEMENT

Bar reinforcement must comply with Section 52, "Reinforcement."

40-2.11 JOINT SEALANT

40-2.11A General
Do not use hot-pour sealant that will melt the backer rod.

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40-2.11B Silicone Joint Sealant

Silicone joint sealant must be low modulus furnished in a one-part silicone formulation. Do not
use acid cure sealant. Silicone joint sealant must be compatible with the surface it is applied to
and comply with:

Silicone Joint Sealant

Property Test Method Specification
Tensile stress, 150% elongation, 7-day cure at 77 °F ± 2 °F and ASTM D 412 45 psi max.
45% to 55% R.H. e (Die C)
Flow at 77 °F ± °F ASTM C 639 a Must not flow from channel
Extrusion Rate at 77 °F ± 2 °F ASTM C 603 b 3 to 9 oz/min.
Specific Gravity ASTM D 792 1.01 to 1.51
Method A
Durometer Hardness, at 0 °F, Shore A, cured 7 days at 77 °F ±2 ASTM C 661 10 to 25
°F
Ozone and Ultraviolet Resistance, after 5,000 hours ASTM C 793 No chalking, cracking or
bond loss
Tack-free at 77 °F ±2 °F and 45% to 55% R.H.e ASTM C 679 Less than 75 minutes
Elongation, 7 day cure at 77 °F ±2 °F and 45% to 55% R.H. e ASTM D 412 500 percent min.
(Die C)
Set to Touch, at 77 °F ±2 °F and 45% to 55% R.H. e ASTM D 1640 Less than 75 minutes
Shelf Life, from date of shipment — 6 months min.
Bond, to concrete mortar-concrete briquettes, air cured 7 days at AASHTO
77 °F ±2 °F T 132 c 50 psi min.
Movement Capability and Adhesion, 100% extension at 0 °F ASTM C 719d No adhesive or cohesive
after, air cured 7 days at 77 °F ±2 °F , and followed by 7 days in failure after 5 cycles
water at 77 °F ±2 °F
Notes:
a
ASTM C 639 Modified (15 percent slope channel A).
b
ASTM C 603, through 0.12-inch opening at 50 psi.
c
Mold briquettes under AASHTO T 132, saw in half and bond with a 0.60-inch maximum thickness of sealant and
test under AASHTO T 132. Briquettes must be dried to constant mass at 212 °F ±10 °F.
d
Prepare 12" x 1" x 3" concrete blocks under ASTM C 719. Use a sawed face for bond surface. Seal 2 inches of
block leaving 0.50 inch on each end of specimen unsealed. The depth of sealant must be 0.40 inch and the width
0.50 inch.
e
R.H. equals relative humidity.

After application, silicone joint sealant must not flow on grades up to 15 percent.

40-2.11C Asphalt Rubber Joint Sealant

Asphalt rubber joint sealant must:

1. Be a mixture of paving asphalt and ground rubber containing not less than 22 percent
ground rubber by weight. One hundred percent of ground rubber must pass a No. 8 sieve.
Ground rubber must be vulcanized or a combination of vulcanized and devulcanized
materials.
2. Comply with ASTM D 6690, Type II except:

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2.1. The cone penetration requirement must not exceed 120 at 77 F, 5 ounces, 5
seconds.
2.2. The resilience requirement must be a minimum 50 percent recovery when tested at
77 F.

3. Have a Ring and Ball softening point of 135 °F minimum when tested under AASHTO T
53.
4. Be capable of being melted and applied to cracks and joints at temperatures below 400
°F.
5. Not be applied when the concrete pavement surface temperature is below 50 °F.

40-2.11D Preformed Compression Joint Seals

Preformed compression joint seals must comply with ASTM D 2628. Lubricant adhesive used
with the seals must comply with ASTM D 2835. Preformed compression joint seals must have 5
or 6 cells, except seals for Type A2 and Type B joints may have 4 cells. Install preformed
compression joint seals in compliance with the manufacturer's recommendations. Show
evidence that the seals are compressed from 40 to 50 percent for the joint width and depth.

40-2.12 WATER
Water for core drilling must be from a local domestic water supply. Water must not contain:

1. More than 1,000 parts per million of chlorides as CL

2. More than 1,300 parts per million of sulfates as S04
3. Impurities in a quantity to cause concrete discoloration or surface etching

40-3 CONSTRUCTION
40-3.01 WATER SUPPLY
Before placing concrete pavement, develop enough water supply for the work.

40-3.02 SUBGRADE PREPARATION

Immediately before placing concrete, the subgrade to receive concrete pavement must be:

1. In compliance with the specified compaction and elevation tolerances

2. Free of loose and extraneous material
3. Uniformly moist, but free of standing or flowing water
4. Excavated for thickened parts of concrete pavement end anchors with no disturbed
compaction outside the end anchor dimensions

If cement treated permeable base is specified, cover the base surface with asphaltic emulsion
before placing concrete pavement. Apply the asphaltic emulsion uniformly at a rate of 0.1

April 11,2011 4-142

gallons per square yard. Asphaltic emulsion must comply with anionic slow-setting type, SS1h
grade in Section 94, "Asphaltic Emulsions." Repair damaged asphaltic emulsion before placing
concrete pavement.

40-3.03 PROPORTIONING
Proportion aggregate and bulk cementitious materials under Section 90-5, "Proportioning."

40-3.04 PLACING CONCRETE

40-3.04A General
Place concrete pavement with stationary side forms or slip-form paving equipment.
Place consecutive concrete loads within 30 minutes of each other. Construct a transverse
construction joint when concrete placement is interrupted by more than 30 minutes. The
transverse construction joint must coincide with the next contraction joint location, or you must
remove fresh concrete pavement to the preceding transverse joint location.
Place concrete pavement in full slab widths separated by construction joints or monolithically in
multiples of full lane widths with a longitudinal contraction joint at each traffic lane line.
Do not retemper concrete.
If the concrete pavement surface width is constructed as specified, you may construct concrete
pavement sides on a batter not flatter than 6:1 (vertical:horizontal).

40-3.04B Concrete Pavement Widening

If concrete pavement is placed adjacent to existing pavement not constructed as part of the
contract, grind the existing concrete pavement lane or shoulder adjacent to the new concrete
pavement. Perform the grinding before new concrete pavement is placed. The new concrete
pavement must match the elevation of the existing concrete pavement after grinding. Grind
existing concrete pavement under Section 42-2, "Grinding," except profile index must comply
with the pavement smoothness specifications in Section 40-1.03, "Quality Control and
Assurance."
Use paving equipment with padded crawler tracks or rubber-tired wheels on the existing
concrete pavement with enough offset to avoid breaking or cracking the existing concrete
pavement's edge.

40-3.04C Concrete Pavement Transition Panel

For concrete pavement placed in a transition panel, texture the surface with a drag strip of
burlap, a broom, or a spring steel tine device that produces scoring in the finished surface. The
scoring must be either parallel with or transverse to the centerline. For the method you choose,
texture at the time that produces the coarsest texture.

April 11,2011 4-143

40-3.04D Stationary Side Form Construction

Stationary side forms must be straight and without defects including warps, bends, and
indentations. Side forms must be metal except at end closures and transverse construction
joints where other materials may be used.
You may build up side forms by attaching a section to the top or bottom. If attached to the top
of metal forms, the attached section must be metal.
The side form's base width must be at least 80 percent of the specified concrete pavement
thickness.
Side forms including interlocking connections with adjoining forms must be rigid enough to
prevent springing from subgrading and paving equipment and concrete pressure.
Construct subgrade to final grade before placing side forms. Side forms must bear fully on the
foundation throughout their length and base width. Place side forms to the specified grade and
alignment of the finished concrete pavement's edge. Support side forms during concrete
placing, compacting, and finishing.
After subgrade work is complete and immediately before placing concrete, true side forms and
set to line and grade for a distance that avoids delays due to form adjustment.
Clean and oil side forms before each use.
Side forms must remain in place for at least 1 day after placing concrete and until the concrete
pavement edge no longer requires protection from the forms.
Spread, screed, shape, and consolidate concrete with 1 or more machines. The machine must
uniformly distribute and consolidate the concrete. The machines must operate to place the
concrete pavement to the specified cross section with minimal hand work.
Consolidate the concrete without segregation. If vibrators are used:

1. The vibration rate must be at least 3,500 cycles per minute for surface vibrators and 5,000
cycles per minute for internal vibrators
2. Amplitude of vibration must cause perceptible concrete surface movement at least 1 foot
from the vibrating element
3. Use a calibrated tachometer for measuring frequency of vibration
4. Vibrators must not rest on side forms or new concrete pavement
5. Power to vibrators must automatically cease when forward or backward motion of the
paving machine is stopped

Use high-frequency internal vibrators within 15 minutes of depositing concrete on the subgrade
to uniformly consolidate the concrete across the paving width including adjacent to forms. Do
not use vibrators to shift the mass of concrete.

40-3.04E Slip-Form Construction

If slip-form construction is used, spread, screed, shape, and consolidate concrete to the
specified cross section with slip-form machines and minimal hand work. Slip-form paving
machines must be equipped with traveling side forms and must not segregate the concrete.
Do not deviate from the specified concrete pavement alignment by more than 0.1 foot.

April 11,2011 4-144

Slip-form paving machines must use high frequency internal vibrators to consolidate concrete.
You may mount vibrators with their axes parallel or normal to the concrete pavement alignment.
If mounted with axes parallel to the concrete pavement alignment, space vibrators no more than
2.5 feet measured center to center. If mounted with axes normal to the concrete pavement
alignment, space the vibrators with a maximum 0.5-foot lateral clearance between individual
vibrators.
Each vibrator must have a vibration rate from 5,000 cycles per minute to 8,000 cycles per
minute. The amplitude of vibration must cause perceptible concrete surface movement at least
1 foot from the vibrating element. Use a calibrated tachometer to measure frequency of
vibration.

40-3.05 TIE BAR PLACEMENT

Place tie bars:

1. Perpendicular to the longitudinal concrete pavement joint

2. Parallel with the concrete pavement surface at mid-slab depth
3. Not less than 1/2-inch below the saw cut depth of joints
4. With not less than 2 inches clearance from the concrete pavement's surface and bottom
5. With embedment length tolerance of ±2 inches
6. For smooth tie bars, with horizontal and vertical skew not more than 1/2 inch per foot of
bar length

Install tie bars at longitudinal joints by 1 of the following methods:

1. Drill concrete and bond tie bars with chemical adhesive in compliance with the
manufacturer's instructions. Clean and dry drilled holes before placing chemical
adhesive and tie bars. After inserting tie bars into chemical adhesive, support the bars to
prevent movement during curing. If the Engineer rejects a tie bar installation, cut the tie
bar flush with the joint face and coat the exposed end of the tie bar with chemical
adhesive under Section 40-2, "Materials." Offset new holes 3 inches horizontally from
the rejected hole's center.
2. Insert tie bars into plastic slip-formed concrete before finishing. Inserted tie bars must
have full contact between the bar and the concrete. If tie bars are inserted through the
plastic concrete surface, eliminate evidence of the insertion by reworking the concrete
over the tie bars.
3. Use threaded tie bar splice couplers fabricated from deformed bar reinforcement free of
external welding or machining.
4. Use tie bar baskets. Anchor baskets at least 200 feet in advance of the concrete
placement activity. If you request a waiver, describe the construction limitations or
restricted access preventing the advanced anchoring. After the baskets are anchored and
before the concrete is placed, cut and remove temporary spacer wires and demonstrate the
tie bars do not move from their specified depth and alignment during concrete placement.
Use fasteners to anchor tie bar baskets.

April 11,2011 4-145

If tie bars are not placed correctly, stop paving activities until you demonstrate to the Engineer
correction of the cause.

40-3.06 DOWEL BAR PLACEMENT

Center dowel bars within 2 inches in the longitudinal direction on transverse contraction joints or
construction joints.
If using curing compound as lubricant, apply the curing compound to dowels in 2 separate
applications. Lubricate each dowel bar entirely with bond breaker before placement. The last
application must be applied not more than 8 hours before placing the dowel bars. Apply each
curing compound application at a rate of 1 gallon per 150 square feet.
If dowel bars are placed by mechanical insertion, eliminate evidence of the insertion by
reworking the concrete over the dowel bars. If drilling and bonding dowel bars at construction
joints, use a grout retention ring.
If using dowel bar baskets, anchor them with fasteners.
Use at least 10 fasteners for basket sections greater than 12 feet and less than or equal to 16
feet. Baskets must be anchored at least 200 feet in advance of the concrete placement activity
unless the Engineer approves your waiver request. If requesting a waiver, describe the
construction limitations or restricted access preventing the advanced anchoring. After the
baskets are anchored and before the concrete is placed, cut and remove temporary spacer
wires and demonstrate the dowel bars do not move from their specified depth and alignment
during concrete placement.
Place dowel bars in compliance with:

April 11,2011 4-146

Dowel Bar Tolerances

Dimension Tolerance
Horizontal offset ±1 inch
Longitudinal translation ±2 inches
Horizontal skew 3/8 inch, max
Vertical skew 3/8 inch, max
Vertical depth The minimum distance below the
concrete pavement surface must be:

DB = d/3 + 1/2 inch

where:
DB = vertical distance in inches,
measured from concrete
pavement surface to any point
along the top of dowel bar
d = concrete pavement thickness
in inches

The maximum distance below the

depth shown on the plans must be 0.05
foot.

If dowel bars are not placed correctly, stop paving activities until you demonstrate to the
Engineer correction of the cause.
Remove and replace the concrete pavement 3 feet on either side of a joint with a rejected dowel
bar.

40-3.07 BAR REINFORCEMENT

Place bar reinforcement under Section 52, "Reinforcement." Bar reinforcement must be more
than 1/2 inch below the saw cut depth at concrete pavement joints.

40-3.08 JOINTS
40-3.08A General
Concrete pavement joints consist of:

1. Longitudinal and transverse construction joints

2. Longitudinal and transverse contraction joints
3. Isolation joints

Construction joints must be normal to the concrete pavement surface.

Until contract acceptance and except for joint filler material, keep joints free of foreign material
including soil, gravel, concrete, or asphalt mix.
Volunteer cracks are cracks not coincident with constructed joints.

April 11,2011 4-147

Repair concrete pavement damaged during joint construction under Section 40-3.17B, "Repair
of Spalls, Raveling, and Tearing."
Do not bend tie bars or reinforcement in existing concrete pavement joints.

40-3.08B Construction Joints

Construction joints form where fresh concrete is placed against hardened concrete, existing
pavements, or structures.
Before placing concrete at construction joints, apply a curing compound under Section 90-
7.01B, "Curing Compound Method," to the vertical surface of existing or hardened concrete and
allow it to dry.
Use a metal or wooden bulkhead to form transverse construction joints. If dowel bars are
specified, the bulkhead must allow dowel bar installation.

40-3.08C Contraction Joints

In multilane monolithic concrete pavement, use the sawing method to construct longitudinal
contraction joints. Construct transverse contraction joints by the sawing method.
Construct transverse contraction joints within 1 foot of their specified spacing. If a slab length of
less than 5 feet would be formed, adjust the transverse contraction joint spacing.
Construct transverse contraction joints across the full concrete pavement width regardless of
the number or types of longitudinal joints crossed. In areas of converging and diverging
pavements, space transverse contraction joints so their alignment is continuous across the full
width where converging and diverging pavements are contiguous. Longitudinal contraction
joints must be parallel with the concrete pavement centerline. Transverse and longitudinal
contraction joints must not deviate by more than 0.1 foot from either side of a 12-foot straight
line, except for longitudinal joints parallel to a curving centerline.

40-3.08D Isolation Joints

Construct isolation joints by saw cutting a minimum 1/8-inch width to full concrete pavement
depth at the existing concrete pavement's edge and removing the concrete to expose a flat
vertical surface. Before placing concrete, secure joint filler material that prevents new concrete
from adhering to the existing concrete face.
Dispose of concrete saw cutting residue under Section 7-1.13, "Disposal of Materials Outside
the Highway Right of Way."

40-3.08E Sawing Method

The sawing method is cutting a groove in the concrete pavement with a power driven concrete
saw. Grooves for longitudinal and transverse contraction joints must be the minimum width
possible for the type of saw used. If necessary, the top of the joint must be sawn wider to
provide space for joint sealant. Immediately wash slurry from the joint with water under 100 psi
maximum pressure.

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Saw longitudinal and transverse contraction joints before volunteer cracking occurs and after
the concrete is hard enough to saw without spalling, raveling, or tearing.
To keep foreign material out of grooves before joint sealant or compression seal installation, you
may use joint filler in sawed contraction joints. Joint filler must not react adversely with the
concrete or cause concrete pavement damage. After sawing and washing a joint, install joint
filler material that keeps moisture in the adjacent concrete during the 72 hours after paving. If
you install joint filler material, the specifications for spraying the sawed joint with additional
curing compound under Section 40-3.13, "Curing," do not apply. If using absorptive filler
material, moisten the filler immediately before or after installation.

40-3.09 JOINT SEALANT AND COMPRESSION SEAL INSTALLATION

40-3.09A General
At least 7 days after concrete pavement placement and not more than 4 hours before installing
joint sealant or compression seal materials, use dry sand blasting and other methods to clean
the joint walls of objectionable material such as soil, asphalt, curing compound, paint, and rust.
The maximum sand blasting nozzle diameter must be 1/4 inch. The minimum pressure must be
90 psi. Sand blast each side of the joint at least once, in at least 2 separate passes. Hold the
nozzle at an angle to the joint from 1 to 2 inches from the concrete pavement. Using a vacuum,
collect sand, dust, and loose material at least 2 inches on each side of the joint. Remove
surface moisture and dampness at the joints with compressed air that may be moderately hot.
Before you install joint sealant or compression seal, the joint wall must be free of moisture,
residue, or film.
If grinding or grooving over or adjacent to sealed joints, remove joint sealant or compression
seal materials and dispose of them under Section 7-1.13, "Disposal of Material Outside the
Highway Right of Way." After grinding or grooving, replace the joint sealant or compression
seal materials.

40-3.09B Liquid Sealant

Do not install liquid sealant in construction joints.
Install backer rods when the concrete pavement temperature is above the air dew point and
when the air temperature is at least 40 °F.
Install liquid sealant immediately after installing the backer rod. Install sealant using a
mechanical device with a nozzle shaped to introduce the sealant from inside the joint. Extrude
sealant evenly and with continuous contact with the joint walls. Recess the sealant surface after
placement. Remove excess sealant from the concrete pavement surface.
Do not allow traffic over sealed joints until the sealant is set.

40-3.09C Preformed Compression Seal

Do not install preformed compression seal in construction or isolation joints.
Install longitudinal seals before transverse seals. Longitudinal seals must be continuous except
at intersections with transverse seals. Install transverse seals in 1 continuous piece for the
entire transverse length of concrete pavement. With a sharp instrument, cut across the

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longitudinal seal at the intersection with transverse construction joints. If the longitudinal seal
does not relax enough to properly install the transverse seal, trim the longitudinal seal to form a
tight seal between the 2 joints.
Use a machine specifically designed for preformed compression seal installation. The machine
must install the seal:

1. To the specified depth

2. To make continuous contact with the joint walls
3. Without cutting, nicking, or twisting the seal
4. With less than 4 percent stretch

Lay a length of preformed compression seal material cut to the exact length of the pavement
joint to be sealed. The Engineer measures this length. After you install the length of preformed
compression joint sealant, the Engineer measures the excess amount of material at the joint
end. The Engineer divides the excess amount length by the original measured length to
determine the percentage of stretch.

40-3.10 SHOULDER RUMBLE STRIP

If specified, construct shoulder rumble strips by rolling or grinding indentations in new concrete
pavement.
Select the method and equipment for constructing ground-in indentations.
Do not construct shoulder rumble strips on structures or approach slabs.
Construct rumble strips within 2 inches of the specified alignment. Roller or grinding equipment
must be equipped with a sighting device enabling the operator to maintain the rumble strip
alignment.
Indentations must not vary from the specified dimensions by more than 1/16 inch in depth or
more than 10 percent in length and width.
The Engineer orders grinding or removal and replacement of noncompliant rumble strips to
bring them within specified tolerances. Ground surface areas must be neat and uniform in
appearance.
The grinding equipment must be equipped with a vacuum attachment to remove residue.
Dispose of removed material under Section 7-1.13, "Disposal of Material Outside the Highway
Right of Way."

40-3.11 PRELIMINARY FINISHING

40-3.11A General
Preliminary finishing must produce a smooth and true-to-grade finish. After preliminary
finishing, mark each day's concrete pavement with a stamp. The stamp must be approved by
the Engineer before paving starts. The stamp must be approximately 1' x 2' in size. The stamp
must form a uniform mark from 1/8 to 1/4 inch deep. Locate the mark 20 feet ± 5 feet from the
transverse construction joint formed at each day's start of paving and 1 foot ± 0.25 foot from the

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concrete pavement's outside edge. The stamp mark must show the month, day, and year of
placement and the station of the transverse construction joint. Orient the stamp mark so it can
be read from the concrete pavement's outside edge.
Do not apply more water to the concrete pavement surface than can evaporate before float
finishing and texturing are completed.
Allow enough time to complete finishing activities during daylight. Work may continue after
daylight if the Engineer approves lighting you provide.

40-3.11B Stationary Side Form Finishing

If stationary side form construction is used, give the concrete a preliminary finish by the machine
float method or the hand method.
If using the machine float method:

1. Use self-propelled machine floats.

2. Determine the number of machine floats required to perform the work at a rate equal to
the concrete delivery rate. When the time from concrete placement to machine float
finishing exceeds 30 minutes, stop concrete delivery . When machine floats are in proper
position, you may resume concrete delivery and paving.
3. Machine floats must run on side forms or adjacent concrete pavement lanes. If running
on adjacent concrete pavement, protect the adjacent concrete pavement surface under
Section 40-3.15, "Protecting Concrete Pavement."
4. Floats must be hardwood, steel, or steel-shod wood. Floats must be equipped with
devices that adjust the under side to a true flat surface.

If using the hand method, finish concrete smooth and true to grade with manually operated
floats or powered finishing machines.

40-3.11C Slip-Form Finishing

If slip-form construction is used, the slip-form paver must give the concrete pavement a
preliminary finish. You may supplement the slip-form paver with machine floats.
Before the concrete hardens, correct concrete pavement edge slump in excess of 0.02 foot
exclusive of edge rounding.

40-3.12 FINAL FINISHING

After completing preliminary finishing, round the edges of the initial paving widths to a 0.04-foot
radius. Round transverse and longitudinal construction joints to a 0.02-foot radius.
Before curing, texture the pavement. Perform initial texturing with a burlap drag or broom
device that produces striations parallel to the centerline. Perform final texturing with a steel-
tined device that produces grooves parallel with the centerline.
Construct longitudinal grooves with a self-propelled machine designed specifically for grooving
and texturing concrete pavement. The machine must have tracks to maintain constant speed,

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provide traction, and maintain accurate tracking along the pavement surface. The machine
must have a single row of rectangular spring steel tines. The tines must be from 3/32 to 1/8
inch wide, on 3/4-inch centers, and must have enough length, thickness, and resilience to form
grooves approximately 3/16 inch wide. The machine must have horizontal and vertical controls.
The machine must apply constant down pressure on the pavement surface during texturing.
The machines must not cause ravels.
Construct grooves over the entire pavement width in a single pass except do not construct
grooves 3 inches from the concrete pavement edges and longitudinal joints. Final texture must
be uniform and smooth. Use a guide to properly align the grooves. Grooves must be parallel
and aligned to the pavement edge across the pavement width. Grooves must be from 1/8 to
3/16 inch deep and 3/16 inch wide after concrete has hardened.
For irregular areas and areas inaccessible to the grooving machine, you may hand-construct
grooves in compliance with the hand method under Section 40-3.11B, "Stationary Side Form
Finishing." Hand-constructed grooves must comply with the specifications for machine-
constructed grooves.
Initial and final texturing must produce a coefficient of friction of at least 0.30 when tested under
California Test 342. Notify the Engineer when the concrete pavement is scheduled to be
opened to traffic. Allow at least 25 days for the Department to test for coefficient of friction from
the later of:

1. Seven days after concrete placement

2. When the concrete pavement has attained a modulus of rupture of 550 psi

Do not open the concrete pavement to traffic unless the coefficient of friction is at least 0.30.
Correct concrete pavement not complying with the Engineer's acceptance criteria for coefficient
of friction by grooving or grinding under Section 42, "Groove and Grind Pavement."
Do not grind before:

1. Ten days after concrete pavement placement

2. Concrete has developed a modulus of rupture of at least 550 psi

Before opening to traffic, allow at least 25 days for the Department to retest sections for
coefficient of friction after corrections are made.

40-3.13 CURING
Cure the concrete pavement's exposed area with waterproof membrane or curing compound (1)
or (2) under Section 90-7.01, "Methods of Curing." When side forms are removed within 72
hours of the start of curing, also cure the concrete pavement edges.
If curing compound is used, apply it with mechanical sprayers. Reapply curing compound to
sawcuts and disturbed areas.

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40-3.14 EARLY USE OF CONCRETE PAVEMENT

If requesting early use of concrete pavement:

1. Furnish molds and machines for modulus of rupture testing

2. Sample concrete
3. Fabricate beam specimens
4. Test for modulus of rupture under California Test 523

When you request early use, concrete pavement must have a modulus of rupture of at least 350
psi. Protect concrete pavement under Section 40-3.15, "Protecting Concrete Pavement."

40-3.15 PROTECTING CONCRETE PAVEMENT

Protect concrete pavement under Section 90-8, "Protecting Concrete."
Maintain the concrete pavement temperature at not less than 40 °F for the initial 72 hours.
Protect the concrete pavement surface from activities that cause damage and reduce texture
and coefficient of friction. Do not allow soil, gravel, petroleum products, concrete, or asphalt
mixes on the concrete pavement surface.
Construct crossings for traffic convenience. If the Engineer approves your request, you may
use Type III portland cement in the concrete for crossings. Do not open crossings until the
Department determines by California Test 523 the concrete pavement's modulus of rupture is at
least 550 psi.
Do not open concrete pavement to traffic or use equipment on the concrete pavement for 10
days after paving or before the concrete has attained a modulus of rupture of 550 psi except:

1. If the equipment is for sawing contraction joints

2. If the Engineer approves your request, one side of paving equipment's tracks may be on
the concrete pavement after a modulus of rupture of 350 psi has been attained, provided:

2.1. Unit pressure exerted on the concrete pavement by the paver does not exceed 20 psi
2.2. You change the paving equipment tracks to prevent damage or the paving
equipment tracks travel on protective material such as planks
2.3. No part of the track is closer than 1 foot from the concrete pavement's edge

If concrete pavement damage including visible cracking occurs, stop operating paving
equipment on the concrete pavement and repair the damage.

40-3.16 OBTAINING DRILLED CORES

Drill concrete pavement cores under ASTM C 42/ C 42M. Core drilling equipment must use
diamond impregnated bits.
Clean, dry, and fill core holes with hydraulic cement grout (non-shrink) or pavement concrete.
Coat the core hole walls with epoxy under the specifications for epoxy adhesive for bonding new

April 11,2011 4-153

concrete to old concrete in Section 95, "Epoxy." The backfill must match the adjacent concrete
pavement surface elevation and texture.
Do not allow residue from core drilling to fall on traffic, flow across shoulders or lanes occupied
by traffic, or flow into drainage facilities including gutters.

40-3.17 REPAIR, REMOVAL, AND REPLACEMENT

40-3.17A General
Working cracks are full-depth cracks essentially parallel to a planned contraction joint beneath
which a contraction crack has not formed. If the Engineer orders, take 4-inch nominal diameter
cores on designated cracks under Section 40-3.16, "Obtaining Drilled Cores."

40-3.17B Repair of Spalls, Raveling, and Tearing

Before concrete pavement is open to traffic, repair spalls, raveling, and tearing in sawed joints.
Make repairs in compliance with the following:

1. Saw a rectangular area with a diamond-impregnated blade at least 2 inches deep.

2. Remove unsound and damaged concrete between the saw cut and the joint and to the saw
cut's depth. Do not use a pneumatic hammer heavier than 15 pounds. Do not damage
concrete pavement to remain in place.
3. Dispose of removed concrete pavement under Section 7-1.13, "Disposal of Materials
Outside the Highway Right of Way."
4. Clean the repair area's exposed surfaces with high pressure abrasive water blasting.
Further clean and dry the exposed surfaces with compressed air free of moisture and oil.
5. Apply epoxy as specified for epoxy resin adhesive for bonding new concrete to old
concrete under Section 95, "Epoxy." Apply the epoxy with a stiff bristle brush.
6. Apply a portland cement concrete or mortar patch immediately following the epoxy
application. Install an insert to prevent bonding of the sides of planned joints.

Repair spalls if they are:

1. Deeper than 0.05 foot

2. Wider than 0.04 foot
3. Longer than 0.3 foot

40-3.17C Route and Seal Working Cracks

Treat working cracks within 0.5 foot of either side of a planned contraction joint in compliance
with the following:

1. Route and seal the crack with epoxy resin in compliance with the following:

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1.1. Use a powered rotary router mounted on wheels, with a vertical shaft and a routing
spindle that casters as it moves along the crack
1.2. Form a reservoir 3/4 inch deep by 3/8 inch wide in the crack
1.3. Use equipment that does not cause raveling or spalling
1.4. Place liquid sealant

2. Treat the contraction joint adjacent to the working crack in compliance with the
following:

2.1. Use epoxy resin under ASTM C 881/C 881M, Type IV, Grade 2 for Type B joints
and secondary saw cuts for Type A1 and Type A2 joints
2.2. Pressure inject epoxy resin under ASTM C 881/C881M, Type IV, Grade 1 for
narrow saw cuts including initial saw cuts for Type A1 and Type A2 joints

If a working crack intersects a contraction joint, route and seal the working crack and seal the
contraction joint as specified for installing liquid sealant under Section 40-3.09, "Joint Seal and
Joint Sealant Installation."

40-3.17D Removal and Replacement of Slabs

As specified, remove and replace slabs or partial slabs for:

1. Insufficient thickness
2. Dowel bar misalignment
3. Working cracks more than 0.5 foot from a planned contraction joint

40-4 MEASUREMENT AND PAYMENT

40-4.01 MEASUREMENT
The contract item for concrete pavement as designated in the Verified Bid Item List is measured
by the cubic yard. The Engineer calculates the pay quantity volume based on the plan
dimensions. The Engineer does not measure concrete pavement placed outside those
dimensions unless it was ordered by the Engineer.
The contract items for sealing joints as designated in the Verified Bid Item List are measured by
the linear foot.
The contract item for shoulder rumble strips is measured by the station along each shoulder on
which the rumble strips are constructed without deductions for gaps between indentations.

40-4.02 PAYMENT
The contract price paid per cubic yard for concrete pavement as designated in the Verified Bid
Item List includes full compensation for furnishing all labor, materials, tools, equipment, and
incidentals, and for doing all the work involved in constructing the concrete pavement, complete
in place including bar reinforcement, tie bars, dowel bars, anchors, and fasteners, as shown on

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the plans and as specified in these specifications and the special provisions, and as directed by
the Engineer.
The Engineer adjusts payment for each primary area deficient in average thickness in
compliance with the following:

Pay Adjustments for Deficient Thickness

Average Thickness Deficiency Adjustment
Deficiency (foot) ($/yd2)
0.01 0.90
0.02 2.30
0.03 4.10
0.04 6.40
0.05 9.11

If the average thickness deficiency is less than 0.01 foot, the Engineer does not adjust payment
for thickness deficiency. If the average thickness deficiency is more than 0.01 foot, the
Engineer rounds to the nearest 0.01 foot and uses the adjustment table.
Full compensation for core drilling and backfilling the cores ordered by the Engineer for
measuring concrete pavement thickness and determining full-depth cracks is included in the
contract price paid per cubic yard for concrete pavement as designated in the Engineer's
Estimate and no additional compensation will be allowed therefor. The Department does not
pay for additional concrete pavement thickness measurements requested by the Contractor.
The Department does not pay for the portion of concrete that penetrates treated permeable
base.
Full compensation for the quality control plan is included in the contract price paid per cubic
yard for concrete pavement as designated in the Verified Bid Item List and no separate payment
will be made therefor.
Full compensation for furnishing and applying asphaltic emulsion on cement treated permeable
base is included in the contract price paid per cubic yard for concrete pavement as designated
in the Engineer's Estimate and no separate payment will be made therefor.
Full compensation for repairing joints is included in the contract price paid per cubic yard for
concrete pavement as designated in the Verified Bid Item List and no separate payment will be
made therefor.
Full compensation for furnishing, calibrating, and operating profilograph equipment for Profile
Index, for submitting profilograms, and for performing corrective work is included in the contract
price paid per cubic yard for concrete pavement as designated in the Verified Bid Item List and
no separate payment will be made therefor.
Full compensation for grooving and grinding for final finishing is included in the contract price
paid per cubic yard for concrete pavement as designated in the Verified Bid Item List and no
separate payment will be made therefor.
Full compensation for removing and replacing joint material for grooving and grinding is included
in the contract price per cubic yard for concrete pavement as designated in the Verified Bid Item
List and no separate payment will be made therefor.

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Full compensation for removing and replacing slabs is included in the contract price paid per
cubic yard for concrete pavement as designated in the Verified Bid Item List and no separate
payment will be made therefor.
Full compensation for drilling holes and bonding tie bars with chemical adhesive is included in
the contract price paid per cubic yard for concrete pavement as designated in the Verified Bid
Item List and no additional compensation will be allowed therefor.
Full compensation for repairing damage caused by operating paving equipment on new
concrete pavement is included in the contract price paid per cubic yard for concrete pavement
as designated in the Verified Bid Item List and no separate payment will be made therefor.
The material and work necessary for the construction of crossings for public convenience, and
their subsequent removal and disposal, will be paid for at the contract prices for the items of
work involved and if there are no contract items for the work involved, payment for concrete
pavement crossings will be made by extra work as specified in Section 4-1.03D, "Extra Work."
The Department will reduce payments to the Contractor by $56.12 per square yard for concrete
pavement slabs allowed to remain in place represented by cores indicating dowel bars placed
with their centers from ±2 inches to ±3 inches from the saw cut of a transverse contraction joint
The Engineer will calculate the reduced payment using the slab dimensions adjacent to and
inclusive of the joints with misplaced dowel bars. This reduced payment is in addition to other
specified payment reductions.
The Department will reduce payments to the Contractor by $59.56 per square yard for concrete
pavement allowed to remain in place represented by cores indicating either of the following:

1. Tie bars placed outside their specified placement and position tolerances
2. Bar reinforcement placed outside their specified placement and position tolerances

The Engineer will calculate the reduced payment using the slab dimensions adjacent to and
inclusive of the joints with misplaced tie bars. This reduced payment is in addition to other
specified payment reductions.
Full compensation for core drilling for checking dowel or tie bar alignment and backfilling the
cores is included in the contract price paid per cubic yard for concrete pavement as designated
in the Engineer's Estimate and no additional compensation will be allowed therefor.
If the initial cores show that dowel bars or tie bars are out of tolerance for alignment and the
Engineer orders additional dowel or tie bar coring, full compensation for drilling the additional
cores is included in the contract price paid per cubic yard for concrete pavement as designated
in the Verified Bid Item List and no additional compensation will be allowed therefor.
If the initial cores show that dowel bars or tie bars are within alignment tolerances and the
Engineer orders more dowel or tie bar coring, the additional cores will be paid for as extra work
as specified in Section 4-1.03D, "Extra Work."
The Department will not pay for additional coring to check dowel or tie bar alignment you
request.
Full compensation for performing profilograph tests, furnishing the profilograms and electronic
files to the Engineer, and for performing corrective work is included in the contract price paid per

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cubic yard for the type of concrete pavement as designated in the Verified Bid Item List and no
additional compensation will be allowed therefor.
The contract prices paid per linear foot for seal pavement joint, seal isolation joint, and seal
longitudinal isolation joint include full compensation for furnishing all labor, materials, tools,
equipment, and incidentals, and for doing all the work involved in sealing pavement joints and
sealing isolation joints, complete in place, as shown on the plans, and as specified in these
specifications and the special provisions, and as directed by the Engineer.
The contract price paid per station for shoulder rumble strip includes full compensation for
furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work
involved in constructing the rumble strip complete in place, as shown on the plans, as specified
in these Standard Specifications and as directed by the Engineer.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 41 PAVEMENT SUBSEALING AND JACKING

(Issued 01-05-07)

In Section 41-1.02 replace the 2nd and 3rd paragraphs with:

Cement for grout shall be Type II portland cement conforming to the provisions in Section 90-
2.01A, "Cement."
Fly ash shall conform to the requirements in AASHTO Designation: M 295 for either Class C or
for Class F. The brand of fly ash used in the work shall conform to the provisions for approval of
admixture brands in Section 90-4.03, "Admixture Approval."

In Section 41-1.02 replace the 5th paragraph with:

Chemical admixtures and calcium chloride may be used. Chemical admixtures in the grout mix
shall conform to the provisions in Section 90-4, "Admixtures." Calcium chloride shall conform to
ASTM Designation: D 98.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 42 GROOVE AND GRIND PAVEMENT

(Issued 05-15-09)

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In Section 42-2.02 replace the 3rd paragraph with:

Existing portland cement concrete pavement not constructed as part of the project shall be
ground as follows:

Grinding shall be performed so that the pavement surface on both sides of all transverse
joints and cracks has essentially the same depth of texture and does not vary from a true
plane enough to permit a 0.006-foot thick shim 0.25-foot wide to pass under a 3-foot
straightedge adjacent to either side of the joint or crack when the straightedge is laid on
the pavement parallel to centerline with its midpoint at the joint or crack. After grinding
has been completed, the pavement shall conform to the straightedge and profile
requirements specified in Section 40-1.03, "Quality Control and Assurance."
Abnormally depressed areas due to subsidence or other localized causes will be excluded
from testing with the profilograph and 12-foot straightedge specified in Section 40-1.03.
The accumulated total of the excluded areas shall not exceed 5 percent of the total area to
be ground. Profilograph testing shall end 25 feet prior to excluded areas and shall resume
25 feet following the excluded areas.

In Section 42-2.03 replace the 2nd paragraph with:

Replacement concrete paving shall conform to the provisions in Section 40, "Concrete
Pavement." Replacement pavement may be spread and shaped by any suitable powered
finishing machines, supplemented by handwork as necessary. Consolidation of the concrete
shall be by means of high-frequency internal vibrators within 15 minutes after the concrete is
deposited on the subgrade. Vibrating shall be done with care and in such manner to assure
adequate consolidation adjacent to forms and uniformly across the full paving width. Use of
vibrators for extensive shifting of the mass of concrete will not be permitted. Methods of
spreading, shaping and compacting that result in segregation, voids or rock pockets shall be
discontinued, and the Contractor shall adopt methods which will produce dense homogeneous
pavement conforming to the required cross section. Finishing may be performed by hand
method, as specified in Section 40-3.11B, "Stationary Side Form Finishing."

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 49 PILING
(Issued 12-19-08)

In Section 49-1.03 replace the 4th paragraph with:

Modification to the specified installation methods and specified pile tip elevation will not be
considered at locations where settlement, tension demands, or lateral load demands control

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design pile tip elevations or when the plans state that specified pile tip elevation shall not be
revised.

In Section 49-1.03 in the 6th paragraph, replace the 1st sentence with:
Indicator compression pile load testing shall conform to the requirements in ASTM Designation:
D 1143-81.

In Section 49-1.03 in the 7th paragraph, replace the 1st sentence with:
Indicator tension pile load testing shall conform to the requirements in ASTM Designation: D
3689-90.

In Section 49-1.03 replace the 9th paragraph with:

The Contractor shall furnish piling of sufficient length to obtain the specified tip elevation shown
on the plans or specified in the special provisions.

In Section 49-1.04 replace the 6th paragraph with:

The Contractor may use additional cementitious material in the concrete for the load test and
anchor piles.

In Section 49-6.01 replace the 1st paragraph with:

The length of timber, steel, and precast prestressed concrete piles, and of cast-in-place
concrete piles consisting of driven shells filled with concrete, shall be measured along the
longest side, from the tip elevation shown on the plans to the plane of pile cut-off.

In Section 49-6.02 add:

When pile tips are revised by the Engineer for timber, steel, and precast prestressed concrete
piles, and for cast-in-place concrete piles consisting of driven shells filled with concrete, the
additional length required, including all materials, equipment, and labor for furnishing, splicing,
and installing the piling, will be paid for as extra work as provided in Section 4-1.03D, "Extra
Work."

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

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SECTION 50 PRESTRESSING CONCRETE

(Issued 06-05-09)

In Section 50-1.05 replace the 1st paragraph with:

Prestressing steel shall be high-tensile wire conforming to the requirements in ASTM
Designation: A 421, including Supplement I; high-tensile seven-wire strand conforming to the
requirements in ASTM Designation: A 416; or uncoated deformed (Type II) high-strength steel
bars conforming to the requirements in ASTM Designation: A 722, including all supplementary
requirements. The maximum weight requirement of ASTM Designation: A 722 will not apply.

In Section 50-1.05 in the 3rd paragraph, delete item A.

In Section 50-1.07 replace the 2nd paragraph with:

Ducts shall be fabricated with either welded or interlocked seams. Galvanizing of the welded
seam will not be required. Ducts shall have sufficient strength to maintain their correct
alignment during placing of concrete. Joints between sections of duct shall be positive metallic
connections which do not result in angle changes at the joints. Waterproof tape shall be used at
the connections. Ducts shall be bent without crimping or flattening. Transition couplings
connecting the ducts to anchoring devices shall be either ferrous metal or polyolefin. Ferrous
metal transition couplings need not be galvanized.

In Section 50-1.07 replace the 7th paragraph with:

All ducts with a total length of 400 feet or more shall be vented. Vents shall be placed at
intervals of not more than 400 feet and shall be located within 6 feet of every high point in the
duct profile. Vents shall be 1/2 inch minimum diameter standard pipe or suitable plastic pipe.
Connections to ducts shall be made with metallic or plastic structural fasteners. Plastic
components, if selected, shall not react with the concrete or enhance corrosion of the
prestressing steel and shall be free of water soluble chlorides. The vents shall be mortar tight,
taped as necessary, and shall provide means for injection of grout through the vents and for
sealing the vents. Ends of vents shall be removed one inch below the roadway surface after
grouting has been completed.

In Section 50-1.08 in the 11th paragraph, replace item B with:

B. When the concrete is designated by class or cementitious material content, either the
concrete compressive strength shall have reached the strength shown on the plans at the
time of stressing or at least 28 days shall have elapsed since the last concrete to be
prestressed has been placed, whichever occurs first.

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In Section 50-1.09 replace the 2nd and 3rd paragraphs with:

Grout shall consist of cement and water and may contain an admixture if approved by the
Engineer.
Cement shall conform to the provisions in Section 90-2.01A, "Cement."

In Section 50-1.11 replace the 1st paragraph with:

No separate payment will be made for pretensioning precast concrete members. Payment for
pretensioning precast concrete members shall be considered as included in the contract price
paid for furnish precast members as provided for in Section 51, "Concrete Structures."

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 51 CONCRETE STRUCTURES

(Issued 07-30-10)

In Section 51-1.05 in the 11th paragraph, replace the 1st sentence with:
Form panels for exposed surfaces shall be furnished and placed in uniform widths of not less
than 3 feet and in uniform lengths of not less than 6 feet, except at the end of continuously
formed surfaces where the final panel length required is less than 6 feet.

In Section 51-1.06C in the 11th paragraph, replace the 1st sentence with:
Falsework for box culverts and other structures with decks lower than the roadway pavement
and with span lengths of 14 feet or less shall not be released until the last placed concrete has
attained a compressive strength of 1,600 psi, provided that curing of the concrete is not
interrupted.

In Section 51-1.11 replace the 6th paragraph with:

Construction methods and equipment employed by the Contractor shall conform to the
provisions in Section 7-1.02, "Load Limitations."

April 11,2011 4-162

In Section 51-1.12D replace the 4th paragraph with:

Expanded polystyrene shall be a commercially available polystyrene board. Expanded
polystyrene shall have a minimum flexural strength of 35 psi determined in conformance with
the requirements in ASTM Designation: C 203 and a compressive yield strength of between 16
and 40 psi at 5 percent compression. Surfaces of expanded polystyrene against which concrete
is placed shall be faced with hardboard. Hardboard shall be 1/8 inch minimum thickness,
conforming to ANSI A135.4, any class. Other facing materials may be used provided they
furnish equivalent protection. Boards shall be held in place by nails, waterproof adhesive, or
other means approved by the Engineer.

In Section 51-1.12F replace the 3rd paragraph with:

Type A and AL joint seals shall consist of a groove in the concrete that is filled with field-mixed
silicone sealant.

In Section 51-1.12F in the 6th paragraph, replace the table with:

Movement Rating (MR) Seal Type
MR ≤ 1 inch Type A or Type B
1 inch < MR ≤ 2 inches Type B
2 inches < MR ≤ 4 inches Joint Seal Assembly (Strip Seal)
MR > 4 inches Joint Seal Assembly (Modular Unit)
or Seismic Joint

In Section 51-1.12F(3)(a) replace the 1st and 2nd paragraphs with:

The sealant must consist of a 2-component silicone sealant that will withstand up to ±50 percent
movement.
Silicone sealants must be tested under California Test 435 and must comply with the following:

Specification Requirement
Modulus at 150 percent elongation 8-75 psi
Recovery
21/32 inch max.
Notch Test Notched or loss of bond 1/4 inch,
max.
Water Resistance Notched or loss of bond 1/4 inch,
max.
Ultraviolet Exposure No more than slight checking or
ASTM Designation: G 154, Table cracking.
X2.1,Cycle 2.
Cone Penetration 4.5-12.0 mm

April 11,2011 4-163

In Section 51-1.12F(3)(a) delete the 3rd and 8th paragraphs.

In Section 51-1.12F(3)(a) replace the 10th paragraph with:

A Certificate of Compliance accompanied by a certified test report must be furnished for each
batch of silicone sealant in conformance with the provisions in Section 6-1.07, "Certificates of
Compliance."

In Section 51-1.12F(3)(b) replace the 2nd paragraph with:

The preformed elastomeric joint seal must conform to the requirements in ASTM D 2628 and
the following:

1. The seal must consist of a multichannel, nonporous, homogeneous material furnished in a

finished extruded form.
2. The minimum depth of the seal measured at the contact surface must be at least 95
percent of the minimum uncompressed width of the seal as designated by the
manufacturer.
3. When tested in conformance with the requirements in California Test 673 for Type B
seals, joint seals must provide a movement rating (MR) of not less than that shown on the
plans.
4. The top and bottom edges of the joint seal must maintain continuous contact with the
sides of the groove over the entire range of joint movement.
5. The seal must be furnished full length for each joint with no more than 1 shop splice in
any 60-foot length of seal.
6. The Contractor must demonstrate the adequacy of the procedures to be used in the work
before installing seals in the joints.
7. One field splice per joint may be made at locations and by methods approved by the
Engineer. The seals are to be manufactured full length for the intended joint, then cut at
the approved splice section and rematched before splicing. The Contractor must submit
splicing details prepared by the joint seal manufacturer for approval before beginning
splicing work.
8. Shop splices and field splices must have no visible offset of exterior surfaces and must
show no evidence of bond failure.
9. At all open ends of the seal that would admit water or debris, each cell must be filled to a
depth of 3 inches with commercial quality open cell polyurethane foam or closed by other
means subject to approval by the Engineer.

In Section 51-1.12F(3)(b) replace the 7th paragraph with:

The joint seal must be installed full length for each joint with equipment that does not twist or
distort the seal, elongate the seal longitudinally, or otherwise cause damage to the seal or to the
concrete forming the groove.

April 11,2011 4-164

In Section 51-1.12F(3)(b) in the 11th paragraph, replace the 1st sentence with:
Samples of the prefabricated joint seals, not less than 3 feet in length, will be taken by the
Engineer from each lot of material.

In Section 51-1.12H(1) in the 6th paragraph, replace the 4th and 5th sentences with:
Each ply of fabric shall have a breaking strength of not less than 800 pounds per inch of width in
each thread direction when 3" x 36" samples are tested on split drum grips. The bond between
double plies shall have a minimum peel strength of 20 pounds per inch.

In Section 51-1.12H(1) in the 8th paragraph in the table, replace the hardness (Type A)
requirements with:
Hardness (Type A) D 2240 with 2kg mass. 55 ±5

In Section 51-1.12H(2) in the 1st paragraph in item A, replace the 1st and 2nd sentences
with:
The bearings shall consist of alternating steel laminates and internal elastomer laminates with
top and bottom elastomer covers. Steel laminates shall have a nominal thickness of 0.075 inch
(14 gage).

In Section 51-1.13 replace the 2nd, 3rd, and 4th paragraphs with:
Surfaces of fresh concrete at horizontal construction joints shall be thoroughly consolidated
without completely removing surface irregularities. Additionally, surfaces of fresh concrete at
horizontal construction joints between girder stems and decks shall be roughened to at least a
1/4-inch amplitude.
Construction joint surfaces shall be cleaned of surface laitance, curing compound, and other
foreign materials using abrasive blast methods before fresh concrete is placed against the joint
surface.
Construction joint surfaces shall be flushed with water and allowed to dry to a surface dry
condition immediately before placing concrete.

In Section 51-1.135 replace the 1st paragraph with:

Mortar shall be composed of cementitious material, sand, and water proportioned and mixed as
specified in this Section 51-1.135.

April 11,2011 4-165

In Section 51-1.135 replace the 3rd paragraph with:

The proportion of cementitious material to sand, measured by volume, shall be 1 to 2 unless
otherwise specified.

In Section 51-1.17 in 4th paragraph, replace the 3rd sentence with:

The surfaces shall have a profile trace showing no high points in excess of 0.25 inch, and the
portions of the surfaces within the traveled way shall have a profile count of 5 or less in any 100
foot section.

Add:
51-1.17A Deck Crack Treatment
The Contractor shall use all means necessary to minimize the development of shrinkage cracks.
The Contractor shall remove all equipment and materials from the deck and clean the surface
as necessary for the Engineer to measure the surface crack intensity. Surface crack intensity
will be determined by the Engineer after completion of concrete cure, before prestressing, and
before the release of falsework. In any 500 square foot portion of deck within the limits of the
new concrete deck, should the intensity of cracking be such that there are more than 50 feet of
cracks whose width at any location exceeds 0.02 inch, the deck shall be treated with a high
molecular weight methacrylate (HMWM) resin system. The area of deck to be treated shall
have a width that extends for the entire width of new deck inside the concrete barriers and a
length that extends at least 5 feet beyond the furthest single continuous crack outside the 500
square foot portion, measured from where that crack exceeds 0.02 inch in width, as determined
by the Engineer.
Deck crack treatment shall include furnishing, testing, and applying the HMWM resin system,
with sand and absorbent material. If grinding is required, deck crack treatment shall take place
before grinding.

51-1.17A(1) Submittals
Submit a HMWM resin system placement plan. When HMWM resin is to be applied within 100
feet of a residence, business, or public space including sidewalks under a structure, also
submit a public safety plan. Submit plans under Section 5-1.02, "Plans and Working Drawings,"
of the Standard Specifications. The review time is 15 days.
The HMWM resin system placement plan must include:

1. Schedule of work and testing for each bridge

2. Description of equipment for applying HMWM resin
3. Range of gel time and final cure time for HMWM resin
4. Absorbent material to be used
5. Description of equipment for applying and removing excess sand and absorbent material

April 11,2011 4-166

6. Procedure for removing HMWM resin from the deck, including equipment
7. Storage and handling of HMWM resin components and absorbent material
8. Disposal of excess HMWM resin and containers

The public safety plan must include:

1. A public notification letter with a list of delivery and posting addresses. The letter must
state HMWM resin work locations, dates, times, and what to expect. Deliver the letter to
residences and businesses within 100 feet of HMWM resin work locations and to local
fire and police officials at least 7 days before starting work. Post the letter at the job site.
2. An airborne emissions monitoring plan prepared and executed by a certified industrial
hygienist (CIH) certified in comprehensive practice by the American Board of Industrial
Hygiene. The plan must have at least 4 monitoring points including the mixing point,
application point, and point of nearest public contact. Monitor airborne emissions during
HMWM resin work and submit emissions monitoring results after completing the work.
3. An action plan for protection of the public when airborne emissions levels exceed
permissible levels.
4. A copy of the CIH's certification.

If the measures proposed in the safety plan are inadequate to provide for public safety
associated with the use of HMWM resin, the Engineer will reject the plan and direct the
Contractor to revise the plan. Directions for revisions will be in writing and include detailed
comments. The Engineer will notify the Contractor of the approval or rejection of a submitted or
revised plan within 15 days of receipt of that plan.

51-1.17A(2) Quality Control and Assurance

Submit samples of HMWM resin components 15 days before use under Section 6-3, "Testing,"
of the Standard Specifications. Notify the Engineer 15 days before delivery of HMWM resin
components in containers over 55 gallons to the job site.
Complete a test area before starting work. Results from airborne emissions monitoring of the
test area must be submitted to the Engineer before starting production work.
The test area must:

1. Be approximately 500 square feet

2. Be placed within the project limits outside the traveled way at an approved location
3. Be constructed using the same equipment as the production work
4. Replicate field conditions for the production work
5. Demonstrate proposed means and methods meet the acceptance criteria
6. Demonstrate production work will be completed within the time allowed
7. Demonstrate suitability of the airborne emissions monitoring plan

The test area will be acceptable if:

April 11,2011 4-167

1. The treated deck surface is tack free and non-oily

2. The sand cover adheres and resists brushing by hand
3. Excess sand and absorbent material has been removed
4. The coefficient of friction is at least 0.35 when tested under California Test 342

51-1.17A(3) Materials
HMWM resin system consists of a resin, promoter, and initiator. HMWM resin must be low odor and
comply with the following:

HMWM Resin
Property Requirement Test Method
Volatile Content* 30 percent, maximum ASTM D 2369
Viscosity * 25 cP, maximum, ASTM D 2196
(Brookfield RVT with
UL adaptor,
50 RPM at 77°F)
Specific Gravity * 0.90 minimum, at 77°F ASTM D 1475
Flash Point * 180°F, minimum ASTM D 3278
Vapor Pressure * 1.0 mm Hg, maximum, ASTM D 323
at 77°F
Tack-free Time 400 minutes, Specimens prepared
maximum, at 25°C per California
Test 551
PCC Saturated 3.5 MPa, minimum at California Test 551
Surface-Dry Bond 24 hours and 21 ± 1°C
Strength
*
Test must be performed before adding initiator.

Sand for abrasive sand finish must:

1. Be commercial quality dry blast sand

2. Have at least 95 percent pass the No. 8 sieve and at least 95 percent retained on the No.
20 sieve when tested under California Test 205

Absorbent material must be diatomaceous earth, abrasive blast dust, or substitute recommended
by the HMWM resin supplier and approved by the Engineer.

51-1.17A(4) Construction
HMWM resin system applied by machine must be:

1. Combined in volumetric streams of promoted resin to initiated resin by static in-line

mixers

April 11,2011 4-168

2. Applied without atomization

HMWM resin system may be applied manually. Limit the quantity of resin mixed for manual
application to 5 gallons at a time.
Prepare the area to be treated by abrasive blasting. Curing compound, surface contaminants,
and foreign material must be removed from the bridge deck surface. Sweep the deck surface
clean after abrasive blasting and blow loose material from cracks using high-pressure air.
The deck surface must be dry when abrasive blast cleaning is performed. When abrasive blast
cleaning within 10 feet of public traffic, remove dust and residue from abrasive blast cleaning
using a vacuum attachment operating concurrently with blasting equipment . If the deck surface
becomes contaminated before placing HMWM, abrasive blast clean the contaminated area and
sweep the deck clean.
The deck must be dry before applying HMWM resin. The concrete surface must be at least 50
degrees F and at most 100 degrees F. Relative humidity must be expected to be at most 85
percent during the work shift.
Thoroughly mix all components of the HMWM resin system. Apply HMWM resin to the deck
surface within 5 minutes of mixing at approximately 90 sq ft per gallon. The Engineer
determines the exact application rate. The resin gel time must be between 40 and 90 minutes.
HMWM resin that thickens during application is rejected.
Spread the HMWM resin system uniformly. Completely cover surfaces to be treated and fill all
cracks. Redistribute excess resin using squeegees or brooms within 10 minutes of application.
For textured or grooved deck surfaces, excess resin must be removed from the texture
indentations.
Apply the abrasive sand finish of at least 2 pounds per square yard or until saturation as
determined by the Engineer no sooner than 20 minutes after applying resin. Apply absorbent
material before opening lane to traffic. Remove excess sand and absorbent material by
vacuuming or power sweeping.
Traffic or equipment will be allowed on the overlay after the Engineer has determined:

1. The treated deck surface is tack free and non-oily

2. The sand cover adheres and resists brushing by hand
3. Excess sand and absorbent material has been removed
4. No material will be tracked beyond limits of treatment by traffic

In Section 51-1.18C replace the 2nd paragraph with:

When Class 2 surface finish (gun finish) is specified, ordinary surface finish shall first be
completed. The concrete surfaces shall then be abrasive blasted to a rough texture and
thoroughly washed down with water. While the washed surfaces are damp, but not wet, a finish
coating of machine applied mortar, approximately 1/4 inch thick, shall be applied in not less than
2 passes. The coating shall be pneumatically applied and shall consist of either (1) sand,
cementitious material, and water mechanically mixed prior to its introduction to the nozzle, or (2)
premixed sand and cementitious material to which water is added prior to its expulsion from the

April 11,2011 4-169

nozzle. The use of admixtures shall be subject to the approval of the Engineer as provided in
Section 90, "Portland Cement Concrete." Unless otherwise specified, supplementary
cementitious materials will not be required. The proportion of cementitious material to sand
shall be not less than one to 4, unless otherwise directed by the Engineer. Sand shall be of a
grading suitable for the purpose intended. The machines shall be operated and the coating
shall be applied in conformance with standard practice. The coating shall be firmly bonded to
the concrete surfaces on which it is applied.

In Section 51-1.18C replace the 5th paragraph with:

When surfaces to be finished are in pedestrian undercrossings, the sand shall be silica sand
and the cementitious material shall be standard white portland cement.

In Section 51-1.23, add:

Full compensation for deck crack treatment, including the public safety plan, shall be considered
as included in the contract price paid per cubic yard for structural concrete, bridge, and no
additional compensation will be allowed therefor.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 52 REINFORCEMENT
(Issued 06-05-09)

In Section 52-1.02(B) between the 3rd and 4th paragraphs, add:

The epoxy powder coating shall be selected from the Department's Pre-Qualified Products List.

In Section 52-1.02(B) replace the 14th paragraph with:

Except for lap splices, splices for epoxy-coated reinforcement shall be coated with a corrosion
protection covering that is selected from the Department's Pre-Qualified Products List. The
covering shall be installed in accordance with the manufacturer's recommendations.

April 11,2011 4-170

In Section 52-1.07 in the 11th paragraph, replace the table with:

Height Zone (H) Wind Pressure Value
(Feet above ground) (psf)
H ≤ 30 20
30 < H ≤ 50 25
50 < H ≤ 100 30
H > 100 35

In Section 52-1.08B(1) replace the 1st paragraph with:

Mechanical splices to be used in the work shall be selected from the Department's Pre-Qualified
Products List.

In Section 52-1.08B(1) in the 2nd paragraph, replace the table with:

Reinforcing Bar Number Total Slip
4 0.020-inch
5 0.020-inch
6 0.020-inch
7 0.028-inch
8 0.028-inch
9 0.028-inch
10 0.036-inch
11 0.036-inch
14 0.048-inch
18 0.060-inch

In Section 52-1.08B(1), in the 6th paragraph, delete item C.

In Section 52-1.08B(2) in the 6th paragraph, replace the subparagraph with:

The minimum preheat and interpass temperatures shall be 400º F for Grade 40 bars and 600º F
for Grade 60 bars. Immediately after completing the welding, at least 6 inches of the bar on
each side of the splice shall be covered by an insulated wrapping to control the rate of cooling.
The insulated wrapping shall remain in place until the bar has cooled below 200º F.

Replace Section 52-1.08B(3) with:

52-1.08B(3) Resistance Butt Welds
Shop produced resistance butt welds shall be produced by a fabricator who is selected from the
Department's Pre-Qualified Products List.
A Certificate of Compliance conforming to the provisions in Section 6-1.07, "Certificates of
Compliance," shall be furnished for each shipment of splice material. The Certificate of
Compliance shall include heat number, lot number and mill certificates.

April 11,2011 4-171

In Section 52-1.08C replace the 3rd paragraph with:

Testing on prequalification and production sample splices shall be performed at an approved
independent testing laboratory. The laboratory shall not be employed or compensated by any
subcontractor, or by other persons or entities hired by subcontractors who will provide other
services or materials for the project.
The independent testing laboratory shall be selected from the Department's Pre-Qualified
Products List.

In Section 52-1.08C replace the 5th paragraph with:

Prequalification and production sample splices and testing shall conform to California Test 670
and these specifications.

In Section 52-1.08C delete the 6th paragraph.

In Section 52-1.08C replace the 8th paragraph with:

Each sample splice, as defined herein, shall be identified as representing either a
prequalification or production test sample splice.

In Section 52-1.08C in the 10th paragraph, delete the last sentence.

Replace Section 52-1.08C(1) with:

52-1.08C(1) Splice Prequalification Report
Before using any service splices or ultimate butt splices in the work, the Contractor shall submit
a Splice Prequalification Report. The report shall include the following:

A. A copy of the manufacturer's product literature giving complete data on the splice
material and installation procedures.
B. Names of the operators who will be performing the splicing.
C. Descriptions of the positions, locations, equipment, and procedures that will be used in
the work.
D. Certifications from the fabricator for prequalification of operators and procedures based
on sample tests performed no more than 2 years before submitting the report. Each
operator shall be certified by performing 2 sample splices for each bar size of each splice
type that the operator will be performing in the work. For deformation-dependent types
of splice devices, each operator shall be certified by performing 2 additional samples for
each bar size and deformation pattern that will be used in the work.

Prequalification sample splices shall be tested by an approved independent testing laboratory

and shall conform to the appropriate production test criteria and slip requirements specified
herein. When epoxy-coated reinforcement is required, resistance butt welded sample splices
shall have the weld flash removed by the same procedure as will be used in the work, before

April 11,2011 4-172

coating and testing. The Splice Prequalification Report shall include the certified test results for
all prequalification sample splices.
The QCM shall review and approve the Splice Prequalification Report before submitting it to the
Engineer for approval. The Contractor shall allow 2 weeks for the review and approval of a
complete report before performing any service splicing or ultimate butt splicing in the work.

In Section 52-1.08C(2)(a) replace the 1st, 2nd, 3rd, 4th, and 5th paragraphs with:
Production tests shall be performed by an approved independent testing laboratory for all
service splices used in the work. A production test shall consist of testing 4 sample splices
prepared for each lot of completed splices. The samples shall be prepared by the Contractor
using the same splice material, position, operators, location, and equipment, and following the
same procedure as used in the work.
At least one week before testing, the Contractor shall notify the Engineer in writing of the date
and location where the testing of the samples will be performed.
The 4 samples from each production test shall be securely bundled together and identified with
a completed sample identification card before shipment to the approved independent testing
laboratory. The card will be furnished by the Engineer. Bundles of samples containing fewer
than 4 samples of splices shall not be tested.
Before performing any tensile tests on production test sample splices, one of the 4 samples
shall be tested for, and shall conform to, the requirements for total slip in Section 52-1.08B(1),
"Mechanical Splices." Should this sample not meet the total slip requirements, one retest, in
which the 3 remaining samples are tested for total slip, will be allowed. Should any of the 3
remaining samples not conform to the total slip requirements, all splices in the lot represented
by this production test will be rejected.
If 3 or more sample splices from a production test conform to the provisions in this Section 52-
1.08C(2), "Service Splice Test Criteria," all splices in the lot represented by this production test
will be considered acceptable.

Replace Section 52-1.08C(2)(b) with:

52-1.08C(2)(b) Quality Assurance Test Requirements for Service Splices
In addition to the required production tests, the Contractor shall concurrently prepare 4 service
quality assurance sample splices for:

A. The first production test performed.

B. One of every 5 subsequent production tests, or fraction thereof, randomly selected by the
Engineer.

These service quality assurance sample splices shall be prepared in the same manner as
specified herein for service production sample splices.
The service quality assurance sample splices shall be shipped to the Transportation Laboratory
for quality assurance testing. Each set of 4 sample splices shall be securely bundled together
and identified by location and contract number with weatherproof markings before shipment.

April 11,2011 4-173

Bundles containing fewer than 4 samples of splices will not be tested. Sample splices not
accompanied by the supporting documentation required in Section 52-1.08B(1), "Mechanical
Splices," for mechanical splices, or in Section 52-1.08B(3), "Resistance Butt Welds," for
resistance butt welds, will not be tested.
Quality assurance testing will be performed in conformance with the requirements for service
production sample splices in Section 52-1.08C(2)(a), "Production Test Requirements for Service
Splices."

Replace Section 52-1.08C(3) with:

52-1.08C(3) Ultimate Butt Splice Test Criteria
Ultimate production and quality assurance sample splices shall be tensile tested in conformance
with the requirements described in ASTM Designation: A 370 and California Test 670.
Each sample splice shall be identified as representing a prequalification, production, or quality
assurance sample splice.
The portion of hoop reinforcing bar, removed to obtain a sample splice, shall be replaced using
a prequalified ultimate mechanical butt splice, or the hoop shall be replaced in kind.
Reinforcing bars, other than hoops, from which sample splices are removed, shall be repaired
using ultimate mechanical butt splices conforming to the provisions in Section 52-1.08C(1),
"Splice Prequalification Report," or the bars shall be replaced in kind. These bars shall be
repaired or replaced such that no splices are located in any "No Splice Zone" shown on the
plans.
Ultimate production and quality assurance sample splices shall rupture either: 1) in the
reinforcing bar but outside of the affected zone, provided that the sample splice has visible
necking or 2) anywhere, provided that the sample splice has achieved the strain requirement for
necking.
When tested in conformance with the requirements in California Test 670, "Necking (Option I),"
the visible necking shall be such that there is a visible decrease in the sample's cross-sectional
area at the point of rupture.
When tested in conformance with the requirements in California Test 670, "Necking (Option II),"
the strain requirement for necking shall be such that the largest measured strain is not less than
6 percent for No. 11 and larger bars, or not less than 9 percent for No. 10 and smaller bars.
The affected zone is the portion of the reinforcing bar where any properties of the bar, including
the physical, metallurgical, or material characteristics, have been altered by fabrication or
installation of the splice. The weld and one inch adjacent to the weld will be considered part of
the affected zone.

In Section 52-1.08C(3)(a) replace the 1st paragraph with:

Production tests shall be performed for all ultimate butt splices used in the work. A production
test shall consist of testing 4 sample splices removed from each lot of completed splices.

April 11,2011 4-174

In Section 52-1.08C(3)(a) replace the 3rd paragraph with:

After notification has been received, the Engineer will randomly select the 4 sample splices to
be removed from the lot and place tamper-proof markings or seals on them. These ultimate
production sample splices shall be removed by the Contractor, and tested by an approved
independent testing laboratory.

In Section 52-1.08(C)(3)(a) replace the 5th, 6th, and 7th paragraphs with:
A sample splice will be rejected if a tamper-proof marking or seal is disturbed before testing.
The 4 sample splices from each production test shall be securely bundled together and
identified with a completed sample identification card before shipment to the approved
independent testing laboratory. The card will be furnished by the Engineer. Bundles of samples
containing fewer than 4 sample splices shall not be tested.
Before performing any tensile tests on production test sample splices, one of the 4 sample
splices shall be tested for, and shall conform to, the requirements for total slip in Section 52-
1.08B(1), "Mechanical Splices." Should this sample splice not meet these requirements, one
retest, in which the 3 remaining sample splices are tested for total slip, will be allowed. Should
any of the 3 remaining sample splices not conform to these requirements, all splices in the lot
represented by this production test will be rejected.

Replace Section 52-1.08C(3)(b) with:

52-1.08C(3)(b) Quality Assurance Test Requirements for Ultimate Butt Splices
In addition to the required production tests, the Contractor shall concurrently prepare 4 ultimate
quality assurance sample splices for:

A. The first production test performed.

B. One of every 5 subsequent production tests, or fraction thereof, randomly selected by the
Engineer.

These ultimate quality assurance sample splices shall be prepared in the same manner as
specified herein for ultimate production sample splices.
The ultimate quality assurance sample splices shall be shipped to the Transportation Laboratory
for quality assurance testing. Each set of 4 sample splices shall be securely bundled together
and identified by location and contract number with weatherproof markings before shipment.
Bundles containing fewer than 4 samples of splices will not be tested. Sample splices not
accompanied by the supporting documentation required in Section 52-1.08B(1), "Mechanical
Splices," for mechanical splices, or in Section 52-1.08B(3), "Resistance Butt Welds," for
resistance butt welds, will not be tested.
Quality assurance testing will be performed in conformance with the requirements for ultimate
production sample splices in Section 52-1.08C(3)(a), "Production Test Requirements for
Ultimate Butt Splices."

April 11,2011 4-175

Replace Section 52-1.08D with:

A Production Test Report for all testing performed on each lot shall be prepared by the
approved independent testing laboratory performing the testing and submitted to the QCM for
review and approval. The report shall be signed by an engineer who represents the laboratory
and is registered as a Civil Engineer in the State of California. The report shall include, as a
minimum, the following information for each test: contract number, bridge number, lot number
and location, bar size, type of splice, length of mechanical splice, length of test specimen,
physical condition of test sample splice, any notable defects, total measured slip, and ultimate
tensile strength of each splice. In addition, the report shall include location of visible necking
area and largest measured strain for ultimate butt splices.
The QCM must review, approve, and forward each Production Test Report to the Engineer for
review before the splices represented by the report are encased in concrete. The Engineer will
have 3 working days to review each Production Test Report and respond in writing after a
complete report has been received. Should the Contractor elect to encase any splices before
receiving notification from the Engineer, it is expressly understood that the Contractor will not be
relieved of the responsibility for incorporating material in the work that conforms to the
requirements of the plans and specifications. Material not conforming to these requirements will
be subject to rejection.
Quality assurance test results for each bundle of 4 samples of splices will be reported in writing
to the Contractor within 3 working days after receipt of the bundle by the Transportation
Laboratory. In the event that more than one bundle is received on the same day, 2 additional
working days shall be allowed for providing test results for each additional bundle received. A
test report will be made for each bundle received. Should the Contractor elect to encase splices
before receiving notification from the Engineer, it is expressly understood that the Contractor will
not be relieved of the responsibility for incorporating material in the work that conforms to the
requirements of the plans and specifications. Material not conforming to these requirements will
be subject to rejection.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 53 SHOTCRETE
(Issued 11-02-07)

In Section 53-1.01 replace the 3rd paragraph with:

The dry-mix process shall consist of delivering dry mixed aggregate and cementitious material
pneumatically or mechanically to the nozzle body and adding water and mixing the materials in
the nozzle body. The wet-mix process shall consist of delivering mixed aggregate, cement, and
water pneumatically to the nozzle and adding any admixture at the nozzle.

April 11,2011 4-176

In Section 53-1.02 replace the 1st through 4th paragraphs with:

Cementitious material, fine aggregate, and mixing water shall conform to the provisions in
Section 90, "Portland Cement Concrete."
Shotcrete to be mixed and applied by the dry-mix process shall consist of one part cementitious
material to not more than 4.5 parts fine aggregate, thoroughly mixed in a dry state before being
charged into the machine. Measurement may be either by volume or by weight. The fine
aggregate shall contain not more than 6 percent moisture by weight.
Shotcrete to be mixed and applied by the wet-mix process shall consist of cementitious material,
fine aggregate, and water and shall contain not less than 632 pounds of cementitious material
per cubic yard. A maximum of 30 percent pea gravel may be substituted for fine aggregate.
The maximum size of pea gravel shall be such that 100 percent passes the 1/2 inch screen and
at least 90 percent passes the 3/8 inch screen.
Admixtures may be added to shotcrete and shall conform to the provisions in Section 90-4,
"Admixtures."

In Section 53-1.04 in the 3rd paragraph, replace item C with:

C. Aggregate and cementitious material that have been mixed for more than 45 minutes
shall not be used unless otherwise permitted by the Engineer.

Replace Section 53-1.07 with:

53-1.07 MEASUREMENT
Quantities of shotcrete will be measured by the cubic yard computed from measurements, along
the slope, of actual areas placed and the theoretical thickness shown on the plans. The
Department does not pay for shotcrete placed outside the dimensions shown on the plans or to
fill low foundation.

Replace Section 53-1.08 with:

53-1.08 PAYMENT
The contract price paid per cubic yard for shotcrete shall include full compensation for furnishing
all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in
placing shotcrete, including preparing the foundation, wire reinforcement, structure backfill, joint
filling material, and if required by the plans, drains with sacked pervious backfill material, as
shown on the plans, as specified in these specifications and the special provisions, and as
directed by the Engineer.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-177

SECTION 55 STEEL STRUCTURES

(Issued 05-02-08

In Section 55-1.05 replace the 3rd paragraph with:

Construction methods and equipment employed by the Contractor shall conform to the
provisions in Section 7-1.02, "Load Limitations."

In Section 55-2.01 in the 5th paragraph in the table, replace the CVN impact value for
Grade HPS 50W with:
Grade HPS 50W* (4 inches and under in 20 at 10 ºF
thickness)

In Section 55-3.05 replace the 1st paragraph with:

Surfaces of bearing and base plates and other metal surfaces that are to come in contact with
each other or with ground concrete surfaces or with asbestos sheet packing shall be flat to
within 1/32-inch tolerance in 12 inches and to within 1/16-inch tolerance overall. Surfaces of
bearing and base plates and other metal bearing surfaces that are to come in contact with
preformed fabric pads, elastomeric bearing pads, or mortar shall be flat to within 1/8-inch
tolerance in 12 inches and to within 3/16-inch tolerance overall.

In Section 55-3.10 in the 1st paragraph, replace item B with:

B. Internal threads shall conform to the requirements in ASTM Designation: A 563.

In Section 55-3.19 replace the 3rd paragraph with:

Immediately before setting bearing assemblies or masonry plates directly on ground concrete
surfaces, the Contractor shall thoroughly clean the surfaces of the concrete and the metal to be
in contact and shall apply a coating of nonsag polysulfide or polyurethane caulking conforming
to the requirements in ASTM Designation: C 920 to contact areas to provide full bedding.

In Section 55-3.19 replace the 5th paragraph with:

Mortar to be placed below masonry plates or bearing plates of the bearing assemblies and in
anchor bolt sleeves or canisters shall conform to the provisions in Section 51-1.135, "Mortar,"
except that the proportion of cementitious material to sand shall be 1:3.

April 11,2011 4-178

In Section 55-4.01 in the 1st paragraph, replace item D with:

D. To determine the pay quantities of galvanized metal, the weight to be added to the
calculated weight of the base metal for the galvanizing will be determined from the table
of weights of zinc coatings specified in ASTM Designation: A 153/A 153M.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 56 SIGNS
(Issued 03-16-07)

In Section 56-1.03 replace the 5th paragraph with:

Clips, eyes, or removable brackets shall be affixed to all signs and all posts and shall be used to
secure the sign during shipping and for lifting and moving during erection as necessary to
prevent damage to the finished galvanized or painted surfaces. Brackets on tubular sign
structures shall be removed after erection. Details of the devices shall be shown on the working
drawings.

In Section 56-1.10 replace the 4th paragraph with:

The contract price paid per pound for install sign structure of the type or types designated in the
Engineer's Estimate shall include full compensation for furnishing all labor, materials, tools,
equipment and incidentals, and for doing all the work involved in installing sign structures,
complete in place, including installing anchor bolt assemblies, removable sign panel frames,
and sign panels and performing any welding, painting or galvanizing required during installation,
as shown on the plans, as specified in these specifications and the special provisions, and as
directed by the Engineer.

In Section 56-2.03 replace the 4th paragraph with:

Backfill material for metal posts shall consist of minor concrete conforming to the provisions in
Section 90-10, "Minor Concrete," and shall contain not less than 463 pounds of cementitious
material per cubic yard.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-179

SECTION 59 PAINTING
(Issued 06-05-09)

In Section 59-1.03 replace the 3rd paragraph with:

Painting shall be done in a neat and workmanlike manner. Unless otherwise specified, paint
shall be applied by brush, or spray, or roller, or any combination of these methods. Gun
extensions shall not be used.

In Section 59-2.01 replace the 2nd paragraph with:

Unless otherwise specified, no painting Contractors or subcontractors will be permitted to
perform work without having the following current "SSPC: The Society for Protective Coatings"
(formerly the Steel Structures Painting Council) certifications in good standing throughout the
duration of the contract:

A. For cleaning and painting structural steel in the field, certification in conformance with
the requirements in Qualification Procedure No. 1, "Standard Procedure For Evaluating
Painting Contractors (Field Application to Complex Industrial Structures)" (SSPC-QP 1).
B. For removing paint from structural steel, certification in conformance with the
requirements in Qualification Procedure No. 2, "Standard Procedure for the Qualification
of Painting Contractors (Field Removal of Hazardous Coatings from Complex
Structures)" (SSPC-QP 2, Category A).
C. For cleaning and painting structural steel in a permanent painting facility, certification in
conformance with the requirements in Qualification Procedure No. 3, "Standard
Procedure For Evaluating Qualifications of Shop Painting Applicators" (SSPC-QP 3,
Enclosed Shop Facility). The AISC's Sophisticated Paint Endorsement (SPE) quality
program, Certification P-1 Enclosed, will be considered equivalent to SSPC-QP 3,
Enclosed Shop Facility.

In Section 59-2.12 replace the 3rd and 4th paragraphs with:

Contact surfaces of stiffeners, railings, built up members or open seam exceeding 6 mils in
width that would retain moisture, shall be caulked with polysulfide or polyurethane sealing
compound conforming to the requirements in ASTM Designation: C 920, Type S, Grade NS,
Class 25, Use O, or other approved material.
The dry film thickness of the paint will be measured in place with a calibrated Type 2 magnetic
film thickness gage in conformance with the requirements in SSPC-PA 2, "Measurement of Dry
Coating Thickness with Magnetic Gages," of the "SSPC: The Society for Protective Coatings,"
except that there shall be no limit to the number or location of spot measurements to verify
compliance with specified thickness requirements.

April 11,2011 4-180

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 64 PLASTIC PIPE

(Issued 06-05-09)

In Section 64-1.02 replace the 5th paragraph with:

HDPE compounds used in the manufacture of corrugated polyethylene pipe and fittings shall
comply with AASHTO M 294 except that the mix shall contain not less than 2 nor greater than 4
percent well dispersed carbon black. HDPE compounds used in the manufacture of ribbed
profile wall polyethylene pipe shall comply with ASTM F 894 except that Type E ultraviolet
stabilizers shall not be allowed and carbon black shall be well dispersed in an amount not less
than 2 percent nor greater than 4 percent.

Manufacturers of corrugated polyethylene pipe shall:

1. Participate in the National Transportation Product Evaluation Control Program (NTPEP)

for each plant supplying corrugated polyethylene pipe and fittings for the project.
2. Conduct and maintain a quality control program under NTPEP.
3. Submit a copy to the Engineer of manufacturing plant audits and NTPEP test results from
the current cycle of NTPEP testing for all pipe diameters supplied.

Type D corrugated polyethylene pipe is not allowed. Corrugated polyethylene pipe greater than
60 inches in nominal diameter is not allowed.

In Section 64-1.05 replace the 1st paragraph with:

Excavation, backfill, and shaped bedding shall comply with Section 19-3, "Structure Excavation
and Backfill," except the following:

1. At locations where pipe is to be backfilled with concrete, the backfill shall comply with
Section 64-1.06, "Concrete Backfill."
2. Corrugated polyethylene pipe that is greater than 48 inches in nominal diameter but not
exceeding 60 inches in nominal diameter shall be backfilled with either controlled low
strength material under the special provisions or slurry cement backfill under Section 19-
3.062, "Slurry Cement Backfill."
3. Where cementitious or flowable backfill is used for structure backfill, the backfill shall be
placed to a level not less than 12 inches above the crown of the pipe.

April 11,2011 4-181

In Section 64-1.06 replace the 1st paragraph with:

At locations where pipe is to be backfilled with concrete as shown on the plans, the concrete
backfill shall be constructed of minor concrete or Class 4 concrete conforming to the provisions
in Section 90, "Portland Cement Concrete." Minor concrete shall contain not less than 380
pounds of cementitious material per cubic yard. The concrete to be used will be designated in
the contract item or shown on the plans.

In Section 64-1.06 replace the 3rd paragraph with:

The surface of the concrete backfill shall be broomed with a heavy broom to produce a uniform
rough surface if hot mix asphalt is to be placed directly thereon.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 65 REINFORCED CONCRETE PIPE

(Issued 11-30-10)

In Section 65-1.02 replace the 1st paragraph with:

Cementitious material and aggregate shall conform to the provisions in Section 90-2, "Materials"
except that grading requirements shall not apply to the aggregate. Use of supplemental
cementitious material shall conform to AASHTO Designation: M 170.

In Section 65-1.02A(1) in the 11th paragraph, replace item c with:

c. Cementitious material and aggregate for non-reinforced concrete pipe shall conform to
the provisions in Section 65-1.02, "Materials."

In Section 65-1.035 replace the 1st paragraph with:

At locations where pipe is to be backfilled with concrete as shown on the plans, the concrete
backfill shall be constructed of minor concrete or Class 4 concrete in conformance with the
provisions in Section 90, "Portland Cement Concrete." Minor concrete shall contain not less
than 380 pounds of cementitious material per cubic yard. The concrete to be used will be
designated in the contract item.

April 11,2011 4-182

In Section 65-1.035 replace the 3rd paragraph with:

The surface of the concrete backfill shall be broomed with a heavy broom to produce a uniform
rough surface if hot mix asphalt is to be placed directly thereon.

In Section 65-1.06 in the 2nd paragraph, replace the 1st subparagraph with:
Cement Mortar. - Mortar shall be composed of one part cementitious material and 2 parts sand
by volume. Supplementary cementitious material will not be required.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 66 CORRUGATED METAL PIPE

(Issued 07-31-07)

In Section 66-1.045 replace the 1st paragraph with:

In Section 66-1.045 replace the 3rd paragraph with:

The surface of the concrete backfill shall be broomed with a heavy broom to produce a uniform
rough surface if hot mix asphalt is to be placed directly thereon.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 68 SUBSURFACE DRAINS

(Issued 07-31-07)

In Section 68-3.02D replace the 1st and 2nd paragraphs with:

Concrete for splash pads shall be produced from minor concrete conforming to the provisions in
Section 90-10, "Minor Concrete." Minor concrete shall contain not less than 470 pounds of
cementitious material per cubic yard.

April 11,2011 4-183

Mortar placed where edge drain outlets and vents connect to drainage pipe and existing
drainage inlets shall conform to the provisions in Section 51-1.135, "Mortar."

In Section 68-3.03 replace the 13th paragraph with:

Cement treated permeable material, which is not covered with hot mix asphalt within 12 hours
after compaction of the permeable material, shall be cured by either sprinkling the material with
a fine spray of water every 4 hours during daylight hours or covering the material with a white
polyethylene sheet, not less than 6 mils thick. The above curing requirements shall begin at
7:00 a.m. on the morning following compaction of the cement treated permeable material and
continue for the next 72 hours or until the material is covered with hot mix asphalt, whichever is
less. The cement treated permeable material shall not be sprayed with water during the first 12
hours after compacting, but may be covered with the polyethylene sheet during the first 12
hours or prior to the beginning of the cure period.

In Section 68-3.03 replace the 17th and 18th paragraphs with:

Hot mix asphalt for backfilling trenches in existing paved areas shall be produced from
commercial quality aggregates and asphalt and mixed at a central mixing plant. The aggregate
shall conform to the 3/4 inch grading, or the 1/2 inch grading for Type A and Type B hot mix
asphalt specified in Section 39-1.02E, "Aggregate." The amount of asphalt binder to be mixed
with the aggregate shall be between 4 percent and 7 percent by weight of the dry aggregate, as
determined by the Engineer.
Hot mix asphalt backfill shall be spread and compacted in approximately 2 equal layers by
methods that will produce a hot mix asphalt surfacing of uniform smoothness, texture and
density. Each layer shall be compacted before the temperature of the mixture drops below 250
ºF. Prior to placing the hot mix asphalt backfill, a tack coat of asphaltic emulsion conforming to
the provisions in Section 94, "Asphaltic Emulsions," shall be applied to the vertical edges of
existing pavement at an approximate rate of 0.05 gallon per square yard.

In Section 68-3.03 replace the 20th paragraph with:

Type A pavement markers conforming to the details shown on the plans and the provisions in
Section 85, "Pavement Markers," shall be placed on paved shoulders or dikes at outlet, vent
and cleanout locations as directed by the Engineer. The waiting period for placing pavement
markers on new hot mix asphalt surfacing will not apply.

Replace Section 68-3.05 with:

68-3.05 PAYMENT
The contract price paid per linear foot for plastic pipe (edge drain) of the size or sizes shown in
the Engineer's Estimate shall include full compensation for furnishing all labor, materials, tools,
equipment, and incidentals and for doing all the work involved in installing edge drains complete
in place, including excavation (and removal of any concrete deposits that may occur along the
lower edge of the concrete pavement in Type 1 installations) and hot mix asphalt backfill for

April 11,2011 4-184

Type 1 edge drain installation, tack coat, filter fabric, and treated permeable material, as shown
on the plans, as specified in these specifications and the special provisions, and as directed by
the Engineer.
The contract price paid per linear foot for plastic pipe (edge drain outlet) of the size or sizes
shown in the Engineer's Estimate shall include full compensation for furnishing all labor,
materials, tools, equipment, and incidentals and for doing all the work involved in installing edge
drain outlets, vents and cleanouts complete in place, including outlet and vent covers,
expansion plugs, pavement markers, concrete splash pads, connecting outlets and vents to
drainage facilities, and excavation and backfill [aggregate base, hot mix asphalt, tack coat, and
native material] for outlets, vents, and cleanouts to be installed in embankments and existing
shoulders, as shown on the plans, as specified in these specifications and the special
provisions, and as directed by the Engineer.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 69 OVERSIDE DRAINS

(Issued 07-31-07)

In Section 69-1.01 replace the 1st paragraph with:

This work shall consist of furnishing and installing entrance tapers, pipe downdrains, tapered
inlets, flume downdrains, anchor assemblies, reducers, slip joints and hot mix asphalt overside
drains to collect and carry surface drainage down the roadway slopes as shown on the plans or
as directed by the Engineer and as specified in these specifications and the special provisions.

Replace Section 69-1.02D with:

69-1.02D Hot Mix Asphalt
Hot mix asphalt for overside drains shall conform to the provisions in Section 39-1.13,
"Miscellaneous Areas."

Replace Section 69-1.04 with:

69-1.04 HOT MIX ASPHALT OVERSIDE DRAINS
Hot mix asphalt overside drains shall be constructed as shown on the plans or as directed by
the Engineer. The hot mix asphalt shall be placed in conformance with the provisions in Section
39-1.13, "Miscellaneous Areas."

April 11,2011 4-185

In Section 69-1.06 replace the 2nd paragraph with:

Quantities of hot mix asphalt placed for overside drains will be paid for as provided in Section
39-5, "Measurement and Payment," for hot mix asphalt placed in miscellaneous areas.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 70 MISCELLANEOUS FACILITIES

(Issued 11-30-10)

In Section 70-1.02C replace the 2nd paragraph with:

Precast concrete flared end sections shall conform to the requirements for Class III Reinforced
Concrete Pipe in AASHTO Designation: M 170M. Cementitious materials and aggregate shall
conform to the provisions in Section 90-2, "Materials," except that grading requirements shall
not apply to the aggregate. Use of supplementary cementitious material shall conform to the
requirements in AASHTO Designation: M 170. The area of steel reinforcement per linear foot
of flared end section shall be at least equal to the minimum steel requirements for circular
reinforcement in circular pipe for the internal diameter of the circular portion of the flared end
section. The basis of acceptance of the precast concrete flared end section shall conform to the
requirements of Section 5.1.2 of AASHTO Designation: M 170.

In Section 70-1.02H replace the 1st paragraph with:

Precast concrete pipe risers and pipe reducers, and precast concrete pipe sections, adjustment
rings and tapered sections for pipe energy dissipators, pipe inlets and pipe manholes shall
conform to the requirements in AASHTO Designation: M 199M/M 199, except that the
cementitious material and aggregate shall conform to the provisions in Section 90-2, "Materials,"
except that grading requirements shall not apply to the aggregate. Use of supplementary
cementitious material shall conform to the requirements in AASHTO Designation: M 170.

In Section 70-1.03 replace the 2nd paragraph with:

Cutoff walls for precast concrete flared end sections shall be constructed of minor concrete
conforming to the provisions in Section 90-10, "Minor Concrete." Minor concrete shall contain
not less than 470 pounds of cementitious material per cubic yard.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-186

SECTION 72 SLOPE PROTECTION

(Issued 03-13-09)

In Section 72-4.04 replace the 6th paragraph with:

Pervious backfill material, if required by the plans, shall be placed as shown. A securely tied
sack containing one cubic foot of pervious backfill material shall be placed at each weep hole
and drain hole. The sack material shall conform to the requirements for filter fabric in Section
88-1.02, "Filtration."

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 73 CONCRETE CURBS AND SIDEWALKS

(Issued 06-05-09)

In Section 73-1.01 in the 2nd paragraph, replace item 2 with:

2. Minor concrete shall contain not less than 463 pounds of cementitious material per
cubic yard except that when extruded or slip-formed curbs are constructed using 3/8-
inch maximum size aggregate, minor concrete shall contain not less than 505 pounds
of cementitious material per cubic yard.

In Section 73-1.06 replace the 15th paragraph with:

Where hot mix asphalt or portland cement concrete pavements are to be placed around or
adjacent to manholes, pipe inlets or other miscellaneous structures in sidewalk, gutter
depression, island paving, curb ramps or driveway areas, the structures shall not be constructed
to final grade until after the pavements have been constructed for a reasonable distance on
each side of the structures.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 74 PUMPING PLANT EQUIPMENT

(Issued 07-01-08)

April 11,2011 4-187

In Section 74-1.02 delete the 2nd paragraph.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 75 MISCELLANEOUS METAL

(Issued 06-05-09)

In Section 75-1.03 replace the 13th paragraph with:

Concrete anchorage devices shall be mechanical expansion or resin capsule types installed in
drilled holes or cast-in-place insert types. The anchorage devices shall be selected from the
Department's Pre-Qualified Products List. The qualification requirements for concrete
anchorage devices may be obtained from the Pre-Qualified Products List Web site.

The anchorage devices shall be a complete system, including threaded studs, hex nuts, and cut
washers. Thread dimensions for externally threaded concrete anchorage devices prior to zinc
coating shall conform to the requirements in ASME Standard: B1.1 having Class 2A tolerances
or ASME Standard: B1.13M having Grade 6g tolerances. Thread dimensions for internally
threaded concrete anchorage devices shall conform to the requirements in ASTM A 563.

In Section 75-1.03 replace the 18th paragraph with:

Mechanical expansion anchors shall, when installed in accordance with the manufacturer's
instructions and these specifications and tested in conformance with the requirements in
California Test 681, withstand the application of a sustained tension test load of at least the
following values for at least 48 hours with a movement not greater than 0.035 inch:

Stud Diameter Sustained

Tension Test
Load
(inches) (pounds)
*3/4 5,000
5/8 4,100
1/2 3,200
3/8 2,100
1/4 1,000
* Maximum stud diameter permitted for
mechanical expansion anchors.

Resin capsule anchors shall, when installed in accordance with the manufacturer's instructions
and these specifications and tested in conformance with the requirements in California Test
681, withstand the application of a sustained tension test load of at least the following values for
at least 48 hours with a movement not greater than 0.010 inch:

April 11,2011 4-188

Stud Diameter Sustained

Tension Test
Load
(inches) (pounds)
1-1/4 31,000
1 17,900
7/8 14,400
3/4 5,000
5/8 4,100
1/2 3,200
3/8 2,100
1/4 1,000

At least 25 days before use, the Contractor shall submit one sample of each resin capsule
anchor per lot to the Transportation Laboratory for testing. A lot of resin capsule anchors is 100
units, or fraction thereof, of the same brand and product name.

In Section 75-1.03 replace the 20th paragraph with:

A Certificate of Compliance for concrete anchorage devices shall be furnished to the Engineer
in conformance with the provisions in Section 6-1.07, "Certificates of Compliance."

In Section 75-1.03 replace the 24th paragraph with:

Sealing compound, for caulking and adhesive sealing, shall be a polysulfide or polyurethane
material conforming to the requirements in ASTM Designation: C 920, Type S, Grade NS,
Class 25, Use O.

In Section 75-1.035 in the 3rd paragraph, replace the 1st sentence with:
Cables shall be 3/4 inch preformed, 6 x 19, wire strand core or independent wire rope core
(IWRC), galvanized in conformance with the requirements in Federal Specification RR-W-410,
right regular lay, manufactured of improved plow steel with a minimum breaking strength of 23
tons.

In Section 75-1.035 in the 4th paragraph, replace item C with:

C. Nuts shall conform to the requirements in ASTM Designation: A 563 including
Appendix X1, except lubrication is not required.

In Section 75-1.035 replace the 12th paragraph with:

Concrete for filling cable drum units shall conform to the provisions in Section 90-10, "Minor
Concrete," or at the option of the Contractor, may be a mix with 3/8-inch maximum size
aggregate and not less than 675 pounds of cementitious material per cubic yard.

April 11,2011 4-189

In Section 75-1.05 replace the 6th paragraph with:

Galvanizing of iron and steel hardware and nuts and bolts, when specified or shown on the
plans, shall conform to the requirements in ASTM Designation: A 153/A 153M, except
whenever threaded studs, bolts, nuts, and washers are specified to conform to the requirements
in ASTM Designation: A 307, A 325, A 449, A 563, or F 436 and zinc coating is required, they
shall be hot-dip zinc coated or mechanically zinc coated in conformance with the requirements
in the ASTM Designations. Unless otherwise specified, galvanizing shall be performed after
fabrication.

In Section 75-1.05 replace the 8th paragraph with:

Tapping of nuts or other internally threaded parts to be used with zinc coated bolts, anchor bars
or studs shall be done after galvanizing and shall conform to the requirements for thread
dimensions and overtapping allowances in ASTM Designation: A 563.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 80 FENCES
(Issued 01-05-07)

In Section 80-3.01F replace the 4th paragraph with:

Portland cement concrete for metal post and brace footings and for deadmen shall be minor
concrete conforming to the provisions in Section 90-10, "Minor Concrete." Minor concrete shall
contain not less than 470 pounds of cementitious material per cubic yard.

In Section 80-4.01C replace the 4th paragraph with:

Portland cement concrete for metal post and for deadmen shall be produced from minor
concrete conforming to the provisions in Section 90-10, "Minor Concrete." Minor concrete shall
contain not less than 470 pounds of cementitious material per cubic yard.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

April 11,2011 4-190

SECTION 83 RAILINGS AND BARRIERS

(Issued 04-03-09)

In Section 83-1.02 replace the 7th paragraph with:

Mortar shall conform to the provisions in Section 51-1.135, "Mortar," and shall consist of one
part by volume of cementitious material and 3 parts of clean sand.

In Section 83-1.02B in the 24th paragraph in the 8th subparagraph, replace the 1st
sentence with:
Anchor cable shall be 3/4 inch preformed, 6 x 19, wire strand core or independent wire rope
core (IWRC), galvanized in conformance with the requirements in Federal Specification RR-W-
410, right regular lay, manufactured of improved plow steel with a minimum breaking strength of
23 tons.

In Section 83-1.02E in the 6th paragraph, replace the 2nd sentence with:
Cable shall be galvanized in conformance with the requirements in Federal Specification RR-W-
410.

In Section 83-1.02I replace the 5th paragraph with:

Where shown on the plans, cables used in the frame shall be 5/16 inch in diameter, wire rope,
with a minimum breaking strength of 5,000 pounds and shall be galvanized in conformance with
the requirements in Federal Specification RR-W-410.

In Section 83-1.02I replace the 14th paragraph with:

Chain link fabric shall be 11-gage conforming to one of the following:

1. AASHTO Designation: M181, Type I, Class C

2. AASHTO Designation: M181, Type IV, Class A
3. ASTM F 1345, Class 2

In Section 83-2.02D(1) replace the 5th paragraph with:

When concrete barriers are to be constructed on existing structures, the dowels shall be bonded
in holes drilled in the existing concrete. Drilling of holes and bonding of dowels shall conform to
the following:

April 11,2011 4-191

1. The bonding materials shall be either magnesium phosphate concrete, modified high
alumina based concrete or portland cement based concrete. Magnesium phosphate
concrete shall be either single component (water activated) or dual component (with a
prepackaged liquid activator). Modified high alumina based concrete and portland
cement based concrete shall be water activated. Bonding materials shall conform to the
following requirements:

Property Test Method Requirements

Compressive Strength
at 3 hours, MPa California Test 551 21 min.
at 24 hours, MPa California Test 551 35 min.
Flexure Strength
at 24 hours, MPa California Test 551 3.5 min.
Bond Strength: at 24 hours
SSD Concrete, MPa California Test 551 2.1 min.
Dry Concrete, MPa California Test 551 2.8 min.
Water Absorption, % California Test 551 10 max.
Abrasion Resistance
at 24 hours, grams California Test 550 25 max.
Drying Shrinkage at 4 days, % ASTM Designation: 0.13 max.
C 596
Soluble Chlorides by weight, % California Test 422 0.05 max.
Water Soluble Sulfates by weight, % California Test 417 0.25 max.

2. Magnesium phosphate concrete shall be formulated for minimum initial set time of 15
minutes and minimum final set time of 25 minutes at 70° F. The materials, prior to use,
shall be stored in a cool, dry environment.
3. Mix water used with water activated material shall conform to the provisions in Section
90-2.03, "Water."
4. The quantity of water for single component type or liquid activator (for dual component
type) to be blended with the dry component, shall be within the limits recommended by
the manufacturer and shall be the least amount required to produce a pourable batter.
5. Addition of retarders, when required and approved by the Engineer, shall be in
conformance with the manufacturer's recommendations.
6. Before using concrete material that has not been previously approved, a minimum of
45 pounds shall be submitted to the Engineer for testing. The Contractor shall allow 45
days for the testing. Each shipment of concrete material that has been previously
approved shall be accompanied by a Certificate of Compliance as provided in Section
6-1.07, "Certificates of Compliance."
7. Magnesium phosphate concrete shall not be mixed in containers or worked with tools
containing zinc, cadmium, aluminum or copper metals. Modified high alumina based
concrete shall not be mixed in containers or worked with tools containing aluminum.
8. The surface of any dowel coated with zinc or cadmium shall be coated with a colored
lacquer before installation of the dowel. The lacquer shall be allowed to dry thoroughly
before embedment of the dowels.

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9. The holes shall be drilled by methods that will not shatter or damage the concrete
adjacent to the hole. The diameter of the drilled hole shall be 1/2 inch larger than the
nominal diameter of the dowels.
10. The drilled holes shall be clean and dry at the time of placing the bonding material and
the steel dowels. Bonding material and dowel shall completely fill the drilled hole. The
surface temperature shall be 40° F or above when the bonding material is placed.
11. After bonding, dowels shall remain undisturbed for a minimum of 3 hours or until the
bonding material has reached a strength sufficient to support the dowels. Dowels that are
improperly bonded, as determined by the Engineer, shall be removed. The holes shall be
cleaned or new holes shall be drilled and the dowels replaced and securely bonded to the
concrete. Removing, redrilling and replacing improperly bonded dowels shall be
performed at the Contractor's expense. Modified high alumina based concrete and
portland cement based concrete shall be cured in conformance with the provisions in
Section 90-7.01B, "Curing Compound Method," of the Standard Specifications.
Magnesium phosphate concrete shall not be cured.

In Section 83-2.02D(2) in the 1st paragraph, replace item b with:

b. If the 3/8-inch maximum size aggregate grading is used to construct extruded or slip-
formed concrete barriers, the cementitious material content of the minor concrete shall be
not less than 675 pounds per cubic yard.

In Section 83-2.02D(2) replace the 3rd paragraph with:

The concrete paving between the tops of the 2 walls of concrete barrier (Types 50E, 60E,
60GE, and 60SE) and the optional concrete slab at the base between the 2 walls of concrete
barrier (Types 50E, 60E, 60GE, and 60SE) shall be constructed of minor concrete conforming to
the provisions of Section 90-10, "Minor Concrete," except that the minor concrete shall contain
not less than 505 pounds of cementitious material per cubic yard.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 85 PAVEMENT MARKERS

(Issued 07-31-07)

In Section 85-1.06 replace the 6th paragraph with:

Pavement markers shall not be placed on new hot mix asphalt surfacing or seal coat until the
surfacing or seal coat has been opened to public traffic for a period of not less than 7 days when
hot melt bituminous adhesive is used, and not less than 14 days when epoxy adhesive is used.

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In Section 85-1.06 in the 14th paragraph, replace the 2nd sentence with:
Cleaning shall be done by blast cleaning on all surfaces regardless of age or type, except that
blast cleaning of clean, new hot mix asphalt and clean, new seal coat surfaces will not be
required when hot melt bituminous adhesive is used.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 86 SIGNALS, LIGHTING AND ELECTRICAL SYSTEMS

(Issued 06-05-09)

Replace Section 86 with:

SECTION 86 ELECTRICAL SYSTEMS
86-1 GENERAL
86-1.01 DESCRIPTION
Section 86 includes specifications for installing, modifying, and removing:

1. Traffic signal
2. Interconnect system
3. Ramp metering system
4. Flashing beacon system
5. Lighting system
6. Sign illumination system
7. Traffic monitoring station
8. Communication system
9. Electrical equipment in structure
10. Falsework lighting

Comply with Part 4 of the California MUTCD. Nothing in this Section 86 is to be construed as to
reduce the minimum standards in this manual.
The locations of electrical system elements are approximate; the Engineer will approve final
location.

86-1.015 DEFINITIONS
Definitions pertain only to Section 86, "Electrical Systems."
actuation: The action of a vehicle or pedestrian causing a detector to create a call in that
phase or movement to request right of way.
channel: Discrete information path.

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controller assembly: Controller unit and auxiliary equipment housed in a rainproof cabinet
to control a system's operations.
controller unit: Part of the controller assembly performing the basic timing and logic
functions.
detector: Device indicating passage or presence of vehicles or pedestrians.
electrolier: Complete assembly of lighting standard and luminaire.
flasher: Device to open and close signal circuits at a repetitive rate.
flashing beacon control assembly: Switches, circuit breakers, terminal blocks, flasher,
wiring, and necessary electrical components all housed in a single enclosure to properly
operate a beacon.
inductive loop detector: Detector capable of being actuated by inductance change caused
by vehicle passing or standing over the loop.
lighting standard: Pole and mast arm supporting the luminaire.
luminaire: Consists of housing, reflector, refractor or lens, lamp socket, integral ballast,
terminal strip, and lamp.
magnetic detector: Detector capable of being actuated by induced voltage caused by
vehicle passing through the earth's magnetic field.
powder coating: A coating applied electrostatically using UV-stable polyester triglycidyl
isocyanurate exterior grade powder
pre-timed controller assembly: Operates traffic signals under a predetermined cycle
length.
signal face: As defined in the California MUTCD.
signal head: As defined in the California MUTCD.
signal indication: As defined in the California MUTCD.
signal section: As defined in the California MUTCD.
signal standard: Pole and mast arm supporting one or more signal faces with or without a
luminaire mast arm.
traffic-actuated controller assembly: Operates traffic signals under the varying demands
of traffic as registered by detector actuation.
traffic phase: Signal phase as defined in the California MUTCD.
vehicle: As defined in the California Vehicle Code.

86-1.02 REGULATIONS AND CODE

Electrical equipment must comply with one or more of the following:

1. EIA
2. ETL
3. NEMA
4. NETA
5. UL

Materials and workmanship must comply with:

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1. ANSI
2. ASTM
3. 8 CA Code of Regs § 2299 et seq.
4. FCC
5. ITE
6. NEC
7. Public Utilities Commission, General Order No. 95, "Rules for Overhead Electrical Line
Construction"
8. Public Utilities Commission, General Order No. 128, "Rules for Construction of
Underground Electric Supply and Communication Systems"

86-1.03 COST BREAK-DOWN

Determine quantities required to complete work. Submit the quantities as part of the cost
breakdown.
The sum of the amounts for the units of work listed in the cost breakdown must equal the
contract lump sum price bid for the work. Include overhead and profit for each unit of work
listed in the cost breakdown. If mobilization is a bid item, include bond premium, temporary
construction facilities, and material plants into the mobilization bid item, otherwise, include in
each unit of work listed in the cost breakdown. Do not include costs for traffic control system in
the cost breakdown.
The cost breakdown may be used to determine partial payment and to calculate payment
adjustments for additional costs incurred due to a change order. If a change order increases or
decreases the quantities, payment adjustment may be determined under Section 4-1.03B,
"Increased or Decreased Quantities."
The cost breakdown must include type, size, and installation method for:

1. Foundations
2. Standards and poles
3. Conduit
4. Pull boxes
5. Conductors
6. Service equipment enclosures
7. Telephone demarcation cabinet
8. Signal heads and hardware
9. Pedestrian signal heads and hardware
10. Pedestrian push buttons
11. Loop detectors
12. Luminaires and lighting fixtures

86-1.04 EQUIPMENT LIST AND DRAWINGS

Within 15 days of contract approval, submit for review a list of equipment and materials that you
propose to install. Comply with Section 5-1.02, "Plans and Working Drawings." The list must
include:

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1. Name of manufacturer
2. Dimension
3. Item identification number
4. List of components

The list must be supplemented by other data as required, including:

1. Schematic wiring diagrams

2. Scale drawings of cabinets showing location and spacing of shelves, terminal blocks, and
equipment, including dimensioning
3. Operation manual

Submit 2 copies of the above data. The Engineer will review within 15 days.
Electrical equipment that is manufactured as detailed on the plans will not require detailed
drawings and diagrams.
Furnish 3 sets of computer-generated cabinet schematic wiring diagrams.
The cabinet schematic wiring diagram must be placed in a heavy duty plastic envelope and
attached to the inside of the door of each cabinet.
Prepare diagrams, plans, and drawings using graphic symbols in IEEE 315, "Graphic Symbols
for Electrical and Electronic Diagrams."

86-1.05 CERTIFICATE OF COMPLIANCE

Submit a Certificate of Compliance for all electrical material and equipment to the Engineer
under Section 6-1.07, "Certificates of Compliance."

86-1.06 MAINTAINING EXISTING AND TEMPORARY ELECTRICAL SYSTEMS

Keep existing electrical system or approved temporary replacement in working order during the
progress of the work. Shutdown is allowed for alteration or removal of the system. Traffic
signal shutdown must be limited to normal working hours. Lighting system shutdown must not
interfere with the regular lighting schedule.
Notify the Engineer before performing work on the existing system.
Notify the local traffic enforcement agency before traffic signal shutdown.
If existing or temporary system must be modified, work not shown on the plans or specified in
the special provisions, but required to keep the system in working order will be paid for as extra
work as specified in Section 4-1.03D, "Extra Work."
The State or local agency will:

1. Continue the operation and maintenance of existing electrical facilities

2. Continue to provide electrical energy to operate existing electrical facilities
3. Repair or replace existing facilities damaged by public traffic

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4. Pay for electrical energy to operate existing or new facilities undergoing the functional
tests described in Section 86-2.14C, "Functional Testing"

Verify location and depth of existing detectors, conduits, pull boxes, and other electrical facilities
before using tools or equipment that may damage those facilities or interfere with an electrical
system.
Notify the Engineer immediately if existing facility is damaged by your activities. Repair or
replace damaged facility promptly. If you fail to complete the repair or replacement, promptly,
the State will repair or replace and deduct the costs.
Damaged detectors must be replaced within 24 hours at your expense. If you fail to complete
the repair within 24 hours, the State will repair and deduct the repair costs.
If roadway remains open to traffic while an existing lighting system is modified:

1. Keep existing system in working order

2. Make final connection so the modified circuit is in operation by nightfall

Keep temporary electrical installations in working order until no longer required. Remove
temporary installations as specified in Section 86-7, "Removing, Reinstalling or Salvaging
Electrical Equipment."
These provisions do not void your responsibilities as specified in Section 7-1.12,
"Indemnification and Insurance," and Section 7-1.16, "Contractor's Responsibility for the Work
and Materials."
During traffic signal system shutdown, place W3-1a, "STOP AHEAD," and R1-1, "STOP," signs
in each direction to direct traffic through the intersection. For 2-lane approaches, place 2 R1-1
signs.
W3-1a and R1-1 signs must comply with Section 12-3.06, "Construction Area Signs." Use a
minimum size of 30 inches for the R1-1 sign.
Cover signal faces when the system is shut down overnight. Cover temporary W3-1a and R1-1
signs when the system is turned on.

86-1.07 SCHEDULING OF WORK

Except service installation and service equipment enclosure, do not work above ground until all
materials are on hand to complete electrical work at each location. Schedule work to allow each
system to be completed and ready for operation before opening the corresponding section of
the roadway to traffic.
If street lighting exists or is installed in conjunction with traffic signals, do not turn on the signals
until the street lighting is energized.
Traffic signals will not be placed in operation until the roadways to be controlled are open to
public traffic.
Lighting and traffic signals, including flashing operation, will not be placed in operation before
starting the functional test period specified in Section 86-2.14, "Testing."
Do not pull conductors into conduit until:

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1. Pull boxes are set to grade

2. Metallic conduit is bonded

In vehicular undercrossings, soffit lights must be in operation as soon as practicable after

falsework has been removed from the structure. Lighting for pedestrian structures must be in
operation before opening the structure to pedestrian traffic.
If the Engineer orders soffit lights or lighting for pedestrian structures to be activated before
permanent power service is available, the cost of installing and removing temporary power
service will be paid for as extra work as specified in Section 4-1.03D, "Extra Work."
The initial traffic signal turn-on must be made between 9:00 a.m. and 2:00 p.m. Before the
initial turn-on, all equipment, including pedestrian signals, pedestrian push buttons, vehicle
detectors, lighting, signs, and pavement delineation must be installed and in working order.
Direct louvers, visors, and signal faces to maximize visibility.
Start functional tests on any working day except Friday or the day before a legal holiday. You
must notify the Engineer 48 hours before the start of functional test.

86-1.08 (BLANK)

86-2 MATERIALS AND INSTALLATION

86-2.01 EXCAVATING AND BACKFILLING
Dispose of surplus excavated material under Section 7-1.13, "Disposal of Materials Outside the
Highway Right of Way."
Backfill as specified in Section 19-3, "Structure Excavation and Backfill." Compact backfill in
conduit trenches outside the hinge point of slopes and not under pavement to a minimum
relative compaction of 90 percent. Compact backfill within hinge points and in areas where
pavement is to be constructed to a minimum relative compaction of 95 percent.
Backfill trenches and restore sidewalk, pavement, and landscaping at one intersection before
starting excavation at another intersection.
If excavating on a street or highway, restrict closure to 1 lane at a time.

86-2.02 REMOVING AND REPLACING IMPROVEMENTS

Replace or reconstruct sidewalk, curb, gutter, concrete pavement, asphalt concrete pavement,
underlying material, lawn, plant, and other facilities damaged by your activities. Replacement
material must be of equal or better quality than the material replaced. Work must be in a
serviceable condition.
If a part of a square or slab of concrete sidewalk, curb, gutter, or driveway is broken or
damaged, the entire square or slab must be removed and reconstructed.
Cut outline of PCC sidewalk or driveway to be removed:

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1. Using a power-driven saw

2. On a neat line
3. To a 0.17-foot minimum depth

86-2.03 FOUNDATIONS
Except for concrete for cast-in-drilled-hole concrete pile foundation, PCC must comply with
Section 90-10, "Minor Concrete."
Construct concrete foundation on firm ground.
After each post, standard, and pedestal is properly positioned, place mortar under the base
plate. Finish exposed portion to present a neat appearance. Mortar must comply with Section
51-1.135, "Mortar," except mortar must have:

1. 1 part by volume of cementitious material

2. 3 parts by volume of clean sand

Reinforced cast-in-drilled-hole concrete pile foundation must comply with Section 49, "Piling,"
except:

1. Material resulting from drilling holes must be disposed of as specified in Section 86-2.01,
"Excavating and Backfilling"
2. Concrete for cast-in-drilled-hole concrete pile will not be considered as designated by
compressive strength

Form exposed portion of the foundation to present a neat appearance and true to line and
grade. The top of a foundation for post and standard must be finished to curb or sidewalk
grade. Forms must be rigid and securely braced in place. Conduit ends and anchor bolts must
be placed at proper height and position. Anchor bolts must be installed a maximum of 1:40 from
vertical and held in place by rigid top and bottom templates. Use a steel bottom template at
least 1/2 inch thick that provides proper spacing and alignment of anchor bolts near the
embedded bottom end. Install bottom template before placing footing concrete.
Provide new foundation and anchor bolts of the proper type and size for relocated standards.
Steel parts must be galvanized as specified in Section 75-1.05, "Galvanizing."
Provide 2 nuts and washers for the upper threaded part of each anchor bolt. Provide 3 nuts and
washers for each anchor bar or stud.
Do not weld high-strength steel used for anchor bolt, anchor bar, or stud.
Before placing concrete, moisten forms and ground. Keep forms in place until the concrete sets
for at least 24 hours and is strong enough to prevent damage to surface.
Except if located on a structure, construct foundation for post, standard, and pedestal
monolithically.
Apply ordinary surface finish as specified in Section 51-1.18A, "Ordinary Surface Finish."

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If a foundation must be extended for additional depth, the extension work will be paid for as
extra work as specified in Section 4-1.03D, "Extra Work."
Do not erect post, pole, standard, pedestal, or cabinet until the foundation is set for a minimum
of 7 days.
The Engineer will choose the plumbing or raking technique for posts, standards, and pedestals.
Plumb or rake by adjusting the leveling nuts before tightening nuts. Do not use shims or similar
devices. After final adjustments of both top nuts and leveling nuts on anchorage assemblies
have been made, and each post, standard, and pedestal on structure is properly positioned,
tighten nuts as follows:

1. Tighten leveling nuts and top nuts, following a crisscross pattern, until bearing surfaces
of all nuts, washers, and base plates are in firm contact.
2. Use an indelible marker to mark the top nuts and base plate with lines showing relative
alignment of the nut to the base plate.
3. Tighten top nuts, following a crisscross pattern, an additional 1/6th of a turn.

In unpaved areas, construct a raised PCC pad in front of each controller cabinet.
Completely remove foundations not to be reused or abandoned.
If abandoning a foundation, remove the top of foundation, anchor bolts, and conduits to a
minimum depth of 0.5 foot below sidewalk surface or original ground. Backfill the resulting hole
with material equivalent to the surrounding material.

86-2.04 STANDARDS, STEEL PEDESTALS AND POSTS

Bolts, including anchor bolts, nuts, and washers for signal and lighting support structures must
comply with Section 55-2, "Materials." Except for bearing-type connection or slip-base, high-
strength bolted connection must comply with Section 55-3.14, "Bolted Connections." Welding,
nondestructive testing of welds, and acceptance and repair criteria for steel member
nondestructive testing must comply with American Welding Society (AWS) D1.1.
Using stainless steel rivets, attach rectangular corrosion-resistant metal identification tag on all
standards and poles, except Type 1:

1. Above the hand hole, near the base of standards and poles
2. On the underside of mast arms near the arm plate

The lettering on each identification tag must be depressed or raised, 1/4 inch tall, legible, and
include the following information:

1. Name of the manufacturer

2. Date of manufacture
3. Identification number
4. Contract number
5. Unique identification code that is:

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5.1. Assigned by the manufacturer

5.2. Traceable to a particular contract and the welds on that component
5.3. Readable after the support structure is coated and installed

Type 1 standard and steel pedestal for controller cabinet must be manufactured of one of the
following:

1. 0.12-inch or thicker galvanized steel

2. 4-inch standard weight galvanized steel pipe as specified in ASTM A 53
3. 4-inch Type 1 conduit with the top designed for post-top slip-fitter

Ferrous metal parts of a standard that has a shaft length of 15 feet or longer must comply with
the provisions in Section 55-2, "Materials," and the following:

1. Standard must be manufactured from sheet steel of weldable grade having a minimum
yield strength of 40,000 psi after manufacturing.
2. Certified test report verifying compliance with minimum yield strength requirements
must be submitted. Test report may be the mill test report for the as-received steel or if
the as-received steel has a lower yield strength than required you must provide test data
assuring that your method of cold forming will consistently increase the tensile properties
of the steel to meet the specified minimum yield strength. Test data must include tensile
properties of the steel after cold forming for specific heats and thicknesses.
3. If a single-ply 5/16-inch thick pole is specified, a 2-ply pole with equivalent section
modulus may be substituted.
4. Standard may be manufactured of full-length sheets or shorter sections. Each section
must be manufactured from 1 or 2 pieces of sheet steel. If 2 pieces are used, the
longitudinal welded seams must be directly opposite from one another. If the sections are
butt-welded together, the longitudinal welded seams of adjacent sections must be placed
to form continuous straight seams from base to top of standard.
5. Butt-welded circumferential joints of tubular sections requiring CJP groove welds must
be made using a metal sleeve backing ring inside each joint. The sleeve must be 1/8 inch
nominal thickness, or thicker, and manufactured from steel having the same chemical
composition as the steel in the tubular sections to be joined. If the sections to be joined
have different specified minimum yield strengths, the steel in the sleeve must have the
same chemical composition as the tubular section having the higher minimum yield
strength. The width of the metal sleeve must be consistent with the type of
nondestructive testing selected and must be a minimum width of 1 inch. At fitting time,
the sleeve must be centered at the joint and in contact with the tubular section at the point
of the weld.
6. Welds must be continuous.
7. Weld metal at the transverse joint must extend to the sleeve, making the sleeve an
integral part of the joint.

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8. During manufacturing, longitudinal seams on vertical tubular members of cantilevered

support structures must be centered on and along the side of the pole that the pole plate is
located. Longitudinal seams on horizontal tubular members, including signal and
luminaire arms, must be within ±45 degrees of the bottom of the arm.
9. Longitudinal seam weld in steel tubular section may be made by the electric resistance
welding process.
10. Longitudinal seam weld must have 60 percent minimum penetration, except:

10.1. Within 6 inches of circumferential weld, longitudinal seam weld must be CJP
groove weld.
10.2. Longitudinal seam weld on lighting support structure having telescopic pole
segment splice must be CJP groove weld on the female end for a length on each end
equal to the designated slip-fit splice length plus 6 inches.

11. Exposed circumferential weld, except fillet and fatigue-resistant weld, must be ground
flush with the base metal before galvanizing or painting. Ground flush is specified as -0,
+0.08-inch.
12. Circumferential weld and base plate-to-pole weld may be repaired only one time.
13. Exposed edges of the plates that make up the base assembly must be finished smooth and
exposed corners of the plates must be broken. Provide shafts with slip-fitter shaft caps.
14. Surface flatness requirements of ASTM A 6 apply to plates:

14.1. In contact with concrete, grout, or washers and leveling nuts

14.2. In high-strength bolted connections
14.3. In joints, where cap screws are used to secure luminaire and signal arms
14.4. Used for breakaway slip-base assemblies

15. Standard must be straight with a maximum variation of:

15.1. 1 inch measured at the midpoint of a 30-foot to 35-foot standard

15.2. 3/4 inch measured at the midpoint of a 17-foot to 20-foot standard
15.3. 1 inch measured 15 feet above the base plate for Type 35 and Type 36 standards

16. Zinc-coated nuts used on fastener assemblies having a specified preload obtained by
specifying a prescribed tension, torque value, or degree of turn must be provided with a
colored lubricant, clean and dry to the touch. The lubricant color must contrast the zinc
coating color on the nut so the presence of the lubricant is visually obvious. Lubricant
must be insoluble in water or the fastener components must be shipped to the job site in a
sealed container.
17. Do not make additional holes in structural members.
18. Standard with an outside diameter of 12 inches or less must be round. Standard with an
outside diameter greater than 12 inches must be round or multisided. Multisided standard
must be convex with a minimum of 12 sides and have a minimum bend radius of 4
inches.
19. Manufacture mast arm from material specified for standard.

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20. Manufacture cast steel option for slip base from material of Grade 70-40, as specified in
ASTM A 27/A 27M. Other comparable material may be used if approved by the
Engineer. The casting tolerances must comply with the Steel Founders' Society of
America's recommendations for green sand molding.
21. One casting from each lot of a maximum of 50 castings must be radiographed as
specified in ASTM E 94. Casting must comply with the acceptance criteria for severity
level 3 or better for the types and categories of discontinuities in ASTM E 186 and E 446.
If the casting fails the inspection, 2 additional castings must be radiographed. If the 2
additional castings fail the inspection, the entire lot will be rejected.
22. Material certification, consisting of physical and chemical properties, and radiographic
film of the casting must be filed at the manufacturer's office. Certification and film must
be available for inspection.
23. High-strength bolts, nuts, and flat washers used to connect slip-base plate must comply
with ASTM A 325 or A 325M and be galvanized as specified in Section 75-1.05,
"Galvanizing."
24. Plate washers must be manufactured by saw cutting and drilling steel plate. Steel plate
must comply with AISI 1018 and be galvanized as specified in Section 75-1.05,
"Galvanizing." Before galvanizing, remove burrs and sharp edges and chamfer both
sides of holes to allow the bolt head to make full contact with the washer without tension.
25. High-strength cap screws for attaching arms to standards must comply with ASTM A
325, A 325M, or A 449, and the mechanical requirements in ASTM A 325 or A 325M
after galvanizing. Cap screws must be galvanized as specified in Section 75-1.05,
"Galvanizing." Coat threads of cap screws with a colored lubricant, clean and dry to the
touch. Lubricant color must contrast the zinc-coating color on the cap screw so the
presence of the lubricant is visually obvious. Lubricant must be insoluble in water or the
fastener components must be shipped to the job site in a sealed container.
26. Bolted connection attaching signal or luminaire arm to pole must be considered slip
critical. Galvanized faying surfaces of plates on luminaire, signal arm, and pole must be
roughened by hand using a wire brush before assembly and must comply with
requirements for Class C surface conditions for slip-critical connections in "Specification
for Structural Joints Using ASTM A 325 or A 490 Bolts," a specification approved by the
Research Council on Structural Connections (RCSC). Paint for faying surfaces must be
as specified in the RCSC specification for Class B coating.
27. The Engineer will randomly take samples of fastener components from each production
lot and submit to the Transportation Laboratory with test reports as specified in ASTM
fastener specifications for QA testing and evaluation. The Engineer will determine
sample sizes for each fastener component.

Change in mast arm configuration is allowed as long as the mounting height and stability are
maintained.
Before manufacturing, details must be adjusted to ensure that cap screw heads can be turned
using conventional installation tools. During manufacturing process, to avoid interference with
the cap screw heads, the position of the luminaire arm on the arm plate must be properly
located.
Configure mast arm as a smooth curving arm.

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Push button post, pedestrian barricade, and guard post must comply with ASTM A 53.
Assemble and tighten slip base when pole is on the ground. Threads of heavy hex nuts for
each slip-base bolt must be coated with additional lubricant that is clean and dry to the touch.
Tighten high strength slip-base bolts to within ±10 foot-pounds of the following:

Slip-Base Bolt-Tightening Requirements

Torque
Standard Type (foot-pounds)
15-SB 150
30 150
31 200
36-20A 165

Hole in shaft of existing standard, due to removal of equipment or mast arms, must be sealed by
fastening a galvanized steel disk to cover the hole. Fasten using a single central galvanized
steel fastener. Seal edges of disk and hole with polysulfide or polyurethane sealing compound
of Type S, Grade NS, Class 25, and Use O, as specified in ASTM C 920.
If existing standard is ordered to be relocated or reused, remove large dents, straighten shafts,
and replace parts that are in poor condition. You must furnish anchor bolts or bars and nuts
required for relocating or reusing standard. Repair and replacement work will be paid for as
extra work as specified in Section 4-1.03D, "Extra Work."
New nuts, bolts, cap screws, and washers must be provided if:

1. Standard or mast arm is relocated

2. Used standard or mast arm is State furnished

If the standard has a slip base, a new keeper plate must be provided.

86-2.05 CONDUIT
Run conductors in conduit except for overhead and where conductors are run inside poles.
You may use a larger size conduit than specified as long as you use it for the entire length
between outlets. Do not use reducing coupling.
New conduit must not pass through existing foundations for standards.

86-2.05A Material
Conduit and conduit fitting must be UL or ETL listed and comply with the following:

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Conduit and Conduit Fitting Requirements

Type 1 Hot-dip galvanized rigid steel conduit and conduit couplings must comply with
UL 6 and ANSI C80.1. Zinc coating testing must comply with copper sulfate test
requirements in UL 6. Conduit couplings for rigid steel conduit must be
electrogalvanized.
Type 2 Hot-dip galvanized rigid steel conduit must comply with requirements for Type
1conduit and be coated with polyvinyl chloride (PVC) or polyethylene. Exterior
thermoplastic coating must have a minimum thickness of 35 mils. Internal
coating must have a minimum thickness of 2 mils. Coated conduit must comply
with UL 6; NEMA RN 1; or ETL PVC-001.
Type 3 Rigid non-metallic conduit must comply with UL 651, UL 651A or UL 651B.
Install at underground locations only.
Type 4 Waterproof flexible metal conduit must consist of conduit with a waterproof non-
metallic sunlight-resistant jacket over an inner flexible metal core. Type4 conduit
must be UL listed for use as the grounding conductor.
Type 5 Intermediate steel conduit and conduit couplings must comply with UL 1242 and
ANSI C80.6. Zinc coating testing must comply with copper sulfate test
requirements in UL 1242. Conduit couplings for intermediate rigid steel conduit
must be electrogalvanized. Type 5 conduit must only be used if specified.

Bonding bushings to be installed on metal conduit must be insulated and either galvanized or
zinc alloy type.
Fittings for steel conduit and for watertight flexible metal conduit must be UL listed at UL 514B.

86-2.05B Use
Install Type 1 conduit on all exposed surfaces and at the following locations:

1. In concrete structures
2. Between a structure and nearest pull box

Exposed conduit installed on painted structure must be painted the same color as the structure.
Change or extend existing conduit runs using the same material. Install pull box if an
underground conduit changes from the metallic type to Type 3.
Minimum trade size of conduit must be:

1. 1-1/2 inches from electrolier to adjacent pull box

2. 1 inch from pedestrian push button post to adjacent pull box
3. 2 inches from signal standard to adjacent pull box
4. 3 inches from controller cabinet to adjacent pull box
5. 2 inches from overhead sign to adjacent pull box
6. 1-1/2 inches if unspecified

Two conduits must be installed between controller cabinet and adjacent pull box.

April 11,2011 4-206

86-2.05C Installation
Whether shop or field cut, ream ends of conduit to remove burrs and rough edges. Make cuts
square and true. Slip joints and running threads are not allowed for coupling conduit. If a
standard coupling cannot be used for coupling metal type conduit, use a threaded union
coupling that is UL or ETL listed. Tighten couplings for metal conduit to maintain a good
electrical connection through conduit run.
Cut Type 3 conduit with tools that will not deform the conduit. Use solvent weld for connections.
Cut Type 2 conduit with pipe cutters; do not use hacksaws. Coated conduit must be threaded
with standard conduit-threading dies. Tighten conduit into couplings or fittings using strap
wrenches or approved groove-joint pliers.
Protect shop-cut threads from corrosion as follows:

Shop-Cut Thread Protection

Steel conduit and ANSI C80.1
conduit couplings
Intermediate metal ANSI C80.6
conduit and conduit
couplings

Paint conduits as specified in Section 91, "Paint." Apply 2 coats of approved unthinned zinc-rich
primer of organic vehicle type. Do not use aerosol cans. Paint the following parts of conduits:

1. All exposed threads

2. Field-cut threads before installing conduit couplings to steel conduit
3. Damaged surfaces on metal conduit

Do not remove shop-installed conduit couplings.

Damaged Type 2 conduit or conduit coupling must be wrapped with at least 1 layer of 2 inch
wide, 20 mil minimum thickness PVC tape, as specified in ASTM D 1000, with a minimum tape
overlap of 1/2 inch. Before applying the tape, conduit or fitting must be cleaned and painted
with 1 coat of rubber-resin based adhesive as recommended by the tape manufacturer. You
may repair damaged spots in the thermoplastic coating by painting over with a brushing type
compound supplied by the conduit manufacturer instead of the tape wrap.
The ends of Types 1, 2, or 5 conduit must be threaded and capped with standard pipe caps until
wiring is started. The ends of Types 3 and 4 conduit must be capped until wiring is started. If
caps are removed, replace with conduit bushings. Fit insulated bonding bushings on the end of
metal conduit ending in pull box or foundation. Bell or end bushings for Type 3 conduit must be
non-metallic type.
Conduit bends, except factory bends, must have a radius of not less than 6 times the inside
diameter of the conduit. If factory bends are not used, bend the conduit without crimping or
flattening using the longest radius practicable. Bend conduits as follows:

April 11,2011 4-207

Conduit-Bending Requirements
Type 1 By methods recommended by the conduit manufacturer and with equipment
approved for the purpose.
Type 2 Use standard bending tool designed for use on thermoplastic coated conduit.
Conduit must be free of burrs and pits.
Type 3 By methods recommended by the conduit manufacturer and with equipment
approved for the purpose. Do not expose conduit to direct flame.
Type 4 --
Type 5 By methods recommended by the conduit manufacturer and with equipment
approved for the purpose.

Install pull tape in conduit that is to receive future conductors. The pull tape must be a flat
woven lubricated soft-fiber polyester tape with a minimum tensile strength of 1,800 pounds and
have printed sequential measurement markings every 3 feet. At least 2 feet of pull tape must be
doubled back into the conduit at each end.
Existing underground conduit to be incorporated into a new system must be cleaned with a
mandrel or cylindrical wire brush and blown out with compressed air.
Install conduit to a depth of not less than 30 inches below finished grade, except in sidewalk and
curbed paved median areas, where it must be at least 18 inches below grade. You may lay
conduit on existing pavement within new curbed median.
Conduit coupling must be a minimum of 6 inches from face of foundation.
Place a minimum of 2 inches of sand bedding in the trench before installing Type 2 or Type 3
conduit. Place a minimum of 4 inches of same material over conduit before placing additional
backfill material.
Obtain approval from the Engineer before disturbing pavement. If obstruction is encountered,
obtain approval from Engineer to cut small holes in the pavement to locate or remove
obstruction If jacking or drilling method is used, keep jacking or drilling pit 2 feet away from
edge of pavement. Pavement must not be weakened or subgrade softened from excess water
use.
Conduit used for drilling or jacking must be removed; install new conduit for completed work. If
a hole larger than the conduit is pre-drilled and you install conduit by hand or by method
recommended by the conduit manufacturer with equipment approved for purpose, you may
install Type 2 or Type 3 conduit under pavement.
If trenching in pavement method is specified, conduit installation under pavement that is not a
freeway lane or freeway to freeway connector ramp, must comply with the following:

1. Use Type 3 conduit. Place conduit under pavement in a trench approximately 2 inches
wider than the outside diameter of conduit, but not exceeding 6 inches in width. Trench
depth must not exceed the greater of 12 inches or conduit trade size plus 10 inches,
except that at pull boxes the trench may be hand dug to required depth. The top of the
installed conduit must be a minimum of 9 inches below finished grade.
2. Trenching installation must be completed before placing final pavement layer.
3. Cut pavement to be removed with a rock cutting excavator. Minimize shatter outside the
removal area.

April 11,2011 4-208

4. Place conduit in bottom of trench and backfill with minor concrete as specified in Section
90-10, "Minor Concrete.". Minor concrete must contain a minimum of 590 pounds of
cementitious material per cubic yard. If the trench is in asphalt concrete pavement and
pavement overlay is not placed, backfill the top 1-3/4-inch of trench with minor HMA.
5. Before spreading HMA, apply tack coat as specified in Section 39, "Hot Mix Asphalt."
6. Backfill trenches, except for the top 0.10 foot, by the end of each day. The top 0.10 foot
must be filled within 3 days after trenching.

Conduit installed beneath railroad tracks must be:

1. Type 1 or 2
2. 1-1/2-inch minimum diameter
3. Placed a minimum depth of 3 feet below bottom of tie

If jacking or drilling method is used, construct jacking pit to a minimum of 13 feet from the
centerline of track at the near side of jacking pit. Cover jacking pit with substantial planking if
left overnight.
Conduit ending in standard or pedestal must not extend more than 3 inches vertically above the
foundation and must be sloped toward the handhole opening. Conduit entering through the side
of non-metallic pull box must end inside the box within 2 inches of the wall and 2 inches above
the bottom and be sloped toward the top of box to facilitate pulling of conductors. Conduit
entering through the bottom of a pull box must end 2 inches above the bottom and be located
near the end walls to leave the major portion of the box clear. At outlet, conduit must enter from
the direction of the run.
Underground conduit runs, including under sidewalks, that are adjacent to gasoline service
stations or other underground gasoline or diesel storage, piping, or pumps and that lead to a
controller cabinet, circuit breaker panel, service, or enclosure where an arc may occur during
normal operations must be sealed if the conduit is within the limits specified in the NEC for
Class 1, Division 1. Use Type 1 or Type 2 conduit for these runs.
Conduit for future use in structures must be threaded and capped. Conduit leading to soffit,
wall, or other lights or fixtures below pull box grade must be sealed and made watertight, except
where conduit ends in a No. 9 or No. 9A pull box.
Support for conduit in or on wall or bridge superstructure must comply with the following:

1. Steel hangers, steel brackets, and other fittings must comply with Section 75-1.03,
"Miscellaneous Bridge Metal."
2. Construct precast concrete conduit cradles using minor concrete and commercial quality
welded wire fabric. Minor concrete must comply with Section 90-10, "Minor Concrete,"
and contain a minimum of 590 pounds of cementitious material per cubic yard.. The
cradles must be moist cured for a minimum of 3 days. Bond precast concrete cradles to
structure with epoxy adhesives specified in one of the following:

April 11,2011 4-209

2.1. Section 95-2.03, "Epoxy Resin Adhesive for Bonding New Concrete to Old
Concrete"
2.2. Section 95-2.04, "Rapid Set Epoxy Adhesive for Pavement Markers"
2.3. Section 95-2.05, "Standard Set Epoxy Adhesive for Pavement Markers"

3. Use pipe sleeve or form opening for conduit through bridge superstructure concrete.
Sleeve or opening through either prestressed member or conventionally reinforced
precast member must be:

3.1. Transverse to the member

3.2. Through the web
3.3. Not more than 3 inches maximum gross opening in concrete

4. Where conduits pass through the abutment concrete, wrap conduit with 2 layers of
asphalt-felt building paper securely taped or wired in place. Fill space around conduit
that runs through bridge abutment wall with mortar as specified in Section 51-1.135,
"Mortar," except the proportion of cementitious material to sand must be 1 to 3. Fill the
space around conduits that run through abutments after prestressing is completed.
5. Run surface-mounted conduit straight and true, horizontal or vertical on the wall, and
parallel to wall on ceiling or other similar surfaces. Support conduit at a maximum of 5-
foot intervals or closer where necessary to prevent vibration or unsightly deflection. The
supports must include galvanized malleable iron conduit clamps and clamp backs secured
with expansion anchorage devices as specified for concrete anchorage devices in Section
75-1.03, "Miscellaneous Bridge Metal." Threaded studs must be galvanized and be of the
largest diameter that will pass through the mounting hole in conduit clamp.
6. Where pull boxes are placed in conduit runs, conduit must be fitted with threaded
bushings and bonded.
7. Mark location of conduit end in structure, curb, or wall with a "Y" that is a minimum of 3
inches tall, directly above conduit.

86-2.05D Expansion Fittings

Install expansion fitting where the conduit crosses an expansion joint in structure. Each
expansion fitting for metal conduit must include a copper bonding jumper having the ampacity
specified in NEC.
Each expansion-deflection fitting for expansion joints of 1-1/2-inch movement rating must be
watertight and include a molded neoprene sleeve, a bonding jumper, and 2 silicon bronze or
zinc-plated iron hubs. Each fitting must allow a minimum of 3/4-inch expansion, contraction,
and lateral deflection.

86-2.06 PULL BOXES

You may use a larger standard size pull box than that shown on the plans or specified. Pull
box, cover, and extensions must be of the same material.

April 11,2011 4-210

86-2.06A Materials
Pull box, cover, and extension for installation in ground or sidewalk area must be precast
reinforced PCC or non-PCC material. Non-PCC material must:

1. Be fire resistant with a burn rate no greater than 0.3-inch per minute per 0.1 inch of
thickness when tested as specified in ASTM D 635
2. Show no significant change in physical properties with exposure to weather
3. Be dense, free of voids or porosity, and gray or brown in color

Non-PCC pull box must comply with the following:

1. Top dimensions must not exceed the bottom dimensions by more than 1 inch.
2. Extension must be attached to pull box to maintain the minimum combined depths.
3. Cover must not fail and must not deflect more than 1/4 inch when a vertical force of
1,500 pounds is applied through a 1/2" x 3" x 6" steel plate to a non-PCC cover on a pull
box. Center the steel plate on cover with its longitudinal axis coinciding with
longitudinal axis of cover.

Non-PCC pull boxes must be of sufficient rigidity that when a designated concentrated force is
applied perpendicularly to the midpoint of one of the long sides at the top while the opposite
long side is supported by a rigid surface, it must be possible to remove the cover without the
use of tools. The designated concentrated force must be 150 pounds for a No. 3-1/2 pull box
and must be 100 pounds for a No. 5 or No. 6 pull box.
If a transformer or other device must be placed in a non-metallic pull box, include recesses for
hanger.
Secure cover, except ceiling pull box cover, with 3/8-inch hold down bolts, cap screws, or studs,
washers, and brass stainless steel or other non-corroding-metal nut. Stainless steel hardware
must have an 18 percent or greater chromium content and an 8 percent or greater nickel
content.
Galvanize ferrous metal parts as specified in Section 75-1.05, "Galvanizing."
Traffic pull box must be provided with steel cover and special concrete footing. Steel cover
must have a embossed non-skid pattern.
Traffic pull box and cover must have a vertical proof-load strength of 25,000 pounds. Comply
with Federal Specification RR-F-621 and distribute the 25,000 pound load through a 9" x 9" x 2"
steel plate. You must be able to place the load anywhere on box and cover for 1 minute without
causing cracks or permanent deformations.
No. 3-1/2(T) and No. 5(T) traffic pull box must be reinforced with a galvanized Z bar welded
frame and cover similar to that shown on the plans for No. 6(T) pull box. Frame must be
anchored to box with 1/4" x 2-1/4" concrete anchors. Four concrete anchors must be included
for No. 3-1/2(T) pull box; one placed in each corner. Six concrete anchors for must be included
for No. 5(T) and No. 6(T) pull boxes; one placed in each corner and one near the middle of each
of the longer sides.

April 11,2011 4-211

Hold down screws must be 3/8 inch hex flange cap screws of Type 316 stainless steel. Nut
must be zinc plated carbon steel, vibration resistant, and have a wedge ramp at the root of the
thread. Nut must be spot welded to the underside or manufactured with galvanized Z bar pull
box frame.
Steel cover must be countersunk approximately 1/4 inch to accommodate bolt head. When
tightened, bolt head must not exceed more than 1/8 inch above the top of cover. A 1/4 inch
tapped hole and brass bonding screw must be included.
Concrete placed around and under traffic pull box must be minor concrete as specified in
Section 90-10, "Minor Concrete."

86-2.06B Cover Marking

Marking must be clearly defined, uniform in depth, and parallel to either the long or short sides
of cover.
Marking letters must be between 1 inch to 3 inch high.
Before galvanizing steel or cast iron cover, apply marking by one of the following methods:

1. Use cast iron strip at least 1/4-inch thick with letters raised a minimum of 1/16 inch.
Fasten strip to cover with 1/4 inch flathead stainless steel machine bolts and nuts. Peen
bolts after tightening.
2. Use sheet steel strip at least 0.027-inch thick with letters raised a minimum of 1/16 inch.
Fasten strip to cover by spot welding, tack welding, or brazing, with 1/4 inch stainless
steel rivets or 1/4 inch roundhead stainless steel machine bolts and nuts. Peen bolts after
tightening.
3. Bead weld the letters on cover so that letters are raised a minimum of 3/32 inch.

86-2.06C Installation and Use

Space pull boxes no more than 200 feet apart. You may install additional pull boxes to facilitate
the work.
Pull box in ground or sidewalk area must be installed as follows:

1. Embed bottom of pull box in crushed rock.

2. Place a layer of roofing paper on crushed rock.
3. Place mortar over layer of roofing paper. Mortar must be 0.50 inch to 1 inch thick and be
sloped toward the drain hole.
4. Make a 1-inch drain hole in center of pull box through mortar and roofing paper.
5. Place mortar between pull box and pull box extension, and around conduits.

Reconstruct sump of existing pull box if disturbed by your operations. Remove old grout and
replace with new if the sump was grouted.

April 11,2011 4-212

After installation of traffic pull box, install steel cover and keep bolted down when your activities
are not in progress at the pull box. When steel cover is placed for final time, cover and Z bar
frame must be cleaned of debris and securely tightened.

86-2.07 (BLANK)

86-2.08 CONDUCTORS AND CABLES

Conductor must be copper wire that complies with ASTM B 3 and B 8.
Wire size must comply with the following:

Wire Size Requirements

Conductor usage Requirement
In loop detector lead-in cable ASTM B 286
Everywhere except in loop American Wire Gage (AWG)a
detector lead-in cable
a
Except conductor diameter must not be less than 98 percent of
specified AWG diameter.

Single conductor and cable, except detector lead-in cable, must have clear, distinctive, and
permanent markings on the outer surface throughout its length. The markings must include the
manufacturer's name or trademark, insulation type letter designation, conductor size, voltage,
and temperature rating, and for cables, it must also include number of conductors.

86-2.08A Conductor Identification

Conductor insulation must be a solid color with a permanent stripe as specified below. The
solid color must be homogeneous through the full depth of insulation. Identification stripe must
be continuous throughout the length of conductor. For conductor sizes No. 2 and larger, the
insulation may be black and the ends of the conductors must be taped for a minimum length of
20 inches with electrical insulating tape of the required color.

April 11,2011 4-213

Conductor Identification
Identification
Insulation Colorj
Circuit Signal Phase or Function Base Stripea Band Symbolsf Size
2,6 Red, Yel, Brn Blk 2,6 14
4,8 Red, Yel, Brn Ora 4,8 14
Vehicle 1,5 Red, Yel, Brn None 1,5 14
Signalsa,b,d 3,7 Red, Yel, Brn Pur 3,7 14
Ramp Meter 1 Red, Yel, Brn None NBR 14
Ramp Meter 2 Red, Yel, Brn Blk NBR 14
2p,6p Red, Brn Blk 2p,6p 14
Pedestrian 4p,8p Red, Brn Ora 4p,8p 14
Signalsd 1p,5p Red, Brn None 1p,5p 14
3p,7p Red, Brn Pur 3p,7p 14
2p,6p Blu Blk P-2,P-6 14
Pedestrian Push 4p,8p Blu Ora P-4,P-8 14
Buttonsd 1p,5p Blu None P-1,P-5 14
3p,7p Blu Pur P-3,P-7 14
Ungrounded Circuit
Traffic Signal
Conductor Blk None CON-1 6
Controller
Grounded Circuit
Cabinet
Conductor Wht None CON-2 6
Highway Ungrounded-Line 1 Blk None NBR 14
Lighting Pull Ungrounded-Line 2 Red None NBR 14
Box to
Luminaire Grounded Wht None NBR 14
Multiple Ungrounded-Line 1 Blk None ML1 10
Highway
Lighting Ungrounded-Line 2 Red None ML2 10
Ungrounded to PEU Blk None C1 14
Lighting
Switching leg from PEU
Control
unit or SM transformer Red None C2 14
Ungrounded-Line 1
Multiple (Signals) Blk None NBRe 6
Service Ungrounded-Line 2
(Lighting) Redi None NBRe 8
Ungrounded-Line 1 Blk None SL-1 10
Sign Lightingh
Ungrounded-Line 2 Red None SL-2 10
Flashing Ungrounded between
Beaconsg Flasher and Beacons Red or Yel None F-Loc.c 14
Pedestrian Push Buttons Wht Blk NBR 14
Signals and Multiple
Lighting Wht None NBR 10
Grounded and
Flashing Beacons and
Common
Sign Lighting Wht None NBR 12
Lighting Control Wht None C-3 14
Multiple Service Wht None NBR 14
Railroad
Preemption Blk None R 14
Spares Blk None NBR 14

April 11,2011 4-214

NBR = No Band Required PEU=Photoelectric unit

a
On overlaps, insulation is striped for 1st phase in designation. e.g., phase (2+3) conductor is striped as for
phase 2.
b
Band for overlap and special phases as required.
c
Flashing beacons having separate service do not require banding.
d
These requirements do not apply to signal cable.
e
"S" if circuit is switched on line side of service equipment by utility.
f
Band conductors in each pull box and near ends of termination points. On signal light circuits, a single
band may be placed around 2 or 3 ungrounded conductors comprising a phase.
g
Ungrounded conductors between service switch and flasher mechanism must be black and banded.
h
Conductors between ballasts and sign lighting lamps must be No. 16 and color must correspond to the
ballast leads.
i
Black acceptable for size No. 2 and larger. Tape ends for 20 inches with indicated color.
j
Color Code: Yel-Yellow, Brn-Brown, Blu-Blue, Blk-Black, Wht-White, Ora-Orange, Pur-Purple.

86-2.08B Multiple Circuit Conductors

Conductor for multiple circuit must be UL or ETL listed and rated for 600 V(ac) operation.
Insulation for No. 14 to No. 4 conductors must be one of the following:

1. Type TW PVC as specified in ASTM D 2219

2. Type THW PVC
3. Type USE, RHH, or RHW cross-linked polyethylene

Minimum insulation thickness must comply with the following:

Insulation Thickness
Insulation Type Conductor Size Insulation Thickness
(mils)
No. 14 to No. 10 39
USE, RHH, or RHW
No. 8 to No. 2 51
No. 14 to No. 10 27
THW or TW No. 8 40
No. 6 to No. 2 54

Insulation for No. 2 and larger conductor must be one of the types listed above or Type THWN.
Conductor for wiring wall and soffit luminaire must be stranded copper with insulation rated for
use at temperatures up to 125 °C.

86-2.08C Signal Cable

Signal cable, except for the 28-conductor type, must:

1. Not be spliced
2. Be marked in each pull box with the signal standard information it is connecting to

Signal cable must comply with the following:

April 11,2011 4-215

1. Cable jacket must be:

1.1. Black polyethylene with an inner polyester binder sheath

1.2. Rated for 600 V(ac) and 75 °C

2. Filler material, if used, must be polyethylene material.

3. Conductor must be solid copper with Type THWN insulation as specified in Section 86-
2.08, "Conductors and Cables," and ASTM B 286. The minimum thickness of Type
THWN insulation must be 12 mils for conductor sizes No. 14 to No. 12 and 16 mils for
conductor size No. 10. The minimum thickness of nylon jacket must be 4 mils.

Conductor Signal Cable Requirements

Cable Jacket Maximum
Thickness Nominal
Conductor (mils) Outside
Cable Quantity and Average Minimum Diameter
Typea Type (inch) Conductor Color Code Remarks
blue/black, blue/orange, Use for pedestrian push
3CSC 3 - No. 14 44 36 0.40 white/black stripe buttons and spare
red, yellow, brown,
5CSC 5 - No. 14 44 36 0.50 black, white
No. 12 - white
No. 14 - red, yellow,
brown, black, and
red/black, yellow/black,
8 - No. 14 brown/black,
9CSC 1 - No. 12 60 48 0.65 white/black stripe
No. 12 - white
No. 14 - see "12CSC Use for vehicle signals,
Color Code and pedestrian signals,
11 - No. 14 Functional Connection" spares, and signal
12CSC 1 - No. 12 60 48 0.80 table common
Keep signal commons
in each cable separate
except at the signal
controller. Label each
No. 10 - white cable as "C1" or "C2" in
No. 14 - see "28CSC pull box. Use "C1" for
Color Code and signal phases 1, 2, 3,
27 - No. 14 Functional Connection" and 4. Use "C2" for
28CSC 1 - No. 10 80 64 0.90 table phases 5, 6, 7, and 8.
a
Conductor signal cable description starts with the number of conductors, followed by "CSC".
(e.g., a signal cable with 3 conductors is labeled "3CSC.")

April 11,2011 4-216

12CSC Color Code and Functional Connection

Color Code Termination Phase
Red Vehicle signal red 2, 4, 6, or 8
Yellow Vehicle signal yellow 2, 4, 6, or 8
Brown Vehicle signal green 2, 4, 6, or 8
Red/black stripe Vehicle signal red 1, 3, 5, or 7
Yellow/black stripe Vehicle signal yellow 1, 3, 5, or 7
Brown/black stripe Vehicle signal green 1, 3, 5, or 7
Black/red stripe Spare, or use as required for red or DONT WALK
Black/white stripe Spare, or use as required for yellow
Black Spare, or use as required for green or WALK
Red/white stripe Ped signal DONT WALK
Brown/white stripe Ped signal WALK

28CSC Color Code and Functional Connection

Color Code Termination Phase
Red/black stripe Vehicle signal red 2 or 6
Yellow/black stripe Vehicle signal yellow 2 or 6
Brown/black stripe Vehicle signal green 2 or 6
Red/orange stripe Vehicle signal red 4 or 8
Yellow/orange stripe Vehicle signal yellow 4 or 8
Brown/orange stripe Vehicle signal green 4 or 8
Red/silver stripe Vehicle signal red 1 or 5
Yellow/silver stripe Vehicle signal yellow 1 or 5
Brown/silver stripe Vehicle signal green 1 or 5
Red/purple stripe Vehicle signal red 3 or 7
Yellow/purple stripe Vehicle signal yellow 3 or 7
Brown/purple stripe Vehicle signal green 3 or 7
Red/2 black stripes Ped signal DONT WALK 2 or 6
Brown/2 black stripes Ped signal WALK 2 or 6
Red/2 orange stripes Ped signal DONT WALK 4 or 8
Brown/2 orange stripes Ped signal WALK 4 or 8
Red/2 silver stripes Overlap A, C red OLA, OLC
Brown/2 silver stripes Overlap A, C green OLA, OLC
Red/2 purple stripes Overlap B, D red OLB, OLD
Brown/2 purple stripes Overlap B, D green OLB, OLD
Blue/black stripe Ped push button 2 or 6
Blue/orange stripe Ped push button 4 or 8
Blue/silver stripe Overlap A, C yellow OLA(y), OLC(y)
Blue/purple stripe Overlap B, D yellow OLB(y), OLD(y)
White/black stripe Ped push button common
Black/red stripe Railroad preemption
Black Spare

86-2.08D Signal Interconnect Cable (SIC)

Signal interconnect cable must be a 3-pair or 6-pair type with stranded tinned copper No. 20
conductors. Each conductor insulation must be 13 mils minimum nominal thickness, color-
coded, polypropylene material. Conductors must be in twisted pairs. Color coding distinguishes
each pair. Each pair must be wrapped with an aluminum polyester shield and must have a No.
22 or larger stranded tinned copper drain wire inside the shielded pair.

April 11,2011 4-217

Cable jacket must be black, high density polyethylene, rated for a minimum of 300 V(ac) and
60 °C, and must have a minimum nominal wall thickness of 40 mils. Cable jacket or moisture-
resistant tape directly under the outer jacket must be marked as specified in Section 86-2.08.
You must have a minimum of 6 feet of slack at each controller cabinet. Splicing is allowed only
if shown on the plans.
Insulate conductor splice with heat-shrink tubing and overlap at least 0.6 inch. Cover overall
cable splice with heat-shrink tubing and overlap the cable jacket at least 1-1/2 inch.

86-2.09 WIRING
Run conductors in conduit, except for overhead and temporary installations and where
conductors are run inside poles.
Solder by hot iron, pouring, or dipping method, connectors and terminal lugs for conductor sizes
No. 8 and smaller. Do not perform open-flame soldering.

86-2.09A Circuitry
Do not run traffic signal indication conductors to a terminal block on a standard unless
connected to a mounted signal head.
Use only 1 conductor to connect to each terminal of a pedestrian push button.
The common for pedestrian push button circuit must be separate from traffic signal circuit
grounded conductor.

86-2.09B Installation
Use a UL- or ETL-listed inert lubricant for placing conductors in conduit.
Pull conductors into conduit by hand using pull tape specified in Section 86-2.05C, "Installation."
Do not use winches or other power-actuated pulling equipment.
If adding new conductors or removing existing conductors, remove all conductors, clean conduit
as specified in Section 86-2.05C, "Installation," and pull all conductors in conduit as 1 unit.
If traffic signal conductors are run in lighting standard containing street lighting conductors from
a different service point, you must encase the traffic signal conductors or the lighting conductors
with a flexible or rigid metal conduit for a length until the 2 types of conductors are no longer in
the same raceway.
If less than 10 feet above grade, enclose temporary conductors in flexible or rigid metal conduit.
Leave slack for each conductor as follows:

April 11,2011 4-218

Conductor Slack Requirements

Slack
Location (feet)
Signal standard 1
Lighting standard 1
Signal and lighting standard 1
Pull box 3
Splice 3
Standards with slip base 0

After conductors are installed, seal ends of conduits with an approved sealing compound.
To form a watertight seal, tape ends of spare conductors and conductors ending in pull boxes.
Conductors and cables inside fixture or cabinet must be neatly arranged and tied together by
function with self-clinching nylon cable ties or enclosed in plastic tubing or raceway.
Identify conductors for:

1. Signal overlap phase as specified for vehicle signals in the table titled "Conductor
Identification."
2. Metered and unmetered conductors occupying the same pull box. Identify unmetered
circuit conductors with "UNMETERED-STREET LTG," or "UNMETERED-COUNT
STATION."

Permanently identify conductors by function. Place identification on each conductor, or each

group of conductors forming a signal phase, at each pull box and near the end of conductors.
Label, tag, or band conductors by mechanical methods. Identification must not move along the
conductors.

86-2.09C Connectors and Terminals

Connectors and terminals must be UL- or ETL-listed crimp type. Use manufacturer-
recommended tool for connectors and terminals to join conductors. Comply with MIL-T-7928.
Terminate stranded conductors smaller than No. 14 in crimp style terminal lugs.

86-2.09D Splicing and Terminations

Splices are allowed for:

1. Grounded conductors in pull box.

2. Pedestrian push button conductors in pull box.
3. Conductors in pull box adjacent to each electrolier or luminaire.
4. Ungrounded traffic signal conductors in pull box, if traffic signals are modified.
5. Ungrounded traffic signal conductors to a terminal compartment or signal head on a
standard with conductors of the same phase in the pull box adjacent to the standard.

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6. Ungrounded lighting circuit conductors in pull box, if lighting circuits are modified.

86-2.09E Splice Insulation

Splice must function under continuous submersion in water.
Multi-conductor cable must be spliced and insulated to form a watertight joint and to prevent
moisture absorption by the cable.
Low-voltage tape must be:

1. UL or ETL listed
2. Self-fusing, oil and flame-resistant, synthetic rubber
3. PVC, pressure-sensitive adhesive of 6 mils minimum thickness

Insulating pad must be a combination of an 80-mils thick electrical grade PVC laminate and a
120-mils thick butyl splicing compound with removable liner.
Heat-shrink tubing must comply with the following:

1. Be medium or heavy wall thickness, irradiated polyolefin tubing with an adhesive mastic
inner wall.
2. Before contraction, minimum wall thickness must be 40 mils.
3. Heating must be as recommended by the manufacturer. Do not perform open-flame
heating.
4. When heated, the inner wall must melt and fill crevices and interstices of the covered
object and the outer wall must shrink to form a waterproof insulation.
5. After contraction, each end of the heat-shrink tubing or the open end of end cap of heat-
shrink tubing must overlap the conductor insulation at least 1-1/2 inches. Coat ends and
seams with electrical insulation coating.
6. Comply with requirements for extruded insulated tubing at 600 V(ac) in UL Standard
468D and ANSI C119.1, and the following requirements:

Heat-Shrink Tubing Requirements

Shrinkage Ratio 33 percent, maximum, of supplied diameter when
heated to 125 °C and allowed to cool to 25 °C
Dielectric Strength 350 kV per inch, minimum
Resistivity 2513 Ω per inch, minimum
Tensile Strength 2,000 psi, minimum
Operating Temperature -40 °C to 90 °C (135 °C in emergency)
Water Absorption 0.5 percent, maximum

7. If 3 or more conductors are to be enclosed in 1 splice, place mastic around each

conductor before placing inside tubing. Use mastic type recommended by heat-shrink
tubing manufacturer.

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You may use "Method B" as an alternative method for splice insulation. Use at least 2
thicknesses of electrical insulating pad. Apply pad to splice as recommended by manufacturer.

86-2.095 FUSED SPLICE CONNECTORS

Install a fused disconnect splice connector in each ungrounded conductor, between the line and
the ballast, in the pull box adjacent to each luminaire. Connector must be accessible in the pull
box.
For 240 and 480 V(ac) circuits, each connector must simultaneously disconnect both
ungrounded conductors. Connector must not have exposed metal parts, except for the head of
stainless steel assembly screw. Recess head of stainless steel assembly screw a minimum of
1/32 inch below top of plastic boss that surrounds the head.
Splice connector must protect fuse from water or weather damage. Contact between fuse and
fuseholder must be spring loaded. Splice connector terminals must be:

1. Rigidly crimped, using a tool recommended by manufacturer of fused splice connector,

onto ungrounded conductors
2. Insulated
3. Watertight

Fuses must be standard midget ferrule type, with "Non-Time-Delay" feature, and 13/32" x 1-
1/2".

86-2.10 BONDING AND GROUNDING

Secure all metallic components, mechanically and electrically, to form a continuous system that
is effectively grounded.
Bonding jumper must be copper wire or copper braid of the same cross sectional area as a No.
8 or larger to match the load. Equipment grounding conductors must be color coded as
specified in NEC or be bare.
Attach bonding jumper to standard as follows:

Bonding Jumper Attachment

Standard type Requirements
Standard with handhole Use UL-listed lug and 3/16-inch diameter or larger brass or
and traffic pull box lid bronze bolt. Run jumper to conduit or bonding wire in
cover adjacent pull box. Grounding jumper must be visible after the
standard is installed and mortar pad is placed on foundation.
Standard without Use UL-listed ground clamp on each anchor bolt.
handhole
Slip-base standard Use UL-listed ground clamp on each anchor bolt or attach UL-
listed lug to bottom slip-base plate with 3/16-inch diameter or
larger brass or bronze bolt.

Ground one side of secondary circuit of step-down transformer.

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Ground metal conduit, service equipment, and grounded conductor at service point as specified
by NEC and service utility, except grounding electrode conductor must be No. 6 or larger.
Equipment bonding and grounding conductors are required in conduit. Run a No. 8 minimum
bare copper wire continuously in conduit system. The bonding wire must be sized as specified
in the NEC.
Ground electrode must be:

1. 1 piece
2. 10-foot minimum length of one of the following:

2.1. Galvanized steel rod or pipe not less than 3/4 inch in diameter
2.2. Copper clad steel rod not less than 5/8 inch in diameter

3. Installed as specified in NEC

4. Bonded to service equipment using one of the following:

4.1. Ground clamp

4.2. Exothermic weld
4.3. No. 6 or larger copper conductor

On wood pole, metallic equipment mounted less than 8 feet above ground surface must be
grounded.
Bond metallic conduit in non-metallic pull box using bonding bushing or bonding jumper.
Bond metallic conduit in metal pull box using bonding bushings and bonding jumpers connected
to bonding wire running in the conduit system.

86-2.11 SERVICE
Electrical service installation and materials must comply with service utility requirements.
If service equipment is to be installed on utility-owned pole, you must furnish and install conduit,
conductors, and other necessary material to complete service installation. Service utility will
decide riser and equipment position.
Install service equipment early on to allow service utility to schedule its work before project
completion.
Furnish each service with a circuit breaker that simultaneously disconnects all ungrounded
service entrance conductors.
Circuit breakers must:

1. Be quick-break on either automatic or manual operation.

2. Have operating mechanism that is enclosed and trip-free from operating handle on
overload.
3. Be trip indicating.

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4. Have frame size plainly marked.

5. Have trip rating clearly marked on operating handle.
6. Have overload tripping of breakers not influenced by ambient temperature range of -
18 °C to 50 °C.
7. Be internal trip type.
8. Be UL or ETL listed and comply with UL 489 or equal.
9. Have minimum interrupting capacity of 10,000 A, rms, if used as service disconnect.

Service equipment enclosure must be a NEMA 3R enclosure with dead-front panel and a hasp
with a 7/16-inch hole for a padlock. Enclosure must be field marked as specified in the NEC to
warn qualified persons of potential electric arc flash hazards.
Service equipment enclosure, except Types II and III, must be galvanized or have a factory-
applied rust-resistant prime coat and finish coat.
Types II and III service equipment enclosures must be manufactured from one of the following:

1. Galvanized sheet steel

2. Sheet steel plated with zinc or cadmium after manufacturing
3. Aluminum

Manufacture service equipment enclosure as specified in Section 86-3.04A, "Cabinet

Construction." Overlapping exterior seams and doors must comply with requirements for NEMA
3R enclosures in the NEMA Enclosure Standards.
If an alternative design is proposed for Type II or III service equipment enclosure, submit plans
and shop drawings to the Engineer for approval before manufacturing.
Except for falsework lighting and power for your activities, when you submit a written request,
the Engineer will arrange:

1. With the service utility to complete service connections for permanent installations and
the Department will pay all costs and fees required by the service utility. Submit request
at least 15 days before service connections are required.
2. For furnishing electrical energy. Energy used before contract completion will be charged
to you, except cost of energy used for public benefit as ordered by the Engineer will be
paid by the Department or local authorities.

Full compensation for furnishing and installing State-owned or permanent service poles, service
equipment, conduit, conductors, and pull boxes, including equipment, conduit, and conductors
placed on utility-owned poles, is included in the contract item of electrical work involved and no
additional compensation will be allowed therefor.
If the service point is indeterminate and is shown on the plans as "approximate location" or
"service point not yet established," the labor and materials required for making the connection
between the service point, when established, and the nearest pull box shown on the plans will
be paid for as extra work as specified in Section 4-1.03D, "Extra Work."

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86-2.12 WOOD POLES

Wood poles must comply with the following:

1. Class 5 or larger as specified in ANSI O 5.1

2. Less than 180-degree twist in grain over the full length
3. 4-inch or less sweep
4. Beveled top
5. Placed in ground at least 6 feet
6. Length must be:

6.1. 25 feet for service pole

6.2. 35 feet for other

After each pole is set in ground, backfill space around pole with selected earth or sand, free of
rocks and other deleterious material, placed in 4-inch thick layers. Moisten each layer and
thoroughly compact.
Manufacture mast arm from standard pipe, free from burrs. Each mast arm must have an
insulated wire inlet and wood pole mounting brackets for mast arm and tie-rod cross arm.
Manufacture tie rod from structural steel and pipe.
Mount mast arm for luminaire to provide a 34-foot mounting height for a 200 W high pressure
sodium luminaire and 40-foot mounting height for 310 W high pressure sodium luminaire.
Traffic signals and flashing beacons on mast arm must provide a minimum vertical clearance of
17 feet from bottom of equipment to pavement.
After manufacturing, pressure-treat pole as specified in Section 58, "Preservative Treatment of
Lumber, Timber and Piling," and AWPA Use Category System: UC4B, Commodity
Specification D.
If specified, treat pole with waterborne wood preservative.

86-2.13 LIGHTING AND SIGN ILLUMINATION CONTROL

Enclosure for the circuit breaker for lighting and sign illumination control must:

1. Be NEMA 3R
2. Be galvanized, cadmium plated, or powder-coated
3. Include dead front panel and a hasp with a 7/16 inch diameter hole for padlock

86-2.14 TESTING

86-2.14A Materials Testing

Deliver material and equipment to be tested to either the Transportation Laboratory or a testing
location ordered by the Engineer.

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Allow 30 days for acceptance testing from the time material or equipment is delivered to test
site. You must pay for all shipping, handling, and related transportation costs associated with
testing. If equipment is rejected, you must allow 30 days for retesting. Retesting period starts
when corrected equipment is delivered to test site. You must pay for all retesting costs. Delays
resulting from submittal of non-compliant materials do not relieve you from executing the
contract within the allotted time.
If equipment submitted for testing does not comply with specifications, remove the equipment
within 5 business days after notification that the equipment is rejected. If equipment is not
removed within that period, it may be shipped to you at your expense.
When testing is complete, you will be notified. You must pick up the equipment at the test site
and deliver it to the job site.
Testing and quality control procedures for all other traffic signal controller assemblies must
comply with NEMA TS Standards for Traffic Control Systems.

86-2.14B Field Testing

Before starting functional testing, perform the following tests in the presence of the Engineer:

86-2.14B(1) Continuity
Test each circuit for continuity.

86-2.14B(2) Ground
Test each circuit for grounds.

86-2.14B(3) Insulation Resistance

Perform insulation resistance test at 500 V(dc) on each circuit between the circuit and a ground.
Insulation resistance must be 10 MΩ minimum on all circuits, except for inductive loop detector
circuits that must have an insulation resistance value at least 100 MΩ.

86-2.14C Functional Testing

Test periods must comply with Section 86-1.07, "Scheduling of Work."
Acceptance of new or modified traffic signal will be made only after all traffic signal circuits have
been thoroughly tested.
Perform functional test to show that each part of the system functions as specified.
Functional test for each new or modified system must include at least 5 business days of
continuous, satisfactory operation. If unsatisfactory performance of the system occurs, the
condition must be corrected and the system retested until the 5 business days of continuous,
satisfactory operation is obtained.
Except for new or modified parts of existing lighting circuit and sign illumination system, the
State or local agency will maintain the system during test period and pay the electrical energy
cost. Except for electrical energy, you must pay the cost of necessary maintenance performed

April 11,2011 4-225

by the State or local agency on new circuits or on the portions of existing circuits modified under
the contract.
Shutdown of electrical system caused by traffic from a power interruption or from unsatisfactory
performance of State-furnished materials does not constitute discontinuity of the functional test.

86-2.15 GALVANIZING
Galvanize as specified in Section 75-1.05, "Galvanizing." Cabinet material may be galvanized
before manufacturing as specified in ASTM A 653/653M, Coating Designation G 90.
Steel pipe standard and pipe mast arm must be hot-dip galvanized after manufacturing and
must comply with Section 75-1.05, "Galvanizing." . Remove spikes from galvanized surfaces.
A minimum of 10 inches of upper end of anchor bolts, anchor bars or studs, and nuts and
washers must be galvanized as specified in Section 75-1.05, "Galvanizing."
After galvanizing, bolt threads must accept galvanized standard nuts without requiring tools or
causing removal of protective coatings.
Galvanizing existing materials in an electrical installation will not be required.

86-2.16 PAINTING
Paint electrical equipment and material as specified in Section 59, "Painting," and the following:

1. Use paint material specified in Section 91, "Paint."

2. Factory or shop cleaning methods for metals are acceptable if equal to the methods
specified.
3. Instead of temperature and seasonal restrictions for painting as specified in Section 59,
"Painting," paint may be applied to equipment and materials for electrical installations if
ordered by the Engineer.
4. Ungalvanized ferrous surface to be painted must be cleaned before applying prime coat.
Blast cleaning is not required.
5. If an approved prime coat is applied by manufacturer, and in good condition, the 1st
primer application is not required.
6. Existing equipment to be painted in the field, including State-furnished equipment, must
be washed with a stiff bristle brush using a solution of water containing 2 tablespoons of
heavy duty detergent powder per gallon. After rinsing, surface must be wire-brushed
with a coarse, cup-shaped, power-driven brush to remove badly bonded paint, rust, scale,
corrosion, grease, or dirt. Dust or residue remaining after wire brushing must be removed
before priming.
7. Do not paint galvanized metal guard post, galvanized equipment, State-furnished
controller cabinet, and wood poles for traffic signal or flashing beacon.
8. New galvanized metal surface to be painted in the field must be cleaned as specified for
existing equipment before applying the prime coat. Do not wire brush new galvanized
surface.
9. After erection, examine exterior surface for damaged primer, clean, and spot coat with
primer.

April 11,2011 4-226

10. Paint Types II and III steel service equipment enclosures with a polymeric or an enamel
coating system matching Color No. 14672, light green, of Federal Standard 595B.
Coating must be commercially smooth and free of flow lines, paint washout, streaks,
blisters, and other defects that would impair serviceability or detract from general
appearance. Coating must comply with the following:

10.1. Coating hardness - Finish must have pencil lead hardness of HB, minimum, using
an Eagle Turquoise pencil.
10.2. Salt spray resistance - Undercutting coating system's film must not exceed 1/8-inch
average, from lines scored diagonally and deep enough to expose the base metal,
after 336 hours of exposure in a salt spray cabinet complying with ASTM B 117.
10.3. Adherence - Must not have coating loss when tested as specified in California Test
645. Perform testing by applying coating to 4" x 8" x 0.024" test specimens of the
same material as the cabinet, using the same application method.

11. Finish interior of metal signal visor, louver, and front face of back plates with 2
applications of lusterless black exterior grade latex paint formulated for application to
properly prepared metal surface. Good condition factory finish will be acceptable.
12. Finish metal signal section, signal head mounting, brackets and fittings, outside of visor,
pedestrian push button housing, pedestrian signal section and visor, and back face of back
plate with 2 applications of lusterless black or dark olive green exterior grade latex paint
formulated for application to properly prepared metal surface. Match dark olive green
color to Color Chip No. 68 filed at the Transportation Laboratory.
13. Prepare and finish conduit and conduit fitting above ground the same as adjacent standard
or post.
14. Relocated, reset or modified equipment previously finished as specified in this section,
except for previously-finished galvanized standard with traffic signal yellow enamel,
must be given a spot finishing application on newly primed areas and 1 finishing
application over the entire surface. If signal face or mounting brackets are required to be
painted under this section, all signal faces and mounting brackets on the same mounting
must be repainted.
15. Small rusted or repaired areas of relocated or reset galvanized equipment must be cleaned
and painted as specified in Section 75-1.05, "Galvanizing," for repairing damaged
galvanized surfaces.
16. Stencil equipment number neatly on the standard or adjacent structure. Obtain number
from the Engineer.
17. Perform painting neatly. The Engineer reserves the right to require use of brushes if the
work performed by paint spraying machine is unsatisfactory.

86-3 CONTROLLER ASSEMBLIES

86-3.01 CONTROLLER ASSEMBLIES
A controller assembly houses a complete mechanism for controlling the operation of traffic
signals or other systems.

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Model 170 and Model 2070, specified as a Model 170/2070 controller assembly, includes a
Model 170, 170E or 2070 controller unit, a wired cabinet, and all auxiliary equipment required to
control the system.

86-3.02 (BLANK)

86-3.03 (BLANK)

86-3.04 CONTROLLER CABINETS

Controller cabinets for controller assemblies other than Model 170/2070 must comply with the
following:

86-3.04A Cabinet Construction

Cabinet must be rainproof and the top crowned 1/2 inch or slanted toward the back to prevent
standing water.
Cabinet and door must be manufactured from one of the following:

1. 0.073-inch minimum thickness cold-rolled steel with continuously-welded exterior seams

2. 0.073-inch minimum thickness stainless steel with overlapping exterior seams complying
with Type 4 enclosures of the NEMA Enclosure Standards
3. 0.125-inch minimum thickness aluminum with continuously-welded exterior seams

Exterior welds must be ground smooth and edges filed to a radius of at least 0.03 inch.
Cabinet manufactured from cold-rolled steel must comply with Section 86-2.16, "Painting," and
the following:

1. Cabinet manufactured from cold-rolled steel must be finished with a polymeric or an

enamel coating system conforming to Color No. 14672 of Federal Standard 595B.
2. Cabinet must not have coating loss when 2 test specimens, 4" x 8", of the same material
and coating as the cabinet are tested. Two 9-inch-diagonal scratches exposing bare metal
will be made on a specimen. Soak specimen in demineralized water for 192 hours.
Tightly affix a 1-inch wide strip of masking tape to the surface and remove with one
quick motion. Specimen showing evidence of blistering, softening, or peeling of paint or
coating from the base metal will be rejected. Testing must comply with California Test
645, except passing 180 Degree Bend Test is not required.
3. Metal must be prepared by the 3-step, iron phosphate conversion coating bonderizing
technique.
4. Inside walls, doors, and ceiling of the housing must be the same as the outside finish.

Cabinet manufactured from stainless steel must comply with the following:

April 11,2011 4-228

1. Use annealed or quarter-hard stainless steel that complies with ASTM A 666 for Type
304, Grades A or B.
2. Use gas tungsten arc welding (GTAW) process with bare stainless steel welding
electrodes. Electrodes must comply with AWS A5.9 for ER308 chromium-nickel bare
arc welding electrodes.
3. Procedures, welder, and welding operator must comply with requirements and practices
recommended in AWS C5.5.
4. Ground or brush exposed, exterior surfaces of stainless steel cabinet to a 25 to 50-
microinch finish using iron-free abrasives or stainless steel brushes.
5. After grinding or brushing, cabinet must not show rust discoloration when:

5.1. Exposed for 48 hours in a salt spray cabinet as specified in ASTM B 117
5.2. Exposed 24 hours in a tap water spray cabinet with the water temperature between
38 °C and 45 °C

6. After the test, cabinet showing rust discoloration anywhere on its surface will be rejected.
Rejected cabinets may be cleaned, passivated, and resubmitted for testing.

Cabinet manufactured from aluminum sheet must comply with ASTM B 209 or B 209M for 5052-
H32 aluminum sheet, and the following:

1. Use gas metal arc welding (GMAW) process with bare aluminum welding electrodes.
Electrodes must comply with AWS A5.10 for ER5356 aluminum alloy bare welding
electrodes.
2. Procedures, welder, and welding operator for welding must comply with requirements in
AWS B3.0, "Welding Procedure and Performance Qualification," and to practices
recommended in AWS C5.6.
3. Surface finish of each aluminum cabinet must comply with MIL-A-8625 for a Type II,
Class I coating, except anodic coating must have a minimum thickness of 0.0007 inch
and a minimum coating weight of 0.001 ounce per square inch. The anodic coating must
be sealed in a 5 percent aqueous solution of nickel acetate, pH 5.0 to 6.5, for 15 minutes
at 97 °C. Before applying anodic coating, clean and etch cabinets using the steps below:

3.1. Clean by immersing into inhibited alkaline cleaner, Oakite 61A, Diversey 909, or
equal, 6 to 8 ounces per gallon at 71 °C for 5 minutes.
3.2. Rinse in cold water.
3.3. Etch in solution of 1-1/2 ounce of sodium fluoride and 4 to 6 ounces of sodium
hydroxide per gallon of distilled water at 60 °C to 65 °C for 5 minutes.
3.4. Rinse in cold water.
3.5. Immerse in 50 percent by volume nitric acid solution at room temperature for 2
minutes.
3.6. Rinse in cold water.

April 11,2011 4-229

Cabinet must have:

1. Single front door with:

1.1. 44-inch maximum door width.

1.2. Lock, when closed and latched, that is locked.
1.3. Police panel mounted on door, equipped with a keyed lock and 2 police keys. Each
police key must have a shaft at least 1-3/4 inch in length.

2. Dust-tight gasketing on all door openings, permanently bonded to the metal. Mating
surface of the gasketing must be covered with silicone lubricant to prevent sticking.
3. Handle that:

3.1. Allows padlocking in closed position

3.2. Has a minimum length of 7 inches
3.3. Has a 5/8-inch, minimum, steel shank
3.4. Is manufactured of cast aluminum, or zinc-plated or cadmium-plated steel

4. Cabinet door frame with:

4.1. Latching mechanism that:

4.1.1. Holds tension on and forms a firm seal between door gasketing and frame.
4.1.2. Is a 3-point cabinet latch with nylon rollers that have a minimum diameter
of 3/4 inch and equipped with ball bearings.
4.1.3. Has a center catch and a pushrod made of zinc-plated or cadmium-plated
steel. Pushrod must be at least 1/4" x 3/4" and turned edgewise at outer
supports. Cadmium plating must comply with MIL-QQ-416. Zinc plating
must comply with MIL-QQ-325.

4.2. Hinging that:

4.2.1. Has 3-bolt butt hinges, each having a stainless steel fixed pin. Hinges must
be stainless steel or may be aluminum for aluminum cabinet.
4.2.2. Is bolted or welded to the cabinet. Hinge pins and bolts must not be
accessible when door is closed.
4.2.3. Has a catch to hold the door open at 90 degrees and 180 degrees, ± 10
degrees, if a door is larger than 22 inches in width or 6 square feet in area.
Catch must be at least 3/8-inch diameter, stainless steel plated rod capable
of holding door open at 90 degrees in a 60 mph wind at an angle
perpendicular to the plane of the door.

5. Lock that:

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5.1. Is solid brass, 6-pin tumbler, rim type

5.2. Has rectangular, spring-loaded bolts
5.3. Is left hand and rigidly mounted with stainless steel machine screws approximately
2 inches apart
5.4. Extends 1/8 to 3/8 inch beyond the outside surface of door

6. 2 keys that are removable in the locked and unlocked positions.

Submit alternative design details for review and approval before manufacturing cabinet.
Use metal shelves or brackets that will support controller unit and auxiliary equipment.
Machine screws and bolts must not protrude outside the cabinet wall.

86-3.04B Cabinet Ventilation

Each controller cabinet must have:

1. 8 screened, 1/2-inch diameter or larger, raintight vent holes, in lower side or bottom of
cabinet. You may use louvered vents with a permanent metal mesh or 4-ply woven
polypropylene air filter held firmly in place, instead.
2. Electric fan with ball or roller bearings and capacity of at least 100 cubic feet per minute.
Fan must be thermostatically controlled and manually adjustable to turn on between
32 °C and 65 °C with a differential of not more than 6 °C between automatic turn on and
turn off. Fan circuit must be fused at 125 percent of ampacity of installed fan motor.

Fan and cabinet vent holes must be positioned to direct bulk of airflow over controller unit or
through ventilating holes of controller unit.

86-3.04C Cabinet Wiring

Conductors used in controller cabinet wiring must:

1. Be neatly arranged and laced, or enclosed in plastic tubing or raceway.

2. End with properly sized captive or spring-spade terminal or be soldered to a through-
panel solder lug on the back side of the terminal block. Apply crimp-style connector with
proper tool to prevent opening of handle until crimp is completed.

Controller cabinet must have an equipment grounding conductor bus that is grounded to the
cabinet and connected to metal conduit system or other approved ground with a No. 8, or larger,
grounding conductor.
With all cabinet equipment in place and connected, resistance between grounded conductor
terminal bus and equipment grounding conductor bus must be 50 M Ω, minimum, when
measured with an applied voltage of 150 V(dc).

April 11,2011 4-231

If direct current is to be grounded, connect to equipment ground only.

Use two or more terminal blocks for field connection. Install field terminal within 22 inches from
front of cabinet and orient for screwdriver operation. Terminal must be a minimum of 5 inches
above foundation.
No more than 3 conductors per terminal are allowed. Two flat metal jumpers, straight or U
shaped, may be placed under terminal screw. At least 2 full threads of terminal screws must be
fully engaged when screw is tightened. Live parts must not extend beyond the barrier.

86-3.05 CABINET ACCESSORIES

86-3.05A Labels
Include permanently printed, engraved, or silk-screened label for equipment and removable
items of equipment.
Labeling must match cabinet wiring diagram. Label for shelf-mounted equipment must be on
shelf face below item. Label for wall-mounted equipment must be below item.

86-3.05B Convenience Receptacle

Mount convenience receptacle in a readily accessible location inside the cabinet.
Convenience receptacle must be a duplex, 3-prong, NEMA 5-15R grounding type outlet that
complies with UL Standard 943.

86-3.05C Surge Arrestor

Surge arrestor must reduce effects of power line voltage transients and have ratings as follows:

Surge Arrestor Requirements

Recurrent peak voltage 184 V(ac)
Energy rating, maximum 20 J
Power dissipation, average 0.85 W
Peak current for pulses less than 7 µs 1,250 A

Standby current must be 1 mA or less for 120 V(ac), 60 Hz sinusoidal input.

86-3.05D Terminal Blocks

Terminal block must be rated 600 V(ac), minimum, and have nickel-, silver-, or cadmium-plated
brass binder head screw terminal.
Heavy duty terminal block must be rated at 20 A and have 12 position with No. 10 x 5/16-inch
nickel-plated brass binder head screws and nickel-plated brass inserts. Each position must
have 2 screw-type terminals. Terminal block must be barrier type with shorting bars in each of
the 12 positions, and must have integral type marking strips.
Light duty terminal block must be rated at 5 A and have 12 positions with No. 6 x 1/8 inch binder
head screws. Each position must have 1 screw-type terminal.

April 11,2011 4-232

86-3.06 COMPONENTS
86-3.06A Toggle Switches
Toggle switch must

1. Have poles as required

2. Be rated at 200 percent of circuit current for circuits of 10 A or less and 125 percent of
circuit current for circuits over 10 A

86-3.06B Cartridge Fuses

Install cartridge fuse in panel-mounted fuseholder. Fuse type and rating must be as
recommended by the fuse manufacturer for protecting the load.

86-3.06C Circuit Breakers

Circuit breaker must comply with Section 86-2.11, "Service," except breaker must have a
minimum interrupting capacity of 5,000 A, rms.

86-3.06D Connectors
Use connector designed to interconnect various parts of circuit together and constructed for the
application involved. Design connector for positive connection of circuit and easy insertion and
removal of mating contacts. Connector must be permanently keyed to prevent improper
connection of circuit.
Connector, or device plugging into connector, must have positive connection to prevent a circuit
from breaking due to vibration, a pull on connecting cable, or similar disruptive force.

86-3.07 ACCESSORIES
Accessories must comply with the following:

86-3.07A Telephone Bridge

Telephone bridge must comply with the following:

86-3.07A(1) General Description

Dual 5-way active data bridge must include:

1. 4-wire transmission interconnection between a dedicated common port and 4 multiple

ports. Ports must be characterized by a balanced 600 Ω terminating impedance. The
module's active circuit must allow unused multiple ports to be left unterminated without
affecting the transmission response of ports in use.

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2. Splitter channel and combiner channel. Connect multiple inputs to a common output in
combiner channel. Connect common input to multiple outputs in splitter channel.
Splitter and combiner must be separate and independent, allowing operation in full-
duplex data transmission applications. Input, output, and line monitor jacks on front
panel of bridge must allow isolated-module, isolated-facility, and cross-bridge
measurement of transmission parameters in both, splitter and combiner channels.
3. Front-panel-accessible potentiometers with continuous adjustment of cross-bridge loss or
gain within -30 to -10 dB and -10 to +10 dB ranges. Select either range for each channel.
Adjusted level must be same for all cross-bridge port combinations so if the splitter-
channel potentiometer is set for +3 dB gain, all common-to-multiple-port paths in the
splitter channel must receive a +3 dB level increase.
4. Input voltage of -22 to -56 V(dc) at a maximum current of 60 mA.

Individually package each dual 5-way active bridge unit in housing. Circuitry must be solid
state, constructed on removable industry standard circuit boards with plug in edge connectors.
Test jack, edge connector, and external plug connector must be made of material suitable for
use in above stated environment without deterioration of electrical connection for useful life of
equipment. Physical size of case must not exceed 225 cubic inches and must be suitable for
mounting to frame of field cabinet. Use mounting holes to attach unit to one side of frame of
relay rack.
Include input and output ports for 5 full duplex telephone circuits with input and output ports
labeled as to function. Level control, or switches and level adjustment potentiometers, and input
and output level test jacks must provide external adjustments without removal of the housing.

86-3.07A(2) Application
Use dual 5-way active data bridge to interconnect 4-wire data modems to a common data
channel or link. At the distant end, terminate common data link into a computer that may time
sequentially poll outlying or remote data terminals. Use bridge for central transmission
arrangement, or "hubbing" network, to extend data transmission to outlying terminals.
To expand number of multiple ports of a 4-wire data hubbing network in a tandem bridge
arrangement, directly connect 1 multiple port in each channel of 1st bridge to common port of
the same channel of 2nd bridge to get a 4-wire data bridge with 1 common and 7 multiple ports.

86-3.07A(3) Circuit Description

Combiner channel of dual 5-way active data bridge must have a variable-gain-integrated-circuit
operational amplifier with an input summing circuit. Summing circuit must add transmission
energy from all multiple input ports at low-impedance summing point for input port isolation.
Connect amplifier output to transformer for balanced connection to facility.
Splitter channel must include a transformer-input, variable-gain, integrated-circuit operational
amplifier and power amplifier. Power transformer output must be very low impedance and drive
eight 300 Ω resistors to derive proper impedance at multiple output circuits and provide isolation
between output circuits.
Multiple ports in bridge splitter and combiner channels must be isolated, and balanced by output
transformer and matched precision resistors in each channel.

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86-3.07A(4) Electrical Requirements

Comply with following electrical requirements:

Electrical Requirements
Specification Requirement
Splitter channel loss or gain -30 to +10 dB usable range
Combiner channel loss or gain -30 to +10 dB usable range
Maximum output level (overload Splitter: +5 dBm
point) Combiner: +12 dBm
Level change with loading 1 dB max, 1 port to all ports loaded
Input port impedance Splitter (multiple ports): 600 Ω
balanced
Combiner (common port): 600 Ω
balanced
Output port impedance Splitter (multiple ports): 600 Ω
balanced
Combiner (common port): 600 Ω
balanced
Harmonic distortion Splitter: less than 1percent at +3 dBm
Combiner: less than 1 percent at +8
dBm
Noise 20 dBm max
Frequency response ±1 dB re 1,000 Hz level, 300 to 5,000
Hz
Delay distortion Less than 75 µs, 400 to 3,000 Hz
Cross-port coupling loss (crosstalk) Greater than 55 dB
Input power -22 to -56 V(dc), 60 mA max
Operating environment -7 °C to 54 °C, humidity to 95% (no
condensation)
Mounting 1 position

86-3.07A(5) Testing and Troubleshooting

You must have complete testing and troubleshooting instructions, circuit diagrams and pictorial
component location, and identification guides for each unit.

86-4 TRAFFIC SIGNAL FACES AND FITTINGS

86-4.01 VEHICLE SIGNAL FACES
Each vehicle signal face must:

1. Be adjustable and allow for 360-degree rotation about vertical axis

2. Comply with ITE publication ST-017B, "Vehicle Traffic Control Signal Heads"
3. Comply with California Test 604, except for arrow and "X" faces
4. Have 3 sections arranged vertically: red at top, yellow at center, and green at bottom
5. Be of the same manufacturer and material, if more than 1 is installed at an intersection,
except for programmed visibility type

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6. Be sealed with neoprene gasket at top opening

7. Be LED modules

86-4.01A Signal Sections

Each signal section must comply with the following:

1. Maximum height must be 10-1/4 inches for an 8-inch section and 14-3/4 inches for a 12-
inch section.
2. Housing must:

2.1. Be either die-cast or permanent mold-cast aluminum, or if specified, be structural

plastic.
2.2. Comply with ITE publication ST-017B if die-cast or permanent mold-cast
aluminum is used.
2.3. Have a 1-piece, hinged, square-shaped door designed to allow access for relamping
without the use of tools. Door must be secured to hold the door closed during
loading tests. Module or lens must be watertight and mounted in the door.

3. Hinge pins, door latching devices, and other exposed hardware must be Type 304 or 305
stainless steel. Interior screws and fittings must be stainless steel, or steel with a
corrosion resistant plating or coating.
4. Opening must be placed on top and bottom to receive 1-1/2-inch pipe. The 8-inch and
12-inch sections of an individual manufacturer must be capable of joining to form a
signal face in any combination. This interchangeability is not required between metal
and plastic sections.
5. Gaskets must be made of a material that is not affected if installed in a section with metal
or plastic housing that is continuously operated for 336 hours.

Structural failure is described as follows:

Signal Section Structural Failure

Signal Requirements Description of Structural Failure
Section Type
Metal California Test 666 Fracture within housing assembly or deflection of more than half
the lens diameter of signal section during wind load test
Plastic California Test 605 Fracture within housing assembly or deflection of more than 10
degrees in either the vertical or horizontal plane after wind load has
been removed from front of signal face, or deflection of more than
6 degrees in either the vertical or horizontal plane after wind load
has been removed from back of signal face

86-4.01A(1) Metal Signal Sections

Each metal signal section must have a metal visor. Metal signal faces requiring backplates
must have metal backplates.

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86-4.01A(2) Plastic Signal Sections

Housing must be molded in 1 piece, or fabricated from 2 or more pieces and joined into a single
piece. Plastic must have ultraviolet stability, be unaffected by lamp heat, and be self-
extinguishing. Housing and door must be colored throughout and be black, matching Color No.
17038, 27038, or 37038 of Federal Standard 595B.
Each face section must be joined to adjacent section by one of the following:

1. Minimum of 3 machine screws for 8-inch sections and 4 machine screws for 12-inch
sections, installed through holes near front and back of housing. Each screw must be a
No. 10 and have a nut, flat washer, and lock washer.
2. Two machine screws, each with a nut, flat washer, and lock washer, installed through
holes near the front of the housing, and a fastening through the 1-1/2-inch pipe opening.
Fastening must have 2 large flat washers to distribute the load around the pipe opening
and 3 carriage bolts, each with a nut and lock washer. Minimum screw size must be No.
10. Minimum carriage bolt size must be 1/4 inch.

Supporting section of each signal face supported only at top or bottom must have
reinforcement.
Reinforcement plate must be either sheet aluminum, galvanized steel, or cast aluminum. Each
plate must be a minimum of 0.11-inch thick and have a hole concentric with 1-1/2-inch pipe-
mounting hole in the housing. Place reinforcement plate as follows:

Reinforcement Plate Placement

Type of Reinforcement Plate Placement
Sheet aluminum Inside and outside of housing
Galvanized steel Inside of housing
Cast aluminum Outside of housing

Reinforcement plates placed outside of the housing must be finished to match signal housing
color and be designed to allow proper serrated coupling between signal face and mounting
hardware. Minimum of 3 No. 10 machine screws must be installed through holes in each plate
and matching holes in the housing. Each screw must have a round or binder head, a nut, and
lock washer.
If signal face is supported by a Type MAS side attachment slip-fitter inserted between 2
sections, place spacers between the 2 sections. Vertical dimension of spacers must allow
proper seating of serrations between the slip-fitter and the 2 sections. In addition to the
fastening through the large openings in housing, the 2 sections must join with at least 2 machine
screws through holes near the front of housing and the spacers, and through matching holes in
a reinforcing plate installed in housing. Machine screws must be No. 10 minimum size.
Spacers must be made of same material as signal housing.
If reinforcing webs are used to connect back of housing to top, bottom, and sides, reinforcing
plates are not required.

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Holes for machine screws must be either cast or drilled during signal section manufacturing.
Surround each hole with a 1/8-inch minimum width boss to allow contact between signal
sections about axis of hole.
Each plastic signal section must have a plastic or metal visor. Plastic signal faces requiring
backplates must have plastic backplates.
Serrated nylon washer must be inserted between each plastic signal section and metal
mounting assembly. Each washer must be between 3/16- and 1/4-inch thick. Serrations must
match those on signal section and mounting assembly.

86-4.01B Visors
Include removable visor with each signal section. Comply with ITE publication ST-017B. Visors
are classified by lens enclosure as full circle, tunnel or cap. Bottom opens for tunnel type and
both, bottom and lower sides open for cap type. Visors must be tunnel type.
Visor must have a downward tilt between 3 and 7 degrees with a length of:

1. 9-1/2-inch minimum for nominal 12-inch round lenses

2. 7 inch for nominal 8-inch round lenses

Metal visor must be formed from 0.050-inch, minimum thickness, aluminum alloy sheet.
Plastic visor must be either formed from sheet plastic or assembled from one or more injection,
rotational, or blow-molded plastic sections. Material must be of a black homogeneous color with
lusterless finish. Sections must be joined using thermal, chemical, or ultrasonic bonding, or with
aluminum rivets and washers permanently colored to match visor.
Secure each visor to its door and prevent removal or permanent deformation when wind load
specified in California Test 605 for plastic visors or 666 for metal visors is applied to its side for
24 hours.
If directional louvers are used, fit louvers snuggly into full-circular signal visors. Outside cylinder
must be constructed of 0.030-inch nominal thickness, or thicker, sheet steel and vanes must be
constructed of 0.016-inch nominal thickness, or thicker, sheet steel, or the cylinder and vanes
must be constructed of 5052-H32 aluminum alloy of equal thickness.

86-4.02 (BLANK)

86-4.03 (BLANK)

86-4.04 BACKPLATES
Background light must not be visible between backplate and signal face or between sections.
Plastic backplates must be either formed from sheet plastic or assembled from extruded,
molded, or cast sections. Sections must be factory joined using one of the following:

April 11,2011 4-238

1. Appropriate solvent cement

2. Aluminum rivets and washers painted or permanently colored to match backplate
3. No. 10 machine screws with washers, lock washers, and nuts, painted to match backplate

Backplate material must be of black homogeneous color with a lusterless finish. Secure each
plastic backplate to the plastic signal face in a manner that prevents its removal or permanent
deformation when the wind-load test is applied to either the front or back of signal face.
Permanent deformation of any portion of backplate must not exceed 5 degrees forward or
backward after wind loading is applied for 24 hours.
If plastic backplate requires field assembly, join with at least 4 No. 10 machine screws at each
field-assembled joint. Each machine screw must have an integral or captive flat washer, a
hexagonal head slotted for a standard screwdriver, and either a locking nut or a nut and
lockwasher. Machine screws, nuts, and washers must be stainless steel or steel with a zinc or
black-oxide finish.
If a metal backplate has 2 or more sections, fasten sections with rivets or aluminum bolts
peened after assembly to avoid loosening.
Instead of the screws shown on the plans, you may use self-threading No. 10 steel screws to
fasten plastic backplates to plastic signal face. Each screw must have an integral or captive flat
washer, a hexagonal head slotted for a standard screwdriver, and is stainless steel or steel with
a zinc or black-oxide finish.

86-4.05 PROGRAMMED VISIBILITY VEHICLE SIGNAL FACES

Programmed visibility signal face and its installation must comply with Section 86-4.01, "Vehicle
Signal Faces," Section 86-4.04, "Backplates," and Section 86-4.08, "Signal Mounting
Assemblies."
Each programmed visibility signal section must:

1. Have a nominal 12-inch diameter circular or arrow indication

2. Comply with ITE publication ST-017B for color and arrow configuration
3. Have a cap visor
4. Have an adjustable connection that provides incremental tilting from 0 to 10 degrees
above or below horizontal while maintaining a common vertical axis through couplers
and mountings

Terminal connection must allow external adjustment about the mounting axis in 5-degree
increments.
Signal must be mountable with ordinary tools and capable of servicing without tools. Preset
adjustment at 4 degrees below horizontal.
Visibility of each programmed visibility signal face must be capable of adjustment or
programming, within the face. When programmed, each signal face's indication must be visible
only in those areas or lanes to be controlled, except that during dusk and darkness a faint glow
to each side is allowed.
You must program the head as recommended by the manufacturer.

April 11,2011 4-239

86-4.06 PEDESTRIAN SIGNAL FACES

Message symbols for pedestrian signal faces must be white "WALKING PERSON" and Portland
orange "UPRAISED HAND." Comply with ITE Standards: "Pedestrian Traffic Control Signal
Indications" and California MUTCD. Each symbol's height must be at least 10 inches and width
must be at least 6-1/2 inches.
Luminance of "UPRAISED HAND" symbol must be 1,100 foot-lamberts, minimum, and
luminance of "WALKING PERSON" symbol must be 1,550 foot-lamberts, minimum, when tested
as specified in California Test 606.
Uniformity ratio of an illuminated symbol must not exceed 4 to 1 between the highest luminance
area and the lowest luminance area.
Luminance difference between a nonilluminated symbol and the background around the symbol
must be less than 30 percent when viewed with the visor and front screen in place and at a low
sun angle.
Each housing, including front screen, must have maximum overall dimensions of 18-1/2-inch
width, 19-inch height, and 11-1/2-inch depth.
All new pedestrian signal faces installed at an intersection must be the same make and type.

86-4.06A Type A
Each Type A pedestrian signal face must include a housing, 1 LED pedestrian signal combo
module and a front screen.

86-4.06B Front Screen

Front screen installation for each Type A signal must comply with one of the following:

1. Install, tilting downward, at an angle of 15±2 degrees out from the top, an aluminum
honeycomb screen with 0.2-inch cells, 3/8-inch thick, or a plastic screen of 3/8-inch
squares, 1/2-inch thick with wall thickness of 1/16-inch. Completely cover message
plate. Include a clear front cover of 1/8-inch minimum thickness acrylic plastic sheet or
1/16-inch minimum thickness polycarbonate plastic. Hold screen and cover firmly in
place with stainless steel or aluminum clips or stainless steel metal screws.
2. Install a 1-1/2-inch deep eggcrate or Z crate type screen of 1/32-inch nominal thickness
polycarbonate. Mount screening in a frame constructed of 0.040-inch minimum
thickness aluminum alloy or polycarbonate. Install screen parallel to face of message
plate and hold in place with stainless steel screws. Visor as specified in Section 86-
4.06D, "Visors," is not required.

The Department will test screens in a horizontal position with its edges supported. When a 3-
inch diameter, 4-pound steel ball is dropped on the screen from a height of 4 feet above, the
front screen must not fracture, separate at the welds, or compress more than 1/8-inch. When

April 11,2011 4-240

pedestrian housing is used to support front screen during test, remove message plate from
pedestrian signal housing, so there is no back support for the screen.
Screen and frame must be one of the following:

1. Manufactured from aluminum anodized flat black

2. Finished with lusterless black exterior grade latex paint formulated for application to
properly prepared metal surfaces
3. Manufactured from flat black plastic

86-4.06C Housing
Pedestrian signal housing must comply with Section 86-4.01A, "Signal Sections."

86-4.06D Visors
Use material similar to housing. Extend top of visor a minimum length of 6 inches at top and 5
inches at bottom when measured from front surface of line. Front must be normal to top.

86-4.06E Finish
Paint exterior of each housing and visor, and interior of visor as specified in Section 86-2.16,
"Painting."

86-4.06F Control
Pedestrian signals must be controllable by solid-state switching devices specified for traffic
signal controller assemblies.

86-4.06G Terminal Blocks

Include light duty terminal block, as specified in Section 86-4.01B, "Electrical Components," with
each pedestrian signal face.

86-4.07 (BLANK)

86-4.08 SIGNAL MOUNTING ASSEMBLIES

Signal mounting assembly must include:

1. 1-1/2-inch standard steel pipe or galvanized conduit

2. Pipe fitting made of ductile iron, galvanized steel, aluminum alloy Type AC-84B No.
380, or bronze
3. Mast arm and post top slip-fitters, and terminal compartments made of cast bronze or hot-
dip galvanized ductile iron

April 11,2011 4-241

After installation, clean and paint exposed threads of galvanized conduit brackets and bracket
areas damaged by wrench or vise jaws. Use wire brush to clean and apply 2 coats of approved
unthinned zinc-rich primer, organic vehicle type, as specified in Section 91, "Paint." Do not use
aerosol can.
Fit each terminal compartment with a terminal block having a minimum of 12 positions, each
with 2 screw-type terminals. Each terminal must accommodate at least five No. 14 conductors.
Include a cover on compartment for ready access to terminal block. Terminal compartment
used to bracket mount signals must be bolted securely to pole or standard.
Horizontal dimension of mounting assembly members between vertical centerline of terminal
compartment or slip-fitter, and the vertical centerline of each signal face must not exceed 11
inches, except where required for proper signal face alignment or to allow programming of
programmed visibility signal faces.
Mounting assembly members must be plumb or level, symmetrically arranged, and securely
assembled.
Mounting assembly must be watertight, and free of sharp edges or protrusions that might
damage conductor insulation. Include positive locking serrated fittings that, if mated with similar
fittings on signal faces, will prevent faces from rotating.
Orient each mounting assembly to allow maximum horizontal clearance to adjacent roadway.
Use slip-fitter for post-top mounting of signals. Fit slip-fitter over a 4-1/2-inch outside diameter
pipe or tapered standard end. Include cadmium-plated steel set screws. Include an integral
terminal compartment for each slip-fitter used to post-top mount signals with brackets.
Do not install signal faces at an intersection until all other signal equipment, including complete
controller assembly, is in place and ready for operation. You may mount signal faces if covered
or not directed toward traffic.

86-4.09 FLASHING BEACONS

Flashing beacon must include:

1. Single section traffic signal face with yellow or red LED module indications
2. Backplate
3. Tunnel visor
4. Flashing beacon control assembly

Beacon flasher unit must be independent of intersection flasher unit.

86-4.09A Flashing Beacon Control Assembly

86-4.09A(1) Enclosure
Enclosure must be:

1. NEMA 3R with a dead front panel and a hasp with a 7/16-inch hole for a padlock

April 11,2011 4-242

2. Powder coated, hot-dip galvanized, or factory-applied rust resistant prime coat and finish
coat

86-4.09A(2) Circuit Breakers and Switches

Circuit breakers must comply with Section 86-2.11, "Service."
Switch for manually operating sign lighting circuit must be a single-hole-mounting toggle type
with a single pole and throw and rated at 12 A, 120 V(ac). Furnish switch with an indicating
nameplate reading "Auto-Test."

86-4.09A(3) Flasher
Comply with Section 8, "Solid-State Flashers," of NEMA Standards publication No. TS 1.
Flasher must be a solid-state device with no contact points or moving parts.
Include 2 output circuits to allow alternate flashing of signal faces. Flasher must be able to carry
a minimum of 10 A per circuit at 120 V(ac).

86-4.09A(4) Wiring
Conductors and wiring in the enclosure must comply with Section 86-2.09B(1), "Cabinet and
Enclosure Installation."

86-4.09A(5) Terminal Blocks

Terminal blocks must be:

1. Rated 25 A, 600 V(ac)

2. Molded phenolic or nylon material
3. Barrier type with plated brass screw terminals and integral marking strips

86-5 DETECTORS
86-5.01 VEHICLE DETECTORS
Sensor unit and isolator must comply with TEES.

86-5.01A Inductive Loop Detectors

86-5.01A(1) General
Inductive loop detector includes a completely installed loop or group of loops, in the roadway,
lead-in cable, and a sensor unit, with power supply installed in a controller cabinet.

86-5.01A(2) Sensor Unit Construction

Card type sensor unit must comply with TEES, issued by the Department. Shelf-mounted
sensor unit must comply with Section 11 of the NEMA Standards Publication No. TS 1.

April 11,2011 4-243

86-5.01A(3) Construction Materials

Conductor for each inductive loop detector must be continuous, unspliced, and one of the
following:

Conductor Options for Inductive Loop Detector

Option Specifications
Type 1 loop wire Type RHW-USE neoprene-jacketed or Type USE cross-linked polyethylene insulated, No.
12, stranded copper wire with a 40 mils minimum thickness at any point.
Type 2 loop wire Type THWN or Type XHHW, No. 14, stranded copper wire in a plastic tubing. Plastic
tubing must be polyethylene or vinyl, rated for use at 105 °C, and resistant to oil and
gasoline. Outside diameter of tubing must be 0.27 inch maximum with a wall thickness of
0.028 inch minimum.

Conductor for loop detector lead-in cable must be two No. 16, 19 x 29, stranded, tinned copper
wires, comply with the calculated cross sectional area of ASTM B 286, Table 1, and be one of
the following:

Conductor Options for Loop Detector Lead-In Cable

Option Specifications
Type B lead-in cable Insulated with 20 mils of high-density polyethylene. Conductors must be twisted
together with at least 2 turns per foot and the twisted pair must be protected with a
copper or aluminum polyester shield. A No. 20, minimum, copper drain wire must
be connected to equipment ground within cabinet. Cable must have a high-density
polyethylene or high-density polypropylene outer jacket with a nominal thickness
of 32 mils. Include an amorphous interior moisture penetration barrier of
nonhydroscopic polyethylene or polypropylene fillers.
Type C lead-in cable Comply with International Municipal Signal Association (IMSA) Specification No.
50-2. A No. 20, minimum, copper drain wire must be connected to equipment
ground within cabinet.

86-5.01A(4) Installation Details

Install loop conductors without splices and end in nearest pull box. Seal open end of cable
jacket or tubing similar to splicing requirements to prevent water from entering. Do not make
final splices between loops and lead-in cable until loop operations under actual traffic conditions
is approved.
Splice all loop conductors for each direction of travel for same phase of a traffic signal system,
in same pull box, to a detector lead-in cable that runs from pull box adjacent to loop detector to
a sensor unit mounted in controller cabinet.
End all loop conductors in a pull box or terminal strip in the cabinet.
Identify and band conductors for inductive loop installations. Band, in pairs, by lane, in the pull
box adjacent to the loops and near the end of conductors in the cabinet. Bands must comply
with Section 86-2.09, "Wiring."

April 11,2011 4-244

If HMA surfacing is to be placed, install loop conductors before placing uppermost layer of HMA.
Install conductors in compacted layer of HMA immediately below the uppermost layer. Install
conductors as shown on the plans, except fill slot with sealant flush to the surface.
When cutting loops:

1. Residue from slot cutting activities must not be allowed to flow across shoulders or lanes
occupied by public traffic and must be removed from the pavement surface before
residue flows off. Dispose of residue from slot cutting activities under Section 7-1.13,
"Disposal of Materials Outside the Highway Right of Way."
2. Surplus sealant must be removed from adjacent road surface without using solvents
before setting.

Sealant for filling slots must comply with one of the following:

Elastomeric Sealant
Polyurethane material that will, within stated shelf life, cure only in the presence of moisture.
Sealant must be suitable for use in both HMA and PCC.
The cured sealant must have the following performance characteristics:

Performance Characteristics of Cured Sealant

Specification ASTM Requirement
Hardness (indentation) at 25 °C and 50% relative D 2240
65-85
humidity. (Type A, Model 1700 only) Rex.
Tensile Strength: D 412
3.45 MPa, min.
Pulled at 508 mm per minute Die C
Elongation: D 412
400%, min.
Pulled at 508 mm per minute Die C
Flex at -40 °C:
-- No cracks
0.6-mm free film bend (180°) over 13-mm mandrel
Weathering Resistance:
Weatherometer 350 h, cured 7 days at 25 °C @ 50% D 822 Slight chalking
relative humidity
Salt Spray Resistance:
3.45 MPa, min. tensile 400%,
28 days at 38 °C with 5% NaCl, Die C & pulled at 508 B 117
min. elongation
mm per minute
Dielectric Constant over a temperature range of -30 °C
D 150 Less than 25% change
to 50 °C

Asphaltic Emulsion Sealant

Comply with State Specification 8040-41A-15. Use for filling slots in HMA pavement that are a
maximum of 5/8 inch in width. Do not use where the slope causes the material to run from the
slot. Material must not be thinned beyond manufacturer's recommendations. Place material
when air temperature is at least 7 °C.

April 11,2011 4-245

Hot-Melt Rubberized Asphalt Sealant

Hot-melt rubberized asphalt must be:

1. In solid form at room temperature and fluid at application temperature of 190 °C to

205 °C. Fumes must be non-toxic.
2. Suitable for use in both HMA and PCC.
3. Melted in a jacketed, double-boiler type melting unit. Temperature of heat transfer
medium must not exceed 245 °C.
4. Applied with a pressure feed applicator or pour pot, when the pavement surface
temperature is greater than 4 °C.
5. Packaged in containers clearly marked "Detector Loop Sealant" and specifying
manufacturer's batch and lot number.

The cured sealant must have the following performance characteristics:

Performance Characteristics of Cured Sealant

Specification ASTM Requirement
Cone Penetration, 25 °C, 150 g, 5 s D 5329, Sec. 6 3.5 mm, max
Flow, 60 °C D 5329, Sec. 8 5 mm, max
Resilience, 25 °C D 5329, Sec. 12 25%, min
Softening Point D 36 82 °C, min
Ductility, 25 °C, 50 mm/min D 113 300 mm, min
Flash Point, COC, °C D 92 288 °C, min
Viscosity, Brookfield Thermosel, Less than 25%
D 150
No. 27 Spindle, 20 rpm, 190 °C change

86-5.01B Magnetic Detectors

Cable from pull box, adjacent to magnetic detector sensing element, to the field terminals in the
controller cabinet must be the type specified for inductive loop detectors.

86-5.02 PEDESTRIAN PUSH BUTTON ASSEMBLIES

Housing must be either die-cast or permanent mold-cast aluminum, or ultraviolet stabilized, self-
extinguishing structural plastic, if specified. Plastic housing must be black matching Color No.
17038, 27038 or 37038 of Federal Standard 595B, and colored throughout. Assembly must be
rainproof and shockproof in any weather condition.
Switch must be a single-pole, double-throw, switching unit, with screw type terminals, rated 15 A
at 125 V(ac), and must have:

1. Plunger actuator and a U frame to allow recessed mounting in push button housing
2. Operating force of 3.5 pounds
3. 1/64-inch maximum pretravel
4. 7/32-inch minimum overtravel
5. 0.0004- to 0.002-inch differential travel

April 11,2011 4-246

6. 2-inch minimum diameter actuator

Where pedestrian push button is attached to a pole, shape housing to fit the pole curvature and
secure. Include saddles to make a neat fit if needed.
Where a pedestrian push button is mounted on top of a 2-1/2-inch diameter post, fit housing
with a slip-fitter and use screws for securing rigidly to post.
Pedestrian push button signs must be porcelain enameled metal or structural plastic.
Install push button and sign on crosswalk side of pole.
Point arrows on push button signs in the same direction as the corresponding crosswalk.
Attach sign on Type B push button assembly.
For Type C pedestrian push button assembly, mount instruction sign on the same standard as
the push button assembly, using 2 straps and saddle brackets. Straps and saddle brackets
must be corrosion-resisting chromium nickel steel and comply with ASTM A 167, Type 302B.
Theft-proof bolts must be stainless steel with a chromium content of at least 17 percent and a
nickel content of at least 8 percent.

86-6 LIGHTING
86-6.01 HIGH PRESSURE SODIUM LUMINAIRES
High pressure sodium luminaires must be the enclosed cutoff type.
Housing must be manufactured from aluminum. Painted or powder-coated housing must
withstand a 1,000-hour salt spray test as specified in ASTM B 117.
Other metal parts must be corrosion resistant.
Each housing must include a slip-fitter that can be mounted on a 2-inch pipe tenon and can be
adjusted 5 degrees from the axis of the tenon. Clamping brackets of slip-fitter must not bottom
out on housing bosses when adjusted within the ±5 degree range.
The slip-fitter mounting bracket must not permanently set in excess of 0.020-inch when the 3/8-
inch diameter cap screw used for mounting is tightened to 10 foot-pounds.
Luminaire to be mounted horizontally on mast arm, when tested as specified in California Test
611, must be capable of withstanding cyclic loading for a minimum of 2 million cycles without
failure of any luminaire parts as follows:

Cyclic Loading
Plane Internal Minimum Peak Acceleration Levela
Ballast
Vertical Removed 3.0 G peak-to-peak sinusoidal loading (same as 1.5 G peak)
Horizontalb Installed 1.5 G peak-to-peak sinusoidal loading (same as 0.75 G peak)
Vertical Installed 1.0 G peak-to-peak sinusoidal loading (same as 0.5 G peak)
a
G = Acceleration of gravity
b
Perpendicular to direction of mast arm

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If a photoelectric unit receptacle is included, a raintight shorting cap must be installed. If

luminaire housing has a hole for the receptacle, hole must be permanently closed, covered, and
sealed with weatherproof material.
Optical system must be in a sealed chamber and include:

1. Reflector shaped so that a minimum of light is reflected through the arc tube of the lamp.
Reflector surface must be specular and protected by either an anodized finish or a silicate
film on it's specular surface.
2. Refractor or lens mounted in a door frame that is hinged to the housing and secured with
a spring-loaded latch. Refractor must be made of glass or polycarbonate plastic. Lens
must be made of heat- and impact-resistant glass.
3. Lamp socket that is a porcelain enclosed mogul-multiple type. Shell must include
integral lamp grips to assure electrical contact under conditions of normal vibration.
Socket must be mounted in the luminaire to allow presetting a variety of specified light
distribution patterns. Socket must be rated for 1,500 W and 600 V(ac), and a 4 kV pulse.
4. Lamp.

Sealing must be provided by a gasket between the reflector and:

1. Refractor or lens
2. Lamp socket

Chamber must allow for filtered flow of air in and out of the chamber from lamp heat. Filtering
must be accomplished by either a separate filter or a filtering gasket.
If components are mounted on a down-opening door, door must be hinged and secured to
luminaire housing separately from refractor or flat lens frame. Door must be easily removable
and replaceable, and secured to housing to prevent accidental opening when refractor or flat
lens frame is opened.
Field wires connected to luminaire must terminate on a barrier-type terminal block secured to
the housing. Terminal screws must be captive and equipped with wire grips for conductors up
to No. 6. Each terminal positions must be clearly identified.
Minimum light distribution for each luminaire must meet the isolux diagrams.
Maximum brightness of each cutoff luminaire, with the lamp indicated, must be as follows:

Cutoff Type
Lamp Lamp Maximum Brightness
ANSI Code No. Wattage foot-lamberts
S55 150 40
S66 200 40
S50 250 50
S67 310 60
S51 400 75

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Brightness readings will be taken using a brightness meter with an acceptance angle of 1.5
degrees. When measured on the 90-degree and 270-degree lateral angle line, maximum
brightness must not exceed above specified brightness when meter is located at a horizontal
distance of 120 feet and a vertical distance of 7.5 feet between luminaire and meter, or at an
angle of 3 degrees 35 minutes from the horizontal to the line between luminaire and meter.
Measurements must be made from 90-degree line and 270-degree line, and averaged. Lamp
used for each test must operate at wattage necessary to produce the following light output:

Light Output
Lamp Wattage Lumens
150 16,000
200 22,000
250 27,000
310 37,000
400 50,000

86-6.01A High Pressure Sodium Lamp Ballasts

Each ballast must:

1. Operate the lamp for its rated characteristics and wattage

2. Continuously operate at ambient air temperatures from -20 °C to 25 °C without reduction
in ballast life
3. Operate for at least 180 cycles of 12 hours on and 12 hours off, with the lamp circuit in
an open or short-circuited condition and without measurable reduction in operating
requirements
4. Have a design life of not less than 60,000 hours
5. Provide proper starting and operating waveforms, voltage, and current
6. Provide reliable lamp starting and operation at ambient temperature down to -20 °C for
the rated life of lamp

Ballast must be tested as specified in ANSI C82.6-1980, "Methods of Measurement of High-

Intensity-Discharge Lamp Ballasts."
Starting aids for ballast of a given lamp wattage must be interchangeable between ballasts of
same wattage and manufacturer, without adjustment.
Each integral ballast must consist of separate components that can be easily replaced. An
encapsulated starting aid will be counted as a single component. Each component must include
screw terminals, NEMA tab connectors, or a single multi-circuit connector. Conductors and
terminals must be identified.
Mount heat-generating component so as to use the portion of the luminaire it is mounted to as a
heat sink. Place capacitor a maximum practicable distance from heat-generating components
or thermally shield to limit the case temperature to 75 °C.
Transformer and inductor must be resin-impregnated for protection against moisture.
Capacitors, except those in starting aids, must be metal cased and hermetically sealed.

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The Department will test high-pressure sodium lamp ballast. High-pressure sodium lamp ballast
must have a characteristic curve that will intersect both of the lamp-voltage limit lines between
the wattage limit lines and remain between the wattage limit lines throughout the full range of
lamp voltage. This requirement must be met at the rated input voltage of the ballast and at the
lowest and highest rated input voltage of the ballast.
Throughout the lifetime of the lamp, ballast curve must fall within the specified limits of the lamp
voltage and wattage.
Ballast for luminaires must be located in the luminaire housing.

86-6.01A(1) Regulator Type Ballasts

Regulator type ballast must comply with the following:

1. For nominal input voltage and lamp voltage, ballast design center must not vary more
than 7.5 percent from rated lamp wattage.
2. Ballast must be designed for a capacitance variance of ±6 percent that will not cause
more than ±8 percent variation in lamp wattage regulation during rated lamp life.
3. Lamp current crest factor must not exceed 1.8 for input voltage variation of ±10 percent
at any lamp voltage during lamp life.

Regulator-type ballast must be one of the following:

Regulator-Type Ballast
Ballast Type Power Factor Lamp Regulation
Lag-typea Not less than 90 percent Lamp wattage regulation spread does not vary by
throughout the life of lamp when more than 18 percent for ±10 percent input
ballast is operated at nominal voltage variation from nominal through life
line voltage with a nominally-
rated reference lamp
Lead-typeb Not less than 90 percent Lamp wattage regulation spread does not vary by
throughout the life of lamp when more than 30 percent for ±10 percent input
ballast is operated at nominal voltage variation from nominal through life
line voltage with a nominally-
rated reference lamp
a
Primary and secondary windings must be electrically isolated
b
Constant wattage autoregulator (CWA)

86-6.01A(2) Nonregulator Type Ballasts

Each nonregulator type ballast must comply with the following:

1. For nominal input voltage and lamp voltage, ballast design center must not vary more
than 7.5 percent from rated lamp wattage.
2. Lamp current crest factor must not exceed 1.8 for input voltage variation of ±5 percent at
any lamp voltage during lamp life.

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Nonregulator-Type Ballast
Ballast Type Power Factor Lamp Regulation
Autotransformer Not less than 90 percent Lamp wattage regulation spread does not vary by
or High- throughout the life of lamp when more than 25 percent for ±5 percent input voltage
Reactance ballast is operated at nominal variation from nominal through life
line voltage with a nominally-
rated reference lamp

86-6.01B High Pressure Sodium Lamps

High pressure sodium lamps must comply with ANSI C 78.42, "High Pressure Sodium Lamps,"
when tested as specified in ANSI C 78.389, "American National Standard for Electric Lamps -
High Intensity Discharge-Methods of Measuring Characteristics." High pressure sodium lamps
must have a minimum average rated life of 24,000 hours.

86-6.02 LOW PRESSURE SODIUM LUMINAIRES

Each low pressure sodium luminaire must be completely assembled with a lamp and ballast,
and must:

1. Be the enclosed type, either semi-cutoff or cutoff type.

2. Include housing, reflector, refractor or lens, lamp socket, integral ballast, removable
ballast tray, lamp support, terminal strip, capacitor, and slip fitter. Reflector may be an
integral part of the housing.

Luminaire housing must be minimum 1/16-inch thick, corrosion resistant die cast aluminum
sheet and plate with concealed continuous welds, or minimum nominal wall thickness of 3/32-
thick acrylonitrile-butadiene-styrene sheet material, on a cast aluminum frame that provides
mounting for all electrical components and slip fitter. Housing must be divided into optical and
power compartments that are individually accessible for service and maintenance. Position and
clamp luminaire to pipe tenon by tightening mounting bolts.
Painted exterior surface of luminaire must be finished with a fused coating of electrostatically
applied polyester powder paint or other ultraviolet inhibiting film. Color must be aluminum gray.
High temperature neoprene, or equal, sealing ring must be installed in pipe tenon opening to
prevent entry of water and insects into power and optical compartments.
Access to power unit assembly must be through a weathertight hinged cover, secured with
spring type latches or captive screws, to luminaire housing.
Hardware must be stainless steel or cadmium plated. Use machine screws or bolts to secure
removable components. Do not use sheet metal screws.
Semi-cutoff luminaires and molded refractor style cutoff luminaires must include a refractor.
Other cutoff luminaires must include a flat lens.
Refractor must be 1-piece injection molded polycarbonate of 3/32 inch minimum thickness, or 1-
piece injection molded acrylic of 1/8 inch minimum thickness. Flat lens must be 1-piece
polycarbonate of 3/32 inch minimum thickness, mounted to metal frame. Refractor assembly
and flat lens assembly must be constructed to rigidly maintain its shape, and hinged and

April 11,2011 4-251

secured with spring type latches to luminaire housing. Alternate methods of manufacturing
refractor may be approved provided minimum specified thicknesses are maintained.
Lamp socket must be high temperature, flame retardant thermoset material with self-wiping
contacts or equivalent. Socket must be rated for 660 W and 1,000 V(ac). Position of socket
and support must maintain the lamp in correct relationship with reflector and refractor for
designed distribution pattern.
Isofootcandle distribution must be ANSI Type III, short or Type IV, medium distribution, for cutoff
or semi-cutoff luminaires.
With a 40-foot mounting height, each type of luminaire must maintain a minimum of 0.2
footcandle at least 60 feet each side, along the longitudinal roadway line below the luminaire,
and a minimum of 0.35 footcandle at a transverse roadway distance from luminaire location
equal to 1.5 times the luminaire mounting height.
Certified luminaire performance data must be provided. This data must include complete
photometric test data in isofootcandle charts at a scale of 1 inch equals 20 feet, for the luminaire
and lamp sizes shown on the plans.
Alternate data may be in horizontal footcandle values recorded on a 15' x 15' area extending 90
feet longitudinally each side of the light source, and 15 feet behind and 90 feet in front of the
light source, for luminaire and lamp sizes, and mounting height shown on the plans. Horizontal
footcandle levels in data submitted must equal or exceed levels specified. Failure to meet
referenced values will be justification for rejection of the luminaires.
Photometric testing must be performed and certified by an independent and recognized testing
laboratory.
Low pressure sodium lamps must:

1. Be 180 W, single-ended, bayonet base, tubular gas discharge lamp

2. Maintain a minimum of 93 percent of initial lumens during rated life and must comply
with the following minimum performance requirements:

Performance Requirements
Lamp Designation ANSI L74-RF-180
Initial Lumens 33,000 lumens
Rated Ave. Life (@ 10 hrs/Start) 18,000 hours
Operating Position Horizontal ±20 degrees

3. Reach 80 percent of light output within 10 minutes and must restrike within 1 minute
after an outage due to power interruption or voltage drop at the lamp socket
4. Identify the month and year of installation.
5. Have an autotransformer or high-reactance type ballast. The ballast must comply with
the following:

5.1. Lamp current crest factor must not exceed 1.8 at nominal line voltage
5.2. Ballast loss must not exceed 24 percent for 180 W ballast at nominal line voltage

April 11,2011 4-252

Autotransformer or High-Reactance Type Ballast

Ballast Type Power Factor Lamp Operation
Autotransformer Not less than 90 percent when Lamp wattage regulation spread does not vary by
or High- ballast is operated at nominal more than ±6 percent for ±10 percent input
Reactance line voltage with a nominally- voltage variation from nominal through life
rated reference lamp

A multi-circuit connector must be included for quick disconnection of ballast tray.

86-6.03 SOFFIT AND WALL LUMINAIRES

Soffit and wall luminaire must be weatherproof and corrosion resistant.
Each flush-mounted soffit luminaire must consist of:

1. Metal body with two 1-inch minimum conduit hubs and provisions for anchoring into
concrete
2. Prismatic refractor made of heat-resistant polycarbonate mounted in a door frame and
clearly identified as to street side
3. Specular anodized aluminum reflector
4. Ballast located either within housing or in a ceiling pull box as shown on the plans
5. Lamp socket

The door frame assembly must be hinged, gasketed, and secured to body by at least 3 machine
screws.
Each pendant soffit luminaire must be enclosed and gasketed, have an aluminum finish, and
include:

1. Reflector with a specular anodized aluminum finish

2. Refractor made of heat-resistant polycarbonate
3. Optical assembly hinged and latched for lamp access and a device to prevent dropping
4. Ballast designed for operation in a raintight enclosure
5. Galvanized metal box with a gasketed cover, 2 captive screws, and 2 chains to prevent
dropping and for luminaire mounting

Each wall-mounted luminaire must consist of:

1. Cast metal body

2. Prismatic refractor, made of glass, mounted in a door frame
3. Aluminum reflector with a specular anodized finish
4. Integral ballast
5. Lamp socket
6. Gasket between refractor and body
7. At least two 5/16-inch minimum diameter mounting bolts

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Cast-aluminum bodies to be cast into or mounted against concrete must have a thick application
of alkali-resistant bituminous paint on all surfaces to be in contact with concrete.
Each soffit luminaire and wall luminaire must include a 70 W high-pressure sodium lamp with a
minimum average rated life of 24,000 hours. Each lamp socket must be positioned to locate the
light center of the lamp within 1/2 inch of light center location of the luminaire design.
Ballast must comply with Section 86-6.01A, "High Pressure Sodium Lamp Ballasts." Wall
luminaire ballast must be located in luminaire housing or, if shown on the plans, in a pull box
adjacent to luminaire.

86-6.04 PEDESTRIAN CROSSING FIXTURES

Before starting fixture manufacturing, submit fixture design for approval. If requested, submit 1
complete prototype fixture for approval at least 30 days before manufacturing the fixtures. The
prototype fixture will be returned to you, and if permitted, the fixture may be installed in the work.
Lens unit in door section must be formed of 1-1/2-inch methyl methacrylate rod cut and fire-
glazed for a clear finish or a cast unit with equivalent tolerances and finish.
Lens must be secured to door section with an extruded lens retainer of 6063-T5 aluminum alloy
that fits the lens shape. Lens retainer must fit the full length of lens on both sides. Continuous
lens retainer for the full length of 3 lenses is allowed. Z bars of 5052-H32 or 5005-H14
aluminum alloy, 1/16 inch minimum thickness may be substituted for extruded lens retainer.
A captive positive-keyed screw-type latching device requiring a special socket wrench must be
installed at upper edge to secure door in the closed position as shown on the plans. Furnish 2
special wrenches to the Engineer.
Each fixture must include a F48T12/CW rapid start fluorescent lamp with recessed, double
contact base installed on back side of door directly behind lens.
Each lampholder must be UL listed for outdoor use without an enclosure and with 1,500 mA
rapid start fluorescent lamp. Lampholder must be spring-loaded type.
For each lamp, the distance from face of lampholder to the lamp must be designed to provide a
compression of at least 0.10-inch on the spring-type lampholder when lamp is in place. Lamp
must have positive mechanical and electrical contact when lamp is in place. Socket on spring-
type lampholder must have enough travel to allow lamp installation. Spring must not be a part
of current-carrying circuit.
Ballast must be high-power-factor type with weatherproof leads for operation of one 48-inch
rapid-start lamp. Ballast must be UL listed for outdoor operation on 110 to 125 V(ac) 60 Hz
circuit and rated at 1,500 mA.
Conductors from ballast leads to lampholder must be minimum size of No. 16, stranded, and
UL-listed copper AWM. Splicing of lampholder conductors to ballast leads must be performed
by using mechanically secure connectors.
Conductors in fixture except ballast leads and entrance line conductors, must be UL-listed
AWM.
Provide sufficient slack in the conductors to allow the fixture door to fully open.

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Circuit conductors entering the fixture must be terminated on molded phenolic barrier-type
terminal blocks rated at 15 A and 600 V(ac) and must have integral-type white waterproof-
marking strips. Current-carrying parts of terminal blocks must be insulated from fixture with
integral plugs or strips to provide protection from line-to-ground flashover voltage. Terminal
blocks must be attached to wireway cover in top section. If you use sectionalized terminal
blocks, each section must include an integral barrier on each side and be capable of rigid
mounting and alignment.
Exposed surfaces of fixture must be uniform in appearance and free from significant defects,
including improper fit, dents, deep scratches and abrasions, burrs, roughness, off-square ends,
holes off-center or jagged, and surface irregularities. Screws for attaching components to
fixture door, including Z bars, ballasts, and terminal block, must be tapped into door from the
inside only. Screwheads, nuts, or other fasteners must not be removable from the outside.

86-6.04A Pedestrian Undercrossing Fixtures

Fixture shell must be cast aluminum alloy, industrial type or Federal Class 18 aluminum of 1/4
inch minimum thickness.
Door must be 1 piece of 6061-T6 aluminum alloy of 1/8 inch minimum thickness.
Continuous piano hinge must be Type 1100 aluminum alloy. The piano hinge must be welded
or riveted to door section with 1/8 inch aluminum rivets. Matching holes must be drilled in the
hinge and lower edge of fixture. After shell is in place, door assembly must be attached by
minimum 3/8-inch No. 8 stainless steel self-tapping screws.
A neoprene gasket must be attached to frame to provide a cushion between the shell and the
door.
Chain or other device must be included to prevent the door, when fully opened, from coming in
contact with the undercrossing wall.
Fixture must be held in place by three 3/8" x 8" anchor bolts with 2 nuts each.
Fixture surfaces in contact with concrete, and with anchor bolts and nuts must be painted with a
thick application of alkali-resistant bituminous paint. Paint must comply with MIL-P-6883.
Circuit conductor entering the fixture must be terminated on 2-position terminal blocks.
Both ends of fixture must have holes for 1-inch conduit. Unused holes must be plugged with
pressed metal closures.

86-6.04B Pedestrian Overcrossing Fixtures

Fixture shell must consist of:

1. Top section and a door section of extruded 6063-T5 aluminum alloy, each with a nominal
1/8 inch wall thickness
2. 2 cast-end sections of 319 aluminum alloy
3. Internal wireway cover of 505-H32 aluminum alloy

April 11,2011 4-255

Top section and door section must be joined together on one side by a continuous hinge formed
as part of the 2 extrusions and must overlay to allow locking on the other side. Hinge must be
treated with a silicone grease that will prevent the entrance of water by capillary action.
Wireway cover with 3/16 inch hemmed ends up and terminal blocks and circuit conductors must
be inserted before welding end sections and must provide clearance at both ends for
conductors. Cover must be fastened by at least two 1/4 inch No. 4 self-threading sheet metal
screws with binding head and blunt point. You may substitute blind rivets of equivalent strength.
One or more bronze sash chains or other device must be included to prevent door from opening
to an extent that will damage the hinge.
Lampholder must include heat-resistant circular cross section neoprene sealing gasket, silver-
coated contacts, and waterproofed lead entrance for use with a 1,500 mA rapid start fluorescent
lamp.
Ballast must be at most 13-1/4 inches long.
Circuit conductors entering the fixture must be terminated on 3-position terminal blocks.
Electrical system of pedestrian overcrossing must be grounded by a No. 8 copper wire installed
in conduit from fixture to fixture, from end fixture to conduit fitting on end post and from conduit
fitting on end post to grounding bushing in nearest pull box.
Ground wire must be secured to inside of telescoping sleeve end casting where conductors are
carried and to the inside of Type LB conduit fitting on end post by a connecting lug and a No. 8
self-threading pan screw.
Lamp, lampholder, ballast, and fixture wire, must be attached to door section. Terminal blocks
must be attached to top section or wireway cover.
Three No. 10, solid copper circuit conductors must be installed between terminal blocks as part
of each completed fixture.
Before shipment to job site, fixture must be completely manufactured and assembled in the
shop.

86-6.05 INDUCTION SIGN LIGHTING FIXTURES

Each induction sign lighting fixture must include housing with door, reflector, refractor or lens,
lamp, power coupler, high frequency generator, socket assembly, fuse block, and fuses.
Each induction sign lighting fixture must:

1. Be designed for mounting near the bottom of sign panel on an overhead sign structure.
2. Be an enclosed design and be raintight and corrosion resistant.
3. Have a minimum average rating of 60,000 hours.
4. Be for a wattage of 87 W, 120/240 V(ac).
5. Have a power factor greater than 90 percent and total harmonic distortion less than 10
percent.
6. Be UL approved for wet locations and be FCC Class A-listed.
7. Not exceed 44 pounds in weight.

April 11,2011 4-256

8. Include the manufacturer's brand name, trademark, model number, serial number, and
date of manufacture on packaged assembly. Same information must be permanently
marked on the outside and inside of housing.
9. Comply with minimum horizontal footcandle requirement shown on the plans.
10. Be a maximum height of 12 inches above the top of the mounting rails.

If fixture is located so that the light center of the lamp is 55 inches in front of, 1 foot below, and
centered on a 10-foot high by 20-foot wide sign panel, the ratio of maximum to minimum
illuminance level on the panel must not exceed 12 to 1 in 95 percent of the points measured.
Illuminance gradient must not exceed 2 to 1 and is defined as the ratio of minimum illuminance
on a 1-foot square of panel to that on an adjacent 1-foot square of panel.
Each fixture must have a mounting assembly that will allow fixture to be mounted on continuous
slot channels. Mounting assembly must be either cast aluminum, hot-dip galvanized steel plate,
or steel plate that has been galvanized and finished with a polymeric coating system or same
finish that is used for housing.
Housing must have a door designed to hold a refractor or lens, and to open without the use of
special tools. Housing and door must be manufactured of sheet or cast aluminum, and have a
powder coat or polyester paint finish of a gray color resembling unfinished manufacturing.
Sheet aluminum must comply with ASTM B 209 or B 209M for 5052-H32 aluminum sheet.
External bolts, screws, hinges, hinge pins, and door closure devices must be corrosion
resistant.
Housing must include weep holes.
Door must be hinged to housing on side of fixture away from the sign panel and include 2
captive latch bolts or other latching device. Door must be designed to lock in the open position,
50 degrees minimum from the plane of the door opening, with an 85-mph 3-second-wind-gust
load striking the door from either side.
Door and housing must be gasketed to be raintight and dusttight. Thickness of gasket must be
1/4 inch, minimum.
Fixture height must be less than 12 inches above the top of mounting rails.
Reflector must be 1 piece, made from specularly finished aluminum protected with an
electrochemically applied anodized finish or a chemically applied silicate film, and designed so
deposited water due to condensation will drain away. Reflector must be secured to housing
with a minimum of 2 screws and removable without removing any fixture parts. Do not attach
reflectors to outside of housing.
Refractor or lens must have a smooth exterior and must be manufactured from the material as
follows:

April 11,2011 4-257

Refractor and Lens Material Requirements

Component Manufactured From
Flat lens Heat-resistant glass
Convex lens Heat resistant, high-impact
resistant tempered glass
Refractor Borosilicate heat resistant
glass

Refractor and convex lens must be designed or shielded so no fixture luminance is visible if
fixture is approached directly from the rear and viewing level is the bottom of the fixture. If a
shield is used, it must be an integral part of the door casting.
Each fixture must include an 85 W induction lamp with an interior wall that is fluorescent
phosphor-coated. Light output must be at least 70 percent at 60,000 hours. Lamp must have a
minimum color-rendering index of 80, be rated at a color temperature of 4,000K and be
removable without the use of tools.
Lamp socket must be a porcelain enclosed mogul type with a shell that contains integral lamp
grips to assure electrical contact under normal vibration conditions. Center contact must be
spring-loaded. Shell and center contact must be nickel-plated brass. Socket must be rated for
1,500 W and 600 V(ac).
Power coupler must include a construction base with antenna, heat sink, and electrical
connection cable, and be designed so it can be removed with common hand tools.
High frequency generator must:

1. Start and operate lamps at an ambient temperature of -25 °C or greater for the rated life of
the lamp
2. Operate continuously at ambient air temperatures from -25 °C to 25 °C without reduction
in generator life
3. Have a design life of at least 100,000 hours at 55 °C
4. Have an output frequency of 2.65 MHz ± 10 percent
5. Have radio frequency interference that complies with FCC Title 47, Part 18, regulations
regarding harmful interference
6. Be replaceable with common hand tools
7. Mounted so the fixture can be used as a heat sink

Conductor terminal must be identified by the component terminal the conductor connects to.
Submit a copy of the high frequency generator test methods and results from the manufacturer
with each lot of fixtures.
Each fixture must include a barrier-type fuse block for terminating field connections. Fuse block
must:

1. Be secured to housing and be accessible without removal of any fixture parts

2. Be mounted to leave a minimum of 1/2 inch air space from sidewalls of housing

April 11,2011 4-258

3. Be designed for easy removal of fuses with a fuse puller, be rated at 600 V(ac), and have
box terminals.

Fuses must be 13/32-inch diameter, 1-1/2 inch long ferrule type and UL or ETL listed. For 120
V(ac) input fixture, only the ungrounded conductor must be fused and there must be a solid link
between the neutral and the high frequency generator.
If shown on the plans, include a wire guard to prevent damage to the refractor or lens. Guard
must be constructed of 1/4-inch minimum diameter galvanized steel wire, and either hot-dip
galvanized or electroplated-zinc coated as specified in ASTM B 633, Service Condition SC4
with a clear chromate dip treatment. Guard elements must be spaced to prevent rocks larger
than 1-1/2-inch diameter from passing through.

86-6.06 SIGN LIGHTING FIXTURES FOR FLASHING BEACON

Sign lighting fixture must:

1. Be UL or ETL listed for outdoor installation

2. Include a hood with side outlet tapped for conduit, a symmetrical 10-inch steel reflector
with a white porcelain-enamel finish, and a medium base socket
3. Be rated at 150 W minimum

86-6.07 INTERNALLY ILLUMINATED STREET NAME SIGNS

Sign fixture must be:

1. Designed and constructed to prevent deformation or failure when subjected to an 85 mph

3-second-wind-gust load as specified in AASHTO publication, "Standard Specifications
for Structural Supports of Highway Signs, Luminaires and Traffic Signals," and its
interim revisions
2. Manufactured from all new material and all ferrous parts must be galvanized or
cadmium-plated
3. Type A or B signs

Top and bottom must be formed or extruded aluminum and must be attached to formed or cast
aluminum end fittings. Housing must be designed for continuous sealing between top and
bottom assemblies, and end fittings, and be constructed to resist torsional twist and warp.
Opening or removing 1 panel must allow access to the interior of the sign for lamp, ballast, and
fuse replacement.
Photoelectric unit sockets are not allowed.
For Type A sign, both sides must be hinged at the top to allow installation or removal of sign
panel, and to allow access to interior of sign.
For Type B sign, sign panel must be slide-mounted into housing.
Reflectors may be used to obtain required sign brightness. Reflectors must be formed
aluminum with acrylic baked white enamel surface having a minimum reflectance of 0.85.

April 11,2011 4-259

Sign panel must be slide-mounted or rigid-mounted in a frame, with white legend, symbols,
arrows, and border on each face. Background must be green.
Sign panels surface must be evenly illuminated. Average of brightness readings for letters must
be 150 foot-lamberts, minimum. Light transmission factor of sign panel must provide a letter to
background brightness ratio between 10 to 1 and 20 to 1. Background luminance must not vary
by more than 40 percent from the average background brightness reading. Luminance of
letters, symbols, and arrows must not vary by more than 20 percent from their average
brightness readings.
Sign panels must be translucent, high impact, resistant plastic panels of one of the following:

1. Glass fiber reinforced acrylated resin

2. Polycarbonate resin
3. Cellulose acetate butyrate plastic

Paint on the outside of plastic must be protected by a plastic film that seals the front surface of
panel and filters out ultraviolet radiation. Paint must be acrylic plastic type.
Surface must be free of blemishes in the plastic or coating that may impair the serviceability or
detract from the general appearance and color matching of sign.
White or green color must not fade or darken when sign is exposed to an accelerated test of
ultraviolet light equivalent to 2 years of outdoor exposure. Green color of sign, when not
illuminated, must match Color No. 14109 of Federal Standard 595B.
Sign panel must not crack or shatter when a 1-inch diameter, steel ball with a weight of 2.4
ounces is dropped from a height of 8.5 feet above the sign panel to any point of sign panel. For
this test, sign panel must be lying in a horizontal position and supported within its frame.
For Type A sign, gasket must be installed between sign panel frame and fixture housing to
prevent water entry between frame and fixture housing. Gasket must be uniform and even-
textured, and be the closed-cell, sponge-neoprene type, designed for use at temperatures
between -20 °C and +74 °C.
Gasket must be neatly applied to thoroughly degreased, clean surface with a suitable heat-
resistant adhesive that will not allow the gasket to slip at temperatures between -20 °C and
+74 °C.
Ballast must be high power factor type and capable of starting the lamp at -20 °C and above.
Ballast for Type A sign must be rated at 200 mA. Ballasts for Type B sign must be rated at 430
mA. Ballast must be UL or ETL listed for operation on 110 to 125 V(ac), 60 Hz circuits, and
comply with ANSI C 82.1 and ANSI C 82.2.
Lampholder must be UL or ETL listed for outdoor use and of the spring-loaded type.
Lampholder must have silver-coated contacts and waterproofed entrance leads for use with a
rapid-start fluorescent lamp. Removal of lamp from socket must de-energize the primary of
ballast. Each lampholder must include heat-resistant, circular cross section, partially-recessed
neoprene ring to seal against lamp ends and protect electrical contacts from moisture, dirt or
other injurious elements.
Distance between face of lampholders must be designed to provide compression of at least
0.10 inch on the spring-type lampholder when lamp is in place. Lamp must have positive

April 11,2011 4-260

mechanical and electrical contact when lamp is in place. Socket on spring-type lampholder
must have sufficient travel to allow lamp installation. Spring must not be a part of current
carrying circuit. Lampholder must match lamp requirements and must not increase cathode
filament circuit resistance by more than 0.10 Ω.
Lamp must comply with ANSI C 78.
Wiring connections in fixture must be terminated on molded, phenolic, barrier-type, terminal
blocks rated at 15 A, 1,000 V(ac), and must have integral-type white waterproof-marking strips.
Current carrying parts of terminal blocks must be insulated from fixture with integral plugs or
strips to provide protection from line-to-ground flashover voltage. If you choose to use
sectionalized terminal blocks, each section must include an integral barrier on each side and be
capable of rigid mounting and alignment. Terminal screws must be No. 10, minimum.
Fuses must be Type 3AG, miniature, slow-blowing type with appropriate current and voltage
ratings.
Fuseholder must be a panel-mounting type with threaded or bayonet-type knob that grips the
fuse tightly for extraction. Use a separate fuse for each ballast.
Screened weep holes must be constructed at strategic locations in members subject to moisture
collection.
Fasteners, screws, and hardware must be passive stainless steel, Type 302 or 304, or
aluminum Type 6060-T6.
Top of fixture housing must have 2 free-swinging mounting brackets. Each bracket must be
adjustable vertically for leveling the sign to either a straight or curved mast arm. Bracket
assembly must allow fixture to swing perpendicular to the sign panel.
Hinge pins for the free-swinging brackets must have a minimum diameter of 1/4 inch.
Message, as shown on the plans, must be displayed on both sign panels.
If not shown on the plans, the message and the size of symbols or arrows will be given by the
Engineer at your request. Letters must be 8-inch upper case and 6-inch lower case, Series E.
Fixture conductors must be UL- or ETL-listed AWM stranded copper wire with 28 mils,
minimum, thermoplastic insulation, rated at 1,000 V(ac) and rated for use at 90 °C. Conductors
must be No. 16 minimum and must match color coding of ballast leads.
Conductors within the fixture must be secured with easily removable spring cross straps, not
clamped, in the chassis or fixture. Straps must be installed 12 inches apart or less.
Stranded copper conductors connected to screw-type terminals must terminate in approved
crimp-type ring connectors.
Splices are not allowed within fixture.
Submit shop drawings showing the message for each sign, including size of letters, symbols or
arrows, as shown on the plans. If requested, you must supply, without cost to the State,
sufficient samples of materials to be used in the manufacturing of the sign or a complete sign
assembly, to allow adequate testing and evaluation of compliance to specified requirements.

86-6.08 PHOTOELECTRIC CONTROLS

Photoelectric controls must be capable of directly switching multiple lighting systems.

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86-6.08A Types
Photoelectric control type must comply with the following:

Photoelectric Control Types

Type I Includes a remote photoelectric unit and a test switch housed in an enclosure.
Type II Includes a remote photoelectric unit, a separate contactor located in a service
equipment enclosure, and a test switch located in service equipment enclosure.
Type III Includes a remote photoelectric unit, a separate contactor, and a test switch
housed in an enclosure.
Type IV Includes a photoelectric unit that plugs into an EEI-NEMA twist-lock
receptacle integral with the luminaire.
Type V Includes a photoelectric unit, contactor, and test switch located in service
equipment enclosure.

A switch to allow manual operation of lighting circuit must be included for each Type I, Type II,
Type III, and Type V photoelectric control. Switches must be single-hole mounting toggle type,
single-pole, single-throw, rated at 12 A with a voltage rating that matches the circuit. Switches
must have an indicating nameplate reading "Auto-Test" and be connected in parallel with the
load contacts of the photoelectric unit. Test switches must not have an "OFF" position.
Photoelectric unit for Types I, II, and III photoelectric controls, must be pole-top mounted.

86-6.08B Equipment Details

86-6.08B(1) Photoelectric Unit
Photoelectric unit must:

1. Have an output in response to changing light levels. Response level must remain stable
throughout life of control unit.
2. Have a "turn-on" between 1 and 5 footcandles, and a "turn-off" between 1.5 and 5 times
"turn-on." Measurements must be made by procedures in EEI-NEMA standards for
physical and electrical interchangeability of light-sensitive control devices used in the
control of roadway lighting.
3. Have a EEI-NEMA type receptacle. Mounting brackets must be used where pole-top
mounting is not possible. Photoelectric controls must be installed at locations show on
the plans and oriented.
4. Be screened to prevent artificial light from causing cycling.
5. Have a supply voltage rating of 60 Hz, 105-130 V(ac), 210-240 V(ac), or 105-240 V(ac),
as specified.
6. Have a load rating of 800 W minimum, incandescent, high intensity discharge, or
fluorescent.
7. Operate at a temperature range of -20 °C to 55 °C.
8. Have a power consumption less than 10 W.
9. Be housed in a weatherproof enclosure.

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10. Have a base with a 3-prong, EEI-NEMA standard, twist-lock plug mounting.
11. Have a "fail-on" feature.

Unit components must not require periodic replacement.

Photoelectric controls, except Type IV and Type V, must include a 4-inch minimum inside
diameter, pole-top mounting adaptor containing a terminal block, and cable supports or clamps
to support pole wires.
For switching 480 V(ac), 60 Hz circuits, a 100 VA, minimum, 480/120 V(ac) transformer must be
installed in the contactor enclosure to allow 120 V(ac) for the photoelectric control unit. If more
than 1 photoelectric unit is to be installed at a location, a single transformer with a volt-ampere
rating capable of handling the total controlled load, may be used.

86-6.08B(2) Contactor
Contactor must:

1. Have contacts rated to switch the specified lighting load

2. Be normally open
3. Be the mechanical armature type with contacts of fine silver, silver alloy, or superior
alternative material

86-6.08B(3) Enclosure
Enclosure for Type I and Type III photoelectric controls must be NEMA 3R. Enclosure must be
supplied with a factory-applied rust-resistant prime coat and finish coat. Two applications of
paint to match the color of the standard must be applied as specified in Section 86-2.16,
"Painting." Enclosure may be hot-dip galvanized instead of painting. A minimum of 2-1/2
inches must be provided between contactor terminals and end of enclosure for wiring
connections. Enclosure must be mounted on the same standard as the photoelectric unit at a
height of about 6 feet above finished grade.

86-6.08B(4) Terminal Blocks

Terminal blocks must be rated at 25 A, 600 V(ac), molded from phenolic or nylon material, and
of the barrier type with plated-brass screw terminals and integral-type marking strips.

86-6.09 TRANSFORMERS
Multiple-to-multiple transformers must be single-phase dry type designed for operation on a 60
Hz supply.

86-6.09A Electrical Requirements

Transformers must have a decal showing a connection diagram. Diagram must show either
color-coding or wire-tagging with primary (H1, H2) or secondary (X1, X2) markers, and the
primary and secondary voltage and volt-ampere rating. Transformers must comply with the
following:

April 11,2011 4-263

Transformer Electrical Requirements

Transformer Characteristic Multiple-to-Multiple Unit
120/480 V(ac), 240/480 V(ac),
Rating
or 480/120 V(ac)
Efficiency Exceed 95 percent
Secondary Voltage Regulation ±3 percent from half load to
and Tolerance full load

Secondary 480 V(ac) windings must be center-tapped.

86-6.09B Physical Requirements

External leads for multiple-to-multiple secondary connections must be Type USE, No. 10, rated
600 V(ac).
Transformer leads must extend a minimum of 12 inches from the case.
Transformer insulation must be NEMA 185 C or better.
Multiple-to-multiple transformers must withstand the application of 2,200 V(ac) from core to coils
and from coil to coil for a 1-minute period.
The above tests must be made immediately after operation of transformer at full load for 24
hours.
Non-submersible transformers must include metal half-shell coil protection, have moisture
resistant synthetic varnish impregnated windings, and be suitable for outdoor operation in a
raintight enclosure.
Each transformer to be installed in a pull box must be the submersible type and include a
handle and a hanger.

86-6.09C Submersible Type Transformers

Submersible type transformers must be securely encased in a rugged corrosion resistant,
watertight case and must withstand a 5-day test submerged in 2 feet of salt water, 2 percent salt
by weight, with 12-hour on and off periods. The operating periods must be at full load.
Leads of submersible transformers must be brought out through one or more sealed hubs and
secured to withstand a 100 pound static pull without loosening or leaking.

86-6.10 (BLANK)

86-6.11 FALSEWORK LIGHTING

86-6.11A General
Falsework lighting must include lighting to illuminate the pavement, portals, and pedestrian
walkways at or under openings in the falsework required for traffic.

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Lighting for pedestrian walkway illumination must be installed at all pedestrian openings through
or under falsework.
Before starting falsework opening construction, you must submit a plan of proposed lighting
installations for review and obtain approval. Approval will be made as specified in Section 5-
1.02, "Plans and Working Drawings."
You must design falsework lighting so that required maintenance can be performed with a
minimum of inconvenience to public traffic. Closing of traffic lanes for routine maintenance will
not be permitted on roadways with posted speed limits greater than 25 mph.
Pavement under falsework with portals less than 150 feet apart and falsework portals must be
illuminated only during the hours of darkness as defined in Division 1, Section 280, of the
California Vehicle Code. Photoelectric switches must be used to control falsework lighting
systems. Pavement under falsework with portals 150 feet or more apart and all pedestrian
openings through falsework must be illuminated 24 hours per day.
Lighting fixtures must be aimed to avoid glare to oncoming motorists.
Type NMC cable with No. 12 minimum conductors, with ground wire, must be used. Fasten
cable to supporting structure at sufficient intervals to adequately support cable and within 12
inches from every box or fitting. Conductors within 8 feet of ground must be enclosed in a 1/2
inch or larger metal conduit.
Each illumination system must be on a minimum of 1 separate branch circuit at each bridge
location. Each branch circuit must be fused, not to exceed 20 A.
For falsework lighting, you must arrange with the serving utility to complete service connections.
You must pay for energy, line extension, service, and service hookup costs.
At completion of project or when ordered by the Engineer, falsework lighting equipment will
become your property and you must remove it from the job site.
You may propose a lighting plan that fulfills light intensity requirements to the systems specified
herein. You must supply sufficient data to allow evaluation of alternative methods.

86-6.11B Pavement Illumination

Illumination of pavement at vehicular openings through falsework must comply with the
following:

1. Fixture must include R/FL commercial type floodlamp holder with protective covers.
2. Fixture must be fully adjustable with brackets and locking screws, and allow mounting
directly to a standard metal junction box.
3. Lamp must be medium-base 120 V(ac), 120 W, minimum, PAR-38 quartz-halogen
floodlamp.
4. A continuous row of fixture types required must be installed at locations and spacing
specified. Fixtures must be installed beneath falsework structure, with the end fixtures
not further than 10 feet inside portal faces. Fixtures must be installed and energized
immediately after the members supporting them have been erected.
5. Fixtures along the sides of the opening must be placed not more than 4 feet behind or 2
feet in front of the roadway face of the temporary railing. Mounting heights of fixtures

April 11,2011 4-265

must be between 12 and 16 feet above the roadway surface and must present an
unobstructed light pattern on the pavement.

86-6.11C Portal Illumination

Illumination of falsework portals must comply with the following:

1. On each side of each entrance portal, plywood sheet clearance guides, 4 feet wide by 8
feet high, must be fastened vertically, facing traffic, with the bottom of the panel 3 feet to
4 feet above the roadway. The center of the panel must be located approximately 3 feet
horizontally behind the roadway face of the railing. Panels must be freshly painted for
each installation with not less than 2 applications of flat white paint. Paint testing will
not be required.
2. If ordered by the Engineer, in order to improve the general appearance of the painted
surfaces, you must repaint designated areas and that painting will be paid for as extra
work as specified in Section 4-1.03D, "Extra Work."
3. Falsework portals must be illuminated on the side facing traffic with 150 W, minimum,
PAR reflector floodlamps mounted on the structure directly over each vertical support
adjacent to the traveled way, as needed to uniformly illuminate the exterior falsework
beam, the clearance guides, and the overhead clearance sign. Each lamp must be
supported approximately 16 feet above the pavement and approximately 6 feet in front of
the portal face.
4. Portal lighting and clearance guides must be installed on the day that vertical members
are erected.

86-6.11D Pedestrian Walkway Illumination

Illumination of pedestrian openings through or under falsework must comply with the following:

1. Fixtures must be flush-mounted in the overhead protection shield and equipped with a
damage-resistant clear polycarbonate diffuser lens. Lamps must be standard
incandescent 100 W, 120 V(ac).
2. Fixtures must be centered over the passageway at intervals of not more than 15 feet with
the end fixtures not more than 7 feet inside the end of the pedestrian openings.
3. Pedestrian passageway light systems must be installed immediately after the overhead
protection shield is erected.

86-7 REMOVING, REINSTALLING OR SALVAGING ELECTRICAL EQUIPMENT

86-7.01 REMOVING ELECTRICAL EQUIPMENT
Existing electrical equipment, pull boxes, and conduits, to be removed and not reused or
salvaged, become your property and you must dispose of it under Section 7-1.13, "Disposal of
Materials Outside the Highway Right of Way." Unused underground conduit may be abandoned
in place after all conductors have been removed, except that conduit terminations from conduit
to be abandoned must be removed from pull boxes to remain.

April 11,2011 4-266

Exercise care in salvaging equipment so that it will not be damaged or destroyed. Mast arms
must be removed from standards. Luminaires, signal heads, and signal mounting assemblies
must be removed from standards and mast arms.
Holes resulting from removing pull boxes must be filled with material equivalent to the
surrounding material.

86-7.02 REINSTALLING REMOVED ELECTRICAL EQUIPMENT

If removed electrical equipment is to be reinstalled, you must supply all necessary materials and
equipment, including signal mounting assemblies, anchor bolts, nuts, washers, and concrete as
required to complete the new installation.
Luminaires to be reinstalled must be cleaned and relamped.
Existing materials required to be reused and found to be unsatisfactory by the Engineer must be
replaced with new material and the replacement cost will be paid for as extra work as specified
in Section 4-1.03D, "Extra Work."

86-8 PAYMENT
86-8.01 PAYMENT
The contract lump sum price or prices paid for signal, ramp metering, flashing beacon, lighting,
sign illumination, traffic monitoring station, highway advisory radio systems, closed circuit
television systems, or combinations thereof; for modifying or removing those systems; for
temporary systems; or the lump sum or unit prices paid for various units of those systems; or
the lump sum or per foot price paid for conduit of the various sizes, types, and installation
methods listed in the Engineer's Estimate include full compensation for furnishing all labor,
materials, tools, equipment and incidentals, and for doing all the work involved in furnishing and
installing, modifying, or removing the systems, combinations or units thereof, including any
necessary pull boxes (except if the type required is shown as a separate contract item);
excavation and backfill; concrete foundations (except if shown as a separate contract item);
pedestrian barricades; furnishing and installing illuminated street name signs; installing sign
panels on pedestrian barricades, on flashing beacon standards, and on traffic signal mast arms;
restoring sidewalk, pavement and appurtenances damaged or destroyed during construction;
salvaging existing materials; and making all required tests, as shown on the plans, as specified
in these specifications and the special provisions, and as directed by the Engineer.
If poles for electrical systems are manufactured from a source located more than 300 air-line
miles from Sacramento and Los Angeles, the Department will deduct $5,000 for inspection
costs for each inspection site. If poles for electrical systems are manufactured from a source
located more than 3,000 air-line miles from Sacramento and Los Angeles, the Department will
deduct $8,000 for inspection costs for each inspection site.
Full compensation for all additional materials and labor, not shown on the plans or specified,
that are necessary to complete the installation of the various systems, is included in the prices
paid for the systems, or units thereof, except as provided in Section 86-1.06, "Maintaining
Existing and Temporary Electrical Systems," and no additional compensation will be allowed
therefor.
If shown as a contract item, the contract price paid per foot for cast-in-drilled-hole concrete pile
(signal foundation) includes full compensation for furnishing all labor, materials, tools,

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equipment, and incidentals, and for doing all the work involved in constructing reinforced
concrete pile foundations of the size shown on the Engineer's Estimate, including drilling holes,
disposing of the material resulting from drilling holes, furnishing and placing anchor bolt
assemblies and reinforcing steel, complete in place, as shown on the plans, and as specified in
these specifications and the special provisions, and as directed by the Engineer.
If shown as a contract item, non-reinforced PCC foundations will be measured and paid for by
the cubic yard for foundation concrete in the same manner as specified for minor concrete
(minor structure) in Section 51, "Concrete Structures."
If shown as a separate contract item by the lump sum or per foot, interconnection conduit and
cable includes all interconnection conductors, and conduit and pull boxes containing
interconnection cable and no other conductors. The quantity of interconnection conduit and
cable to be paid for by the foot is the length of that conduit. Compensation for conduit
containing interconnection cable and other conductors is included in the contract price paid for
the item requiring the other conductors.
Full compensation for furnishing, installing, maintaining, and removing falsework lighting
equipment is included in the contract prices paid for the items of work involved in the structure
that requires the falsework lighting and no additional compensation will be allowed therefor.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 88 ENGINEERING FABRICS

(Issued 06-05-09)

Replace Section 88 with:

SECTION 88 GEOSYNTHETICS
88-1.01 GENERAL
88-1.01A Summary
Section 88 includes specifications for geosynthetics. Geosynthetics are used for:

1. Filtration
2. Drainage
3. Reinforcement
4. Water pollution control
5. Channel and shore protection
6. Pavement interlayer
7. Separation and stabilization

88-1.01B Submittals
Submit:

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1. Certificate of Compliance under Section 6-1.07, "Certificates of Compliance"

2. Samples representing each lot
3. Minimum average roll values (MARV)

Label submittals with the manufacturer's name and product information.

88-1.01C Quality Control and Assurance

Treat geosynthetics to resist degradation from exposure to sunlight. Using covers, protect
geosynthetics from moisture, sunlight, and shipping and storage damage.

88-1.02 FILTRATION
88-1.02A Filter Fabric
Geosynthetics used for filter fabric must be permeable and nonwoven. Filter fabric must consist
of 1 of the following:

1. Polyester
2. Polypropylene
3. Combined polyester and polypropylene

Filter fabric must comply with:

Filter Fabric
Property ASTM Specification
Class A Class B Class C
Grab breaking load, 1-inch grip, lb
minimum in each direction D 4632 157
Apparent elongation, percent
minimum in each direction D 4632 50
Hydraulic bursting strength, psi
minimum D 3786 210
Ultraviolet resistance, percent
minimum retained grab breaking
load, 500 hr D 4355 70
Permittivity, sec-1
minimum D 4491 0.5 0.2 0.1
Apparent opening size, average roll
value, U.S. Standard sieve size
maximum D 4751 40 60 70

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88-1.03 DRAINAGE
88-1.03A Geocomposite Wall Drain
Geocomposite wall drain must consist of a polymeric core with filter fabric integrally bonded to 1
or both sides of the core creating a stable drainage void.
Filter fabric must comply with Section 88-1.02, "Filtration."
Geocomposite wall drain must comply with:

Geocomposite Wall Drain

Property ASTM Specification
Thickness with fabric, -- 2
inches
maximum
Transmissivity, gradient = D 4716 4
1.0, normal stress = 5,000
psf, gal/min/ft

88-1.04 REINFORCEMENT
88-1.04A Geotechnical Subsurface Reinforcement
General
Geosynthetic used for geotechnical subsurface reinforcement must be either of the following:

1. Geotextile
2. Geogrid

Geotextile permittivity must be at least 0.05 sec-1 determined under ASTM D 4491.
Geogrid must have a regular and defined open area. The open area must be from 50 to 90
percent of the total grid area.

Long Term Design Strength

Long Term Design Strength (LTDS) of geosynthetic reinforcement is the ultimate tensile
strength in the primary strength direction divided by reduction factors. Calculate the LTDS from
the guidelines in Geosynthetic Research Institute (GRI) Standard Practice GG4a, GRI GG4b, or
GRI GT7.
The product of the appropriate reduction factors must be at least 1.30. Determine the reduction
factor for creep using a 75-year design life for permanent applications and a 5-year design life
for temporary applications. Determine the installation damage reduction factor based on the
characteristics of the backfill materials used.
If test data is not available, use default values of reduction factors in the GRI Standard Practice
to calculate LTDS.
Submit the LTDS and its supporting calculations at least 15 days before placing geosynthetic
reinforcement. Do not install before the Engineer's approval. The LTDS must be signed by an
engineer who is registered as a civil engineer in the State.

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88-1.05 WATER POLLUTION CONTROL

Geosynthetics used for water pollution control must comply with:

Water Pollution Control Geosynthetics

Application
Silt Fence Sediment Gravel- Temporary
Filter Filled Cover
Bag Bags
Woven Non-
Property ASTM woven
Grab breaking load, 1-inch
grip, lb
minimum in each direction D 4632 120 120 255 205 200
Apparent elongation, percent
minimum, in each direction D 4632 15 50 -- -- 50
Water flow rate, gallons per
minute/square foot
minimum and maximum
average roll value D 4491 10 - 100 100 - 150 80 - 200 80 - 150 75 - 120
Permittivity, sec-1
minimum D 4491 0.1 1.1 1.0 0.2 1.0
Apparent opening size, inches
maximum average roll
value D 4751 0.023 0.023 0.033 0.016 0.007
Ultraviolet resistance, percent
minimum retained grab
breaking load, 500 hr. D 4355 70 70 70 70 70

88-1.06 CHANNEL AND SHORE PROTECTION

88-1.06A Rock Slope Protection
Rock slope protection (RSP) fabric must be a permeable, nonwoven, needle-punched
geotextile. RSP fabric consists of 1 of the following:

1. Polyester
2. Polypropylene
3. Combined polyester and polypropylene

Polymers must be either virgin compounds or clean reworked material. Do not subject virgin
compounds to use or processing other than required for initial manufacture. Clean reworked
material must be previously processed material from the processor's own production that has
been reground, pelletized, or solvated. RSP fabric must not consist of more than 20 percent by
weight of clean reworked material. Do not use recycled materials from either post-consumer or
post-industrial sources.
Class 8 or Class 10 RSP fabric must comply with:

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Rock Slope Protection Fabric

Property ASTM Specification
Class 8 Class 10
Weight, oz/yd2
minimum D 5261 7.5 9.5
Grab breaking load, lb
1-inch grip, min. in each
direction D 4632 200 250
Apparent elongation, percent
min., in each direction D 4632 50 50
Permittivity, sec-1,
minimum D 4491 1.0 0.70
Apparent opening size, U.S.
Standard sieve size
minimum and maximum D 4751 70 - 100 70 - 100
Ultraviolet resistance, percent
minimum retained grab
breaking load, 500 hr. D4355 70 70

88-1.07 PAVEMENT INTERLAYER

88-1.07A Paving Fabric
Geosynthetics used for paving fabric must be nonwoven. Paving fabric must comply with:

Geosynthetic Paving Fabric

Property ASTM Specification
Mass per unit area, oz/yd2
minimum D 5261 4.1
Grab breaking load, lb
1-inch grip, minimum, in each direction D 4632 100
Apparent elongation, percent
minimum in each direction D 4632 50
Hydraulic bursting strength, psi
minimum D 3786 200
Melting point, °F
minimum D 276 325
Asphalt retention, gal/yd2
minimum D 6140 0.2

88-1.07B Paving Mat

Geosynthetics used for paving mat must be a nonwoven fiberglass and polyester hybrid
material. Paving mat must comply with:

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Geosynthetic Paving Mat

Property ASTM Specification
Breaking force, lb/2 inches
minimum D 5035 45
Ultimate elongation, percent
maximum D 5035 5
Mass per unit area, oz/ sq yd
minimum D 5261 3.7
Melting point, °F
minimum D 276 400
Asphalt retention, gal/yd2
minimum D 6140 0.10

88-1.07C Paving Grid

Geosynthetics used for paving grid must be a geopolymer material formed into a grid of
integrally connected elements with openings. Paving grid must comply with:

Geosynthetic Paving Grid

Property Test Specification
Class I Class II Class III
Tensile strength at
ultimate, lb/in a
minimum ASTM D 6637 560 x 1,120 560 280
Aperture size, inch
minimum Calipered 0.5 0.5 0.5
Elongation, %
maximum ASTM D 6637 12 12 12
Mass per area, oz / sqyd
minimum ASTM D 5261 16 10 5.5
Melting point, °F
minimum ASTM D 276 325 325 325
Note:
a
For Class I, machine direction x cross direction. For Class II and Class III, both directions.

88-1.07D Paving Geocomposite Grid

Paving geocomposite grid consists of paving grid specified under Section 88-1.07C, "Paving
Grid," bonded or integrated with paving fabric specified under Section 88-1.07A, "Paving
Fabric."
Paving geocomposite grid must have a peel strength of at least 10 pounds per foot determined
under ASTM D 413.

88-1.07E Geocomposite Strip Membrane

Geocomposite strip membrane must consist of various widths of strips manufactured from of
asphaltic rubber and geosynthetics. Geocomposite strip membrane must comply with:

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Geocomposite Strip Membrane

Property ASTM Specification
Strip tensile strength, lbs/inch
minimum D 882 50
Elongation at break, %
minimum D 882 50
Resistance to puncture, lbs.
minimum E 154 200
Permeance, perms
maximum E 96/E 96M 0.10
Pliability, 1/4 inch mandrel with sample No cracks in
conditioned at 25 °F D 146 fabric or bitumen
Melting point, °F D 276 325

88-1.08 SEPARATION AND STABILIZATION

88-1.08A Subgrade Enhancement Geotextile
Subgrade enhancement geotextile must consist of either of the following:

1. Polyester
2. Polypropylene

Subgrade enhancement geotextile must comply with:

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Subgrade Enhancement Geotextile

Property ASTM Specification a
Class A1 Class A2 Class B1 Class B2 Class B3
Elongation at break, % D 4632 <50 ≥50 <50 <50 ≥50
Grab tensile strength, lb
minimum D4632 250 160 -- 320 200
Wide width tensile strength at 5%
strain, lb/ft
minimum D 4595 -- -- 2,000 -- --
Wide width tensile strength at
ultimate strength, lb/ft
minimum D 4595 -- -- 4,800 -- --
Tear strength, lb
minimum D 4533 90 60 -- 120 80
Puncture strength, lb
minimum D 6241 500 310 620 620 430
Permittivity, sec-1
minimum D 4491 0.05 0.05 0.20 0.20 0.20
Apparent opening size, inches
maximum D 4751 0.012 0.012 0.024 0.012 0.012
Ultraviolet stability (retained
strength after 500 hrs exposure), %
minimum D 4355 70 70 70 70 70
Notes:
a
Specifications are based on minimum average roll value in the weaker principle direction except apparent opening
size is based on maximum average roll value.

88-1.09 PAYMENT
The Department measures and pays for geosynthetics under the specifications requiring their
use.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 90 PORTLAND CEMENT CONCRETE

(Issued 11-30-10)

Replace Section 90 with:

SECTION 90 PORTLAND CEMENT CONCRETE

April 11,2011 4-275

90-1 GENERAL
90-1.01 DESCRIPTION
Portland cement concrete shall be composed of cementitious material, fine aggregate, coarse
aggregate, admixtures if used, and water, proportioned and mixed as specified in these
specifications.
The Contractor shall determine the mix proportions for concrete in conformance with these
specifications.
Minor concrete shall contain not less than 505 pounds of cementitious material per cubic yard
unless otherwise specified in these specifications or the special provisions.
Unless otherwise designated on the plans or specified in these specifications or the special
provisions, the amount of cementitious material used per cubic yard of concrete in structures or
portions of structures shall conform to the following:

Use Cementitious Material Content

(Pounds/CY)
Concrete designated by compressive strength:
Deck slabs and slab spans of bridges 675 min., 800 max.
Roof sections of exposed top box culverts 675 min., 800 max.
Other portions of structures 590 min., 800 max.
Concrete not designated by compressive strength:
Deck slabs and slab spans of bridges 675 min.
Roof sections of exposed top box culverts 675 min.
Prestressed members 675 min.
Seal courses 675 min.
Other portions of structures 590 min.
Concrete for precast members 590 min., 925 max.

Except for minor structures, the minimum required compressive strength for concrete in
structures or portions of structures shall be the strength specified, or 3600 pounds per square
inch at 28 days, whichever is greater.
Except for when a modulus of rupture is specified, the minimum required compressive strength
for concrete shall be the strength specified, or 2,500 pounds per square inch, whichever is
greater. Concrete shall be proportioned such that the concrete will attain the minimum required
compressive strength.
If the specified 28-day compressive strength is 3,600 pounds per square inch or greater, the
concrete is designated by compressive strength. For concrete with a 28-day compressive
strength greater than 3,600 pounds per square inch, 42 days will be allowed to obtain the
specified strength.
For concrete not designated by compressive strength, the Engineer may test the concrete for
compressive strength. The concrete will be accepted if the compressive strength at 28 days
attains 85 percent or more of the minimum required compressive strength.
Concrete shall be proportioned to conform to the following shrinkage limitations when tested in
conformance with the requirements of AASHTO Designation: T 160, modified as follows:

April 11,2011 4-276

Condition Maximum Shrinkage of Laboratory Cast

Specimens at 28 days Drying (average of 3, %)
Paving and approach slab concrete 0.050
Bridge deck concrete 0.045
Note: Shrinkage requirement is waived for concrete that is used for precast elements.

Shrinkage tests shall be either:

A. Performed by a laboratory accredited to perform AASHTO Designation: T 160, or

B. Performed by a laboratory that maintains a current rating of 3 or better for the Cement
and Concrete Reference Laboratory (CCRL) concrete proficiency sample program.

Laboratory cast specimens shall have a 4" x 4" cross section. Specimens shall be removed
from the molds 23 ± 1 hours after mixing the concrete and placed in lime water at 73 ± 3 °F to 7
days age. A comparator reading shall be taken at 7 days age and recorded as the initial
reading. Specimens then shall be stored in a humidity controlled room maintained at 73 ± 3 °F
and 50 ± 4 percent relative humidity for the remainder of the test. Subsequent readings shall be
taken at 7, 14, 21, and 28 days drying.
Test data verifying conformance to the shrinkage limitations shall be submitted with the mix
design. Shrinkage testing data accepted by the Engineer no more than 3 years prior to the first
working day of this contract will be acceptable for this entire contract, provided the data was for
concrete with similar proportions and the same materials and material sources to be used on
this contract. Concrete shall be considered to have similar proportions if, when compared to
concrete to be used on this project, no more than 2 mix design elements are varied. Varied mix
design elements shall fall within the tolerances in the following table:

Mix Design Element Tolerance (±)

Water to cementitious material ratio 0.03
Total water content 5%
Coarse aggregate (weight per cubic yard) 10 %
Fine aggregate (weight per cubic yard) 10 %
Supplementary cementitious material content 5%
Admixture (as originally dosed) 25 %
Note: Admixtures must be of the same brand.

Before using concrete or in advance of revising the mix proportions, the Contractor shall submit
in writing to the Engineer a copy of the mix design.
Compliance with cementitious material content requirements will be verified in conformance with
procedures described in California Test 518 for cement content. For testing purposes,
supplementary cementitious material (SCM) shall be considered to be cement. Batch
proportions shall be adjusted as necessary to produce concrete having the specified
cementitious material content.
If any concrete has a cementitious material, portland cement, or SCM content that is less than
the minimum required, the concrete shall be removed. However, if the Engineer determines
that the concrete is structurally adequate, the concrete may remain in place and the Contractor
shall pay to the State $0.25 for each pound of cementitious material, portland cement, or SCM

April 11,2011 4-277

that is less than the minimum required. The Department may deduct the amount from any
moneys due, or that may become due, the Contractor under the contract. The deductions will
not be made unless the difference between the contents required and those actually provided
exceeds the batching tolerances permitted by Section 90-5, "Proportioning." No deductions will
be made based on the results of California Test 518.
The requirements of the preceding paragraph shall not apply to minor concrete.

90-2 MATERIALS
90-2.01 CEMENTITIOUS MATERIALS
Unless otherwise specified, cementitious material shall be either a combination of Type II or
Type V portland cement and SCM, or a blended cement. No cementitious material shall be
used in the work unless it is on the Department's Pre-Qualified Products List at the time of mix
design submittal. Information regarding cementitious material qualification and placement on
the Department's approved list can be obtained at the Transportation Laboratory.
Cementitious materials used in cast-in-place concrete for exposed surfaces of like elements of a
structure shall be from the same sources and of the same proportions.
Cementitious materials shall be protected from moisture until used. Sacked cementitious
materials shall be piled to permit access for tallying, inspecting, and identifying each shipment.
Facilities shall be provided to ensure that the various cementitious materials meeting this
Section 90-2.01 are kept separate from each other and from other cementitious materials. A
storage silo containing a cementitous material shall be emptied before using that silo for a
different cementitious material. Blended cements with a percentage of SCM differing by more
than 2 percentage points are considered different cementitious materials. Sampling
cementitious materials shall be in conformance with California Test 125.
The Contractor shall furnish a Certificate of Compliance for cementitious materials in
conformance with the provisions in Section 6-1.07, "Certificates of Compliance." The Certificate
of Compliance shall indicate the source by name and location (including country, state, and
city). If cementitious material is delivered directly to the job site, the Certificate of Compliance
shall be signed by the cementitious material supplier. If the cementitious material is used in
ready-mixed concrete or in precast concrete products purchased as such by the Contractor, the
Certificate of Compliance shall be signed by the manufacturer of the concrete or product. If
blended cement is used, the Certificate of Compliance shall include a statement signed by the
blended cement supplier that indicates the actual percentage, by weight, of SCM in the blend.
Weight of SCM shall be by weighing device conforming to Section 9-1.01, "Measurement of
Quantities," or as determined by chemical analysis.

90-2.01A Cement
Portland cement shall conform to the requirements in ASTM Designation: C 150 except the C3S
content of Type II cement shall not exceed 65 percent.
Blended cement shall conform to the requirements for Portland Blast-Furnace Slag Cement,
Type IS (MS) or Portland-Pozzolan Cement, Type IP (MS) in AASHTO Designation: M 240,
except that the maximum limits on the pozzolan content shall not apply. Blended cement shall
be comprised of Type II or Type V cement and SCM produced either by intergrinding portland

April 11,2011 4-278

cement clinker and SCM, by blending portland cement and either finely ground granulated blast
furnace slag or finely divided pozzolan, or a combination of intergrinding and blending.
In addition, Type II portland cement and Type V portland cement shall conform to the following
requirements:

A. The cement shall not contain more than 0.60-percent by mass of alkalies, calculated as
the percentage of Na2O plus 0.658 times the percentage of K2O, when determined by
methods as required in AASHTO Designation: T 105; and
B. The autoclave expansion shall not exceed 0.50-percent

Type III portland cement shall be used only as specified or with the approval of the Engineer.
Type III portland cement shall conform to the additional requirements listed above for Type II
portland cement. The Contractor may use Type III portland cement in the manufacturing of
precast concrete.

90-2.01B Supplementary Cementitious Materials

Each supplementary cementitious material shall conform to one of the following:

A. Fly ash conforming to the requirements in AASHTO Designation: M 295, Class F, and
these specifications. The available alkali, as sodium oxide equivalent, shall not exceed
1.5 percent when determined in conformance with the requirements in ASTM
Designation: C 311 or the total alkali, as sodium oxide equivalent, shall not exceed 5.0
percent when determined in conformance with the requirements in AASHTO
Designation: T 105.
B. Ultra fine fly ash (UFFA) conforming to the requirements in AASHTO Designation: M
295, Class F, and the following chemical and physical requirements:

Chemical Requirements Percent

Sulfur Trioxide (SO3) 1.5 max.
Loss on ignition 1.2 max.
Available Alkalies (as Na2O) equivalent 1.5 max.

Physical Requirements Percent

Particle size distribution
Less than 3.5 microns 50
Less than 9.0 microns 90
Strength Activity Index with portland cement
7 days 95 (minimum % of control)
28 days 110 (minimum % of control)
Expansion at 16 days when testing job materials in 0.10 max.
conformance with ASTM C 1567*
* In the test mix, Type II or Type V portland cement shall be replaced with at least 12% UFFA by weight.

C. Raw or calcined natural pozzolans conforming to the requirements in AASHTO

Designation: M 295, Class N. and the following requirements and these specifications.

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The available alkali, as sodium oxide equivalent, shall not exceed 1.5 percent when
determined in conformance with the requirements in ASTM Designation: C 311 or the
total alkali, as sodium oxide equivalent, shall not exceed 5.0 percent when determined in
conformance with the requirements in AASHTO Designation: T 105.
D. Metakaolin conforming to the requirements in AASHTO Designation: M 295, Class N,
and the following chemical and physical requirements:

Chemical Requirements Percent

Silicon Dioxide (SiO2) + Aluminum Oxide (Al2O3) 92.0 min.
Calcium Oxide (CaO) 1.0 max
Sulfur Trioxide (SO3) 1.0 max.
Loss on ignition 1.2 max.
Available Alkalies (as Na2O) equivalent 1.0 max.

Physical Requirements Percent

Particle size distribution 95
Less than 45 microns

Strength Activity Index with portland cement

7 days 100 (minimum % of control)
28 days 100 (minimum % of control)

E. Ground Granulated Blast Furnace Slag (GGBFS) conforming to the requirements in

AASHTO Designation: M 302, Grade 100 or Grade 120.
F. Silica Fume conforming to the requirements of AASHTO Designation: M 307, with
reduction in mortar expansion of 80 percent, minimum, using the cement from the
proposed mix design.

Commingling of fly ash from different sources at uncontrolled ratios is permissible only if the
following criteria are satisfied:

A. Sources of fly ash to be commingled shall each produce fly ash that conforms to the
requirements in AASHTO Designation: M 295, Class F.
B. Testing of the commingled product is the responsibility of the fly ash supplier.
C. Each fly ash's running average of relative density shall not differ from any other by more
than 0.25 pound per cubic inch at the time of commingling.
D. Each fly ash's running average of loss on ignition shall not differ from any other by more
than one percent at the time of commingling.
E. The final product of commingled fly ash shall conform to the requirements in AASHTO
Designation: M 295, Class F.

April 11,2011 4-280

90-2.01C Required Use Of Supplementary Cementitious Materials

General
The amount of portland cement and SCM used in portland cement concrete shall conform to the
minimum cementitious material content provisions in Section 90-1.01, "Description," or Section
90-4.05, "Optional Use of Chemical Admixtures," and these specifications.
The SCM content in portland cement concrete shall conform to one of the following:

A. Any combination of portland cement and at least one SCM, satisfying Equations (1) and
(2):

Equation (1)

(25 x UF) + (12 x FA) + (10 x FB) + (6 x SL) ≥X

Where:

UF = Silica fume, metakaolin, or UFFA, including the amount in blended cement,

pounds per cubic yard.
FA = Fly ash or natural pozzolan conforming to the requirements in AASHTO
Designation: M 295, Class F or N with a CaO content up to 10 percent, including
the amount in blended cement, pounds per cubic yard.
FB = Fly ash or natural pozzolan conforming to the requirements in AASHTO
Designation: M 295, Class F or N with a CaO content up to 15 percent, including
the amount in blended cement, pounds per cubic yard.
SL = GGBFS, including the amount in blended cement, pounds per cubic yard.
MC = Minimum amount of cementitious material specified, pounds per cubic yard.
X = 1.8 for innocuous aggregate, 3.0 for all other aggregate.

Equation (2)

MC – MSCM - PC ≥0

Where:

MC = Minimum amount of cementitious material specified, pounds per cubic yard.

MSCM = The minimum sum of SCMs that satisfies Equation (1) above, pounds per cubic
yard.
PC = The amount of portland cement, including the amount in blended cement, pounds
per cubic yard.

B. 15 percent of Class F fly ash with at least 48 ounces of LiNO3 solution added per 100
pounds of portland cement. CaO content of the fly ash shall not exceed 15 percent.

April 11,2011 4-281

Precast Concrete
The SCM content in precast portland cement concrete shall conform to one of the following:

A. Any combination of portland cement and SCM, satisfying the following equation:

Equation (3)

(25 x UF) + (12 x FA) + (10 x FB) + (6 x SL) ≥X

Where:

UF = Silica fume, metakaolin, or UFFA, including the amount in blended cement,

pounds per cubic yard.
FA = Fly ash or natural pozzolan conforming to the requirements in AASHTO
Designation: M 295, Class F or N with a CaO content up to 10 percent, including
the amount in blended cement, pounds per cubic yard.
FB = Fly ash or natural pozzolan conforming to the requirements in AASHTO
Designation: M 295, Class F or N with a CaO content up to 15 percent, including
the amount in blended cement, pounds per cubic yard.
SL = GGBFS, including the amount in blended cement, pounds per cubic yard.
TC = Total amount of cementitious material used in the mix, pounds per cubic yard.
X = 0.0 if precast members are constructed with portland cement concrete using
aggregate that is "innocuous" in conformance with the provisions in Section 90-
2.02, "Aggregates."
X = 3.0 for all other aggregate.

B. 15 percent of Class F fly ash with at least 48 ounces of LiNO3 solution added per 100
pounds of portland cement. CaO content of the fly ash shall not exceed 15 percent.
C. Any combination of supplementary cementitious material and portland cement may be
used if the expansion of cementitious material and aggregate does not exceed 0.10
percent when tested in conformance with the requirements in ASTM C 1567. Test data
shall be submitted with each mix design. Test data accepted by the Engineer no more
than 3 years prior to the first working day of this contract will be acceptable for this
entire contract, provided the data was for the same concrete mix and the same materials
and material sources to be used on this contract.

90-2.02 AGGREGATES
To be considered innocuous, aggregate must be on the Department's approved list, "Innocuous
Aggregates for use in Concrete." Information regarding aggregate qualification and placement
on the Department's approved list can be obtained at the Transportation Laboratory.
Both coarse and fine aggregate must be on the approved list for the aggregate used in concrete
to be considered innocuous.

April 11,2011 4-282

Aggregates shall be free from deleterious coatings, clay balls, roots, bark, sticks, rags, and
other extraneous material.
The Contractor shall provide safe and suitable facilities, including necessary splitting devices for
obtaining samples of aggregates, in conformance with California Test 125.
Aggregates shall be of such character that it will be possible to produce workable concrete
within the limits of water content provided in Section 90-6.06, "Amount of Water and
Penetration."
Aggregates shall have not more than 10 percent loss when tested for soundness in
conformance with the requirements in California Test 214. The soundness requirement for fine
aggregate will be waived, provided that the durability index, Df, of the fine aggregate is 60 or
greater when tested for durability in conformance with California Test 229.
If the results of any one or more of the Cleanness Value, Sand Equivalent, or aggregate grading
tests do not meet the requirements specified for "Operating Range" but all meet the "Contract
Compliance" requirements, the placement of concrete shall be suspended at the completion of
the current pour until tests or other information indicate that the next material to be used in the
work will comply with the requirements specified for "Operating Range."
If the results of either or both the Cleanness Value and coarse aggregate grading tests do not
meet the requirements specified for "Contract Compliance," the concrete that is represented by
the tests shall be removed. However, if the Engineer determines that the concrete is structurally
adequate, the concrete may remain in place, and the Contractor shall pay to the State $3.50 per
cubic yard for paving concrete and $5.50 per cubic yard for all other concrete for the concrete
represented by these tests and left in place. The Department may deduct the amount from any
moneys due, or that may become due, the Contractor under the contract.
If the results of either or both the Sand Equivalent and fine aggregate grading tests do not meet
the requirements specified for "Contract Compliance," the concrete which is represented by the
tests shall be removed. However, if the Engineer determines that the concrete is structurally
adequate, the concrete may remain in place, and the Contractor shall pay to the State $3.50 per
cubic yard for paving concrete and $5.50 per cubic yard for all other concrete for the concrete
represented by these tests and left in place. The Department may deduct the amount from any
moneys due, or that may become due, the Contractor under the contract.
The 2 preceding paragraphs apply individually to the "Contract Compliance" requirements for
coarse aggregate and fine aggregate. When both coarse aggregate and fine aggregate do not
conform to the "Contract Compliance" requirements, both paragraphs shall apply. The
payments specified in those paragraphs are in addition to any payments made in conformance
with the provisions in Section 90-1.01, "Description."
No single Cleanness Value, Sand Equivalent, or aggregate grading test shall represent more
than 300 cubic yards of concrete or one day's pour, whichever is smaller.
When the source of an aggregate is changed, the Contractor shall adjust the mix proportions
and submit in writing to the Engineer a copy of the mix design before using the aggregates.

90-2.02A Coarse Aggregate

Coarse aggregate shall consist of gravel, crushed gravel, crushed rock, reclaimed aggregate,
crushed air-cooled iron blast furnace slag or combinations thereof. Crushed air-cooled blast
furnace slag shall not be used in reinforced or prestressed concrete.

April 11,2011 4-283

Reclaimed aggregate is aggregate that has been recovered from plastic concrete by washing
away the cementitious material. Reclaimed aggregate shall conform to all aggregate
requirements.
Coarse aggregate shall conform to the following quality requirements:

California
Tests Test Requirements
Loss in Los Angeles Rattler (after 500 211 45% max.
revolutions)
Cleanness Value
Operating Range 227 75 min.
Contract Compliance 227 71 min.

In lieu of the above Cleanness Value requirements, a Cleanness Value "Operating Range" limit
of 71, minimum, and a Cleanness Value "Contract Compliance" limit of 68, minimum, will be
used to determine the acceptability of the coarse aggregate if the Contractor furnishes a
Certificate of Compliance, as provided in Section 6-1.07, "Certificates of Compliance," certifying
that:

A. Coarse aggregate sampled at the completion of processing at the aggregate production

plant had a Cleanness Value of not less than 82 when tested in conformance with the
requirements in California Test 227; and
B. Prequalification tests performed in conformance with the requirements in California Test
549 indicated that the aggregate would develop a relative strength of not less than 95
percent and would have a relative shrinkage not greater than 105 percent, based on
concrete.

90-2.02B Fine Aggregate

Fine aggregate shall consist of natural sand, manufactured sand produced from larger
aggregate or a combination thereof. Manufactured sand shall be well graded.
Fine aggregate shall conform to the following quality requirements:

California
Test Test Requirements
Organic Impurities 213 Satisfactorya
Sand Equivalent:
Operating Range 217 75, min.
Contract Compliance 217 71, min.
a
Fine aggregate developing a color darker than the reference standard color
may be accepted if 95% relative mortar strength is achieved when tested in
conformance with ASTM C87.

In lieu of the above Sand Equivalent requirements, a Sand Equivalent "Operating Range" limit
of 71, minimum, and a Sand Equivalent "Contract Compliance" limit of 68, minimum, will be

April 11,2011 4-284

used to determine the acceptability of the fine aggregate if the Contractor furnishes a Certificate
of Compliance, as provided in Section 6-1.07, "Certificates of Compliance," certifying that:

A. Fine aggregate sampled at the completion of processing at the aggregate production plant
had a Sand Equivalent value of not less than 82 when tested by California Test 217; and
B. Prequalification tests performed in conformance with California Test 549 indicated that
the aggregate would develop a relative strength of not less than 95 percent and would
have a relative shrinkage not greater than 105 percent, based on concrete.

90-2.03 WATER
In conventionally reinforced concrete work, the water for curing, for washing aggregates, and for
mixing shall be free from oil and shall not contain more than 1,000 parts per million of chlorides
as Cl, when tested in conformance with California Test 422, nor more than 1,300 parts per
million of sulfates as SO4, when tested in conformance with California Test 417. In prestressed
concrete work, the water for curing, for washing aggregates, and for mixing shall be free from oil
and shall not contain more than 650 parts per million of chlorides as Cl, when tested in
conformance with California Test 422, nor more than 1,300 parts per million of sulfates as SO4,
when tested in conformance with California Test 417. In no case shall the water contain an
amount of impurities that will cause either: 1) a change in the setting time of cement of more
than 25 percent when tested in conformance with the requirements in ASTM Designation: C
191 or ASTM Designation: C 266 or 2) a reduction in the compressive strength of mortar at 14
days of more than 5 percent, when tested in conformance with the requirements in ASTM
Designation: C 109, when compared to the results obtained with distilled water or deionized
water, tested in conformance with the requirements in ASTM Designation: C 109.
In nonreinforced concrete work, the water for curing, for washing aggregates and for mixing
shall be free from oil and shall not contain more than 2,000 parts per million of chlorides as Cl,
when tested in conformance with California Test 422, or more than 1,500 parts per million of
sulfates as SO4, when tested in conformance with California Test 417.
In addition to the above provisions, water for curing concrete shall not contain impurities in a
sufficient amount to cause discoloration of the concrete or produce etching of the surface.
Water reclaimed from mixer wash-out operations may be used in mixing concrete. The water
shall not contain coloring agents or more than 300 parts per million of alkalis (Na2O + 0.658
K2O) as determined on the filtrate. The specific gravity of the water shall not exceed 1.03 and
shall not vary more than ±0.010 during a day's operations.

90-2.04 Admixture Materials

Admixture materials shall be stored and dispersed in liquid form and conform to the following
requirements:

A. Chemical Admixtures—ASTM Designation: C 494.

B. Air-entraining Admixtures—ASTM Designation: C 260.
C. Lithium Nitrate shall be in an aqueous solution conforming to the following:

1. Lithium Nitrate (LiNO3) must be 30 percent +/- 0.5 percent by weight

April 11,2011 4-285

2. Sulfate (SO4) must be less than 1000 ppm

3. Chloride (Cl) must be less than 1000 ppm
4. Alkalis (Na2O + 0.658 K2O) must be less than 1000 ppm

90-3 AGGREGATE GRADINGS

90-3.01 GENERAL
Before beginning concrete work, the Contractor shall submit in writing to the Engineer the
gradation of the primary aggregate nominal sizes that the Contractor proposes to furnish. If a
primary coarse aggregate or the fine aggregate is separated into 2 or more sizes, the proposed
gradation shall consist of the gradation for each individual size, and the proposed proportions of
each individual size, combined mathematically to indicate one proposed gradation. The
proposed gradation shall meet the grading requirements shown in the table in this section, and
shall show the percentage passing each of the sieve sizes used in determining the end result.
The Engineer may waive, in writing, the gradation requirements in this Section 90-3.01 and in
Sections 90-3.02, "Coarse Aggregate Grading," 90-3.03, "Fine Aggregate Grading," and 90-
3.04, "Combined Aggregate Gradings," if, in the Engineer's opinion, furnishing the gradation is
not necessary for the type or amount of concrete work to be constructed.
Gradations proposed by the Contractor shall be within the following percentage passing limits:

Primary Aggregate Nominal Size Sieve Size Limits of Proposed Gradation

1-1/2" x 3/4" 1" 19 - 41
1" x No. 4 3/4" 52 - 85
1" x No. 4 3/8" 15 - 38
1/2" x No. 4 3/8" 40 - 78
3/8" x No. 8 3/8" 50 - 85
Fine Aggregate No. 16 55 - 75
Fine Aggregate No. 30 34 - 46
Fine Aggregate No. 50 16 - 29

Should the Contractor change the source of supply, the Contractor shall submit in writing to the
Engineer the new gradations before their intended use.

90-3.02 COARSE AGGREGATE GRADING

The grading requirements for coarse aggregates are shown in the following table for each size
of coarse aggregate:

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Percentage Passing Primary Aggregate Nominal Sizes

1-1/2" x 3/4" 1" x No. 4 1/2" x No. 4 3/8" x No. 8
Operating Contract Operating Contract Operating Contract Operating Contract
Sieve Sizes Range Compliance Range Compliance Range Compliance Range Compliance
2" 100 100 — — — — — —
1-1/2" 88 - 100 85 - 100 100 100 — — — —
1" X ±18 X ±25 88 - 100 86 - 100 — — — —
3/4" 0 - 17 0 - 20 X ±15 X ±22 100 100 — —
1/2" — — — — 82 - 100 80 - 100 100 100
3/8" 0-7 0-9 X ±15 X ±22 X ±15 X ±22 X ±15 X ±20
No. 4 — — 0 - 16 0 - 18 0 - 15 0 - 18 0 - 25 0 - 28
No. 8 — — 0-6 0-7 0-6 0-7 0-6 0-7

In the above table, the symbol X is the gradation that the Contractor proposes to furnish for the
specific sieve size as provided in Section 90-3.01, "General."
Coarse aggregate for the 1-1/2 inch, maximum, combined aggregate grading as provided in
Section 90-3.04, "Combined Aggregate Gradings," shall be furnished in 2 or more primary
aggregate nominal sizes. Each primary aggregate nominal size may be separated into 2 sizes
and stored separately, provided that the combined material conforms to the grading
requirements for that particular primary aggregate nominal size.
When the one inch, maximum, combined aggregate grading as provided in Section 90-3.04,
"Combined Aggregate Gradings," is to be used, the coarse aggregate may be separated into 2
sizes and stored separately, provided that the combined material shall conform to the grading
requirements for the 1" x No. 4 primary aggregate nominal size.

90-3.03 FINE AGGREGATE GRADING

Fine aggregate shall be graded within the following limits:

Percentage Passing
Sieve Sizes Operating Range Contract Compliance
3/8" 100 100
No. 4 95 - 100 93 - 100
No. 8 65 - 95 61 - 99
No. 16 X ±10 X ±13
No. 30 X ±9 X ±12
No. 50 X ±6 X ±9
No. 100 2 - 12 1 - 15
No. 200 0-8 0 - 10

In the above table, the symbol X is the gradation that the Contractor proposes to furnish for the
specific sieve size as provided in Section 90-3.01, "General."
In addition to the above required grading analysis, the distribution of the fine aggregate sizes
shall be such that the difference between the total percentage passing the No. 16 sieve and the
total percentage passing the No. 30 sieve shall be between 10 and 40, and the difference
between the percentage passing the No. 30 and No. 50 sieves shall be between 10 and 40.

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Fine aggregate may be separated into 2 or more sizes and stored separately, provided that the
combined material conforms to the grading requirements specified in this Section 90-3.03.

90-3.04 COMBINED AGGREGATE GRADINGS

Combined aggregate grading limits shall be used only for the design of concrete mixes.
Concrete mixes shall be designed so that aggregates are combined in proportions that shall
produce a mixture within the grading limits for combined aggregates as specified herein.
The combined aggregate grading, except when otherwise specified in these specifications or
the special provisions, shall be either the 1-1/2 inch, maximum grading, or the 1 inch, maximum
grading, at the option of the Contractor.

Grading Limits of Combined Aggregates

Percentage Passing
Sieve Sizes 1-1/2" Max. 1" Max. 1/2" Max. 3/8" Max.
2" 100 — — —
1-1/2" 90 - 100 100 — —
1" 50 - 86 90 - 100 — —
3/4" 45 - 75 55 - 100 100 —
1/2" — — 90 - 100 100
3/8" 38 - 55 45 - 75 55 - 86 50 - 100
No. 4 30 - 45 35 - 60 45 - 63 45 - 63
No. 8 23 - 38 27 - 45 35 - 49 35 - 49
No. 16 17 - 33 20 - 35 25 - 37 25 - 37
No. 30 10 - 22 12 - 25 15 - 25 15 - 25
No. 50 4 - 10 5 - 15 5 - 15 5 - 15
No. 100 1-6 1-8 1-8 1-8
No. 200 0-3 0-4 0-4 0-4

Changes from one grading to another shall not be made during the progress of the work unless
permitted by the Engineer.

90-4 ADMIXTURES
90-4.01 GENERAL
Admixtures used in portland cement concrete shall conform to and be used in conformance with
the provisions in this Section 90-4 and the special provisions. Admixtures shall be used when
specified or ordered by the Engineer and may be used at the Contractor's option as provided
herein.
Chemical admixtures and air-entraining admixtures containing chlorides as Cl in excess of one
percent by weight of admixture, as determined by California Test 415, shall not be used.
Admixtures shall be uniform in properties throughout their use in the work. Should it be found
that an admixture as furnished is not uniform in properties, its use shall be discontinued.
If more than one admixture is used, the admixtures shall be compatible with each other so that
the desirable effects of all admixtures used will be realized.

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Chemical admixtures shall be used in conformance with the manufacturer's written

recommendations. The manufacturer's written recommendations shall include a statement that
the admixtures are compatible with the types and amounts of SCMs used.

90-4.02 MATERIALS
Admixture materials shall conform to the provisions in Section 90-2.04, "Admixture Materials."

90-4.03 ADMIXTURE APPROVAL

No admixture brand shall be used in the work unless it is on the Department's current list of
approved brands for the type of admixture involved. Information regarding admixture
qualification and placement on the Department's list can be obtained at the Transportation
Laboratory.
If the Contractor proposes to use an admixture of a brand and type on the current list of
approved admixture brands, the Contractor shall furnish a Certificate of Compliance from the
manufacturer, as provided in Section 6-1.07, "Certificates of Compliance," certifying that the
admixture furnished is the same as that previously approved. If a previously approved
admixture is not accompanied by a Certificate of Compliance, the admixture shall not be used in
the work until the Engineer has had sufficient time to make the appropriate tests and has
approved the admixture for use. The Engineer may take samples for testing at any time,
whether or not the admixture has been accompanied by a Certificate of Compliance.

90-4.04 REQUIRED USE OF CHEMICAL ADMIXTURES

If the use of a chemical admixture is specified, the admixture shall be used at the dosage
specified, except that if no dosage is specified, the admixture shall be used at the dosage
normally recommended by the manufacturer of the admixture.

90-4.05 OPTIONAL USE OF CHEMICAL ADMIXTURES

The Contractor may use Type A or F, water-reducing; Type B, retarding; or Type D or G, water-
reducing and retarding admixtures as described in ASTM Designation: C 494 to conserve
cementitious material or to facilitate any concrete construction application subject to the
following conditions:

A. If a water-reducing admixture or a water-reducing and retarding admixture is used, the

cementitious material content specified or ordered may be reduced by a maximum of 5
percent by weight, except that the resultant cementitious material content shall be not less
than 505 pounds per cubic yard; and
B. When a reduction in cementitious material content is made, the dosage of admixture used
shall be no less than the dosage used in determining approval of the admixture.

The Contractor may use Type S admixtures conforming to the requirements in ASTM
Designation: C 494.

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Unless otherwise specified, a Type C accelerating chemical admixture conforming to the

requirements in ASTM Designation: C 494, may be used in portland cement concrete.
Inclusion in the mix design submitted for approval will not be required provided that the
admixture is added to counteract changing conditions that contribute to delayed setting of the
portland cement concrete, and the use or change in dosage of the admixture is approved in
writing by the Engineer.

90-4.06 REQUIRED USE OF AIR-ENTRAINING ADMIXTURES

When air-entrainment is specified or ordered by the Engineer, the air-entraining admixture shall
be used in amounts to produce a concrete having the specified air content as determined by
California Test 504.

90-4.07 OPTIONAL USE OF AIR-ENTRAINING ADMIXTURES

When air-entrainment has not been specified or ordered by the Engineer, the Contractor will be
permitted to use an air-entraining admixture to facilitate the use of any construction procedure
or equipment provided that the average air content, as determined by California Test 504, of 3
successive tests does not exceed 4 percent, and no single test value exceeds 5.5 percent. If
the Contractor elects to use an air-entraining admixture in concrete for pavement, the
Contractor shall so indicate at the time the Contractor designates the source of aggregate.

90-4.08 BLANK

90-4.09 BLANK

90-4.10 PROPORTIONING AND DISPENSING LIQUID ADMIXTURES

Chemical admixtures and air-entraining admixtures shall be dispensed in liquid form.
Dispensers for liquid admixtures shall have sufficient capacity to measure at one time the
prescribed quantity required for each batch of concrete. Each dispenser shall include a
graduated measuring unit into which liquid admixtures are measured to within ±5 percent of the
prescribed quantity for each batch. Dispensers shall be located and maintained so that the
graduations can be accurately read from the point at which proportioning operations are
controlled to permit a visual check of batching accuracy prior to discharge. Each measuring unit
shall be clearly marked for the type and quantity of admixture.
Each liquid admixture dispensing system shall be equipped with a sampling device consisting of
a valve located in a safe and readily accessible position such that a sample of the admixture
may be withdrawn slowly by the Engineer.
If more than one liquid admixture is used in the concrete mix, each liquid admixture shall have
a separate measuring unit and shall be dispensed by injecting equipment located in such a
manner that the admixtures are not mixed at high concentrations and do not interfere with the
effectiveness of each other. When air-entraining admixtures are used in conjunction with other
liquid admixtures, the air-entraining admixture shall be the first to be incorporated into the mix,
unless it is demonstrated that a different sequence improves performance.

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When automatic proportioning devices are required for concrete pavement, dispensers for liquid
admixtures shall operate automatically with the batching control equipment. The dispensers
shall be equipped with an automatic warning system in good operating condition that will
provide a visible or audible signal at the point at which proportioning operations are controlled
when the quantity of admixture measured for each batch of concrete varies from the preselected
dosage by more than 5 percent, or when the entire contents of the measuring unit are not
emptied from the dispenser into each batch of concrete.
Unless liquid admixtures are added to premeasured water for the batch, their discharge into the
batch shall be arranged to flow into the stream of water so that the admixtures are well
dispersed throughout the batch, except that air-entraining admixtures may be dispensed directly
into moist sand in the batching bins provided that adequate control of the air content of the
concrete can be maintained.
Liquid admixtures requiring dosages greater than one-half gallon per cubic yard shall be
considered to be water when determining the total amount of free water as specified in Section
90-6.06, "Amount of Water and Penetration."

90-4.11 BLANK

90-5 PROPORTIONING
90-5.01 STORAGE OF AGGREGATES
Aggregates shall be stored or stockpiled in such a manner that separation of coarse and fine
particles of each size shall be avoided and the various sizes shall not become intermixed before
proportioning.
Aggregates shall be stored or stockpiled and handled in a manner that prevent contamination by
foreign materials. In addition, storage of aggregates at batching or mixing facilities that are
erected subsequent to the award of the contract and that furnish concrete to the project shall
conform to the following:

A. Intermingling of the different sizes of aggregates shall be positively prevented. The

Contractor shall take the necessary measures to prevent intermingling. The preventive
measures may include, but are not necessarily limited to, physical separation of stockpiles
or construction of bulkheads of adequate length and height; and
B. Contamination of aggregates by contact with the ground shall be positively prevented.
The Contractor shall take the necessary measures to prevent contamination. The
preventive measures shall include, but are not necessarily limited to, placing aggregates
on wooden platforms or on hardened surfaces consisting of portland cement concrete,
asphalt concrete, or cement treated material.

In placing aggregates in storage or in moving the aggregates from storage to the weigh hopper
of the batching plant, any method that may cause segregation, degradation, or the combining of
materials of different gradings that will result in any size of aggregate at the weigh hopper failing
to meet the grading requirements, shall be discontinued. Any method of handling aggregates
that results in excessive breakage of particles shall be discontinued. The use of suitable
devices to reduce impact of falling aggregates may be required by the Engineer.

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90-5.02 PROPORTIONING DEVICES

Weighing, measuring, or metering devices used for proportioning materials shall conform to the
requirements in Section 9-1.01, "Measurement of Quantities," and this Section 90-5.02. In
addition, automatic weighing systems shall comply with the requirements for automatic
proportioning devices in Section 90-5.03A, "Proportioning for Pavement." Automatic devices
shall be automatic to the extent that the only manual operation required for proportioning the
aggregates, cement, and SCM for one batch of concrete is a single operation of a switch or
starter.
Proportioning devices shall be tested as frequently as the Engineer may deem necessary to
ensure their accuracy.
Weighing equipment shall be insulated against vibration or movement of other operating
equipment in the plant. When the plant is in operation, the weight of each batch of material
shall not vary from the weight designated by the Engineer by more than the tolerances specified
herein.
Equipment for cumulative weighing of aggregate shall have a zero tolerance of ±0.5 percent of
the designated total batch weight of the aggregate. For systems with individual weigh hoppers
for the various sizes of aggregate, the zero tolerance shall be ±0.5 percent of the individual
batch weight designated for each size of aggregate. Equipment for cumulative weighing of
cement and SCM shall have a zero tolerance of ±0.5 percent of the designated total batch
weight of the cement and SCM. Equipment for weighing cement or SCM separately shall have
a zero tolerance of ±0.5 percent of their designated individual batch weights. Equipment for
measuring water shall have a zero tolerance of ±0.5 percent of its designated weight or volume.
The weight indicated for any batch of material shall not vary from the preselected scale setting
by more than the following:

A. Aggregate weighed cumulatively shall be within 1.0 percent of the designated total batch
weight of the aggregate. Aggregates weighed individually shall be within 1.5 percent of
their respective designated batch weights; and
B. Cement shall be 99 to 102 percent of its designated batch weight. When weighed
individually, SCM shall be 99 to 102 percent of its designated batch weight. When SCM
and cement are permitted to be weighed cumulatively, cement shall be weighed first to 99
to 102 percent of its designated batch weight, and the total for cement and SCM shall be
99 to 102 percent of the sum of their designated batch weights When a blended cement is
used, the percentages of cement and SCM used for calculating batch weights shall be
based on the percentage of SCM indicated in the Certificate of Compliance from the
blended cement supplier; and
C. Water shall be within 1.5 percent of its designated weight or volume.

Each scale graduation shall be approximately 0.001 of the total capacity of the scale. The
capacity of scales for weighing cement, SCM, or cement plus SCM and aggregates shall not
exceed that of commercially available scales having single graduations indicating a weight not
exceeding the maximum permissible weight variation above, except that no scale shall be
required having a capacity of less than 1,000 pounds, with one pound graduations.

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90-5.03 PROPORTIONING
Proportioning shall consist of dividing the aggregates into the specified sizes, each stored in a
separate bin, and combining them with cementitious material and water as provided in these
specifications. Aggregates shall be proportioned by weight.
At the time of batching, aggregates shall have been dried or drained sufficiently to result in a
stable moisture content such that no visible separation of water from aggregate will take place
during transportation from the proportioning plant to the point of mixing. In no event shall the
free moisture content of the fine aggregate at the time of batching exceed 8 percent of its
saturated, surface-dry weight.
Should separate supplies of aggregate material of the same size group, but of different moisture
content or specific gravity or surface characteristics affecting workability, be available at the
proportioning plant, withdrawals shall be made from one supply exclusively and the materials
therein completely exhausted before starting upon another.
Bulk Type IP (MS) or Type IS (MS) cement shall be weighed in an individual hopper and shall
be kept separate from the aggregates until the ingredients are released for discharge into the
mixer.
Bulk cement and SCM may be weighed in separate, individual weigh hoppers or may be
weighed in the same weigh hopper and shall be kept separate from the aggregates until the
ingredients are released for discharge into the mixer. If the cement and SCM are weighed
cumulatively, the cement shall be weighed first.
If cement and SCM are weighed in separate weigh hoppers, the weigh systems for the
proportioning of the aggregate, the cement, and the SCM shall be individual and distinct from all
other weigh systems. Each weigh system shall be equipped with a hopper, a lever system, and
an indicator to constitute an individual and independent material-weighing device. The cement
and the SCM shall be discharged into the mixer simultaneously with the aggregate.
The scales and weigh hoppers for bulk weighing cement, SCM, or cement plus SCM shall be
separate and distinct from the aggregate weighing equipment.
For batches of one cubic yard or more, the batching equipment shall conform to one of the
following combinations:

A. Separate boxes and separate scale and indicator for weighing each size of aggregate.
B. Single box and scale indicator for all aggregates.
C. Single box or separate boxes and automatic weighing mechanism for all aggregates.

In order to check the accuracy of batch weights, the gross weight and tare weight of batch
trucks, truck mixers, truck agitators, and non-agitating hauling equipment shall be determined
when ordered by the Engineer. The equipment shall be weighed on scales designated by the
Engineer.

90-5.03A Proportioning For Pavement

Aggregates and bulk SCM for use in pavement shall be proportioned by weight by means of
automatic proportioning devices of approved type conforming to these specifications.

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The Contractor shall install and maintain in operating condition an electronically actuated
moisture meter that will indicate, on a readily visible scale, changes in the moisture content of
the fine aggregate as it is batched within a sensitivity of 0.5 percent by weight of the fine
aggregate.
The batching of cement, SCM, or cement plus SCM and aggregate shall be interlocked so that a
new batch cannot be started until all weigh hoppers are empty, the proportioning devices are
within zero tolerance, and the discharge gates are closed. The interlock shall permit no part of
the batch to be discharged until all aggregate hoppers and the cement and SCM hoppers or the
cement plus SCM hopper are charged with weights that are within the tolerances specified in
Section 90-5.02, "Proportioning Devices."
If interlocks are required for cement and SCM charging mechanisms and cement and SCM are
weighed cumulatively, their charging mechanisms shall be interlocked to prevent the
introduction of SCM until the weight of cement in the cement weigh hopper is within the
tolerances specified in Section 90-5.02, "Proportioning Devices."
If concrete is completely mixed in stationary paving mixers, the SCMs shall be weighed in a
separate weigh hopper and the SCM and cement shall be introduced simultaneously into the
mixer proportionately with the aggregate. If the Contractor provides certification that the
stationary mixer is capable of mixing the cement, SCM, aggregates, and water uniformly before
discharge, weighing the SCM cumulatively with the cement is permitted. Certification shall
contain the following:

A. Test results for 2 compressive strength test cylinders of concrete taken within the first
one-third and 2 compressive strength test cylinders of concrete taken within the last one-
third of the concrete discharged from a single batch from the stationary paving mixer.
Strength tests and cylinder preparation will be in conformance with the provisions of
Section 90-9, "Compressive Strength";
B. Calculations demonstrating that the difference in the averages of 2 compressive strengths
taken in the first one-third is no greater than 7.5 percent different than the averages of 2
compressive strengths taken in the last one-third of the concrete discharged from a single
batch from the stationary paving mixer. Strength tests and cylinder preparation will be in
conformance with the provisions of Section 90-9, "Compressive Strength;" and
C. The mixer rotation speed and time of mixing before discharge that are required to
produce a mix that meets the requirements above.

The discharge gate on the cement and SCM hoppers or the cement plus SCM hopper shall be
designed to permit regulating the flow of cement, SCM, or cement plus SCM into the aggregate
as directed by the Engineer.
If separate weigh boxes are used for each size of aggregate, the discharge gates shall permit
regulating the flow of each size of aggregate as directed by the Engineer.
Material discharged from the several bins shall be controlled by gates or by mechanical
conveyors. The means of withdrawal from the several bins, and of discharge from the weigh
box, shall be interlocked so that not more than one bin can discharge at a time, and so that the
weigh box cannot be tripped until the required quantity from each of the several bins has been
deposited therein. Should a separate weigh box be used for each size of aggregate, all may be
operated and discharged simultaneously.

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If the discharge from the several bins is controlled by gates, each gate shall be actuated
automatically so that the required mass is discharged into the weigh box, after which the gate
shall automatically close and lock.
The automatic weighing system shall be designed so that all proportions required may be set on
the weighing controller at the same time.

90-6 MIXING AND TRANSPORTING

90-6.01 GENERAL
Concrete shall be mixed in mechanically operated mixers, except that when permitted by the
Engineer, batches not exceeding 1/3 cubic yard may be mixed by hand methods in
conformance with the provisions in Section 90-6.05, "Hand-Mixing."
Equipment having components made of aluminum or magnesium alloys that would have contact
with plastic concrete during mixing, transporting, or pumping of portland cement concrete shall
not be used.
Concrete shall be homogeneous and thoroughly mixed, and there shall be no lumps or evidence
of undispersed cementitious material.
Uniformity of concrete mixtures will be determined by differences in penetration as determined
by California Test 533, or slump as determined by ASTM Designation: C 143, and by variations
in the proportion of coarse aggregate as determined by California Test 529.
When the mix design specifies a penetration value, the difference in penetration, determined by
comparing penetration tests on 2 samples of mixed concrete from the same batch or truck mixer
load, shall not exceed 1/2 inch. When the mix design specifies a slump value, the difference in
slump, determined by comparing slump tests on 2 samples of mixed concrete from the same
batch or truck mixer load, shall not exceed the values given in the table below. Variation in the
proportion of coarse aggregate will be determined by comparing the results of tests of 2
samples of mixed concrete from the same batch or truck mixer load and the difference between
the 2 results shall not exceed 170 pounds per cubic yard of concrete.

Average Slump Maximum Permissible Difference

Less than 4" 1"
4" to 6" 1-1/2"
Greater than 6" to 9" 2"

The Contractor shall furnish samples of the freshly mixed concrete and provide satisfactory
facilities for obtaining the samples.

90-6.02 MACHINE MIXING

Concrete mixers may be of the revolving drum or the revolving blade type, and the mixing drum
or blades shall be operated uniformly at the mixing speed recommended by the manufacturer.
Mixers and agitators that have an accumulation of hard concrete or mortar shall not be used.
The temperature of mixed concrete, immediately before placing, shall be not less than 50 °F or
more than 90 °F. Aggregates and water shall be heated or cooled as necessary to produce

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concrete within these temperature limits. Neither aggregates nor mixing water shall be heated
to exceed 150 °F. If ice is used to cool the concrete, discharge of the mixer will not be permitted
until all ice is melted.
The batch shall be so charged into the mixer that some water will enter in advance of
cementitious materials and aggregates. All water shall be in the drum by the end of the first
one-fourth of the specified mixing time. When concrete is delivered in a truck mixer, a portion of
the mixing water may be withheld and may be added at the point of delivery as specified under
Section 90-6.03, "Transporting Mixed Concrete."
Cementitious materials shall be batched and charged into the mixer by means that will not result
either in loss of cementitious materials due to the effect of wind, in accumulation of cementitious
materials on surfaces of conveyors or hoppers, or in other conditions that reduce or vary the
required quantity of cementitious material in the concrete mixture.
Paving and stationary mixers shall be operated with an automatic timing device. The timing
device and discharge mechanism shall be interlocked so that during normal operation no part of
the batch will be discharged until the specified mixing time has elapsed.
The total elapsed time between the intermingling of damp aggregates and all cementitious
materials and the start of mixing shall not exceed 30 minutes.
The size of batch shall not exceed the manufacturer's guaranteed capacity.
When producing concrete for pavement or base, suitable batch counters shall be installed and
maintained in good operating condition at job site batching plants and stationary mixers. The
batch counters shall indicate the exact number of batches proportioned and mixed.
Concrete shall be mixed and delivered to the job site by means of one of the following
combinations of operations:

A. Mixed completely in a stationary mixer and the mixed concrete transported to the point of
delivery in truck agitators or in nonagitating hauling equipment (central-mixed concrete).
B. Mixed partially in a stationary mixer, and the mixing completed in a truck mixer (shrink-
mixed concrete).
C. Mixed completely in a truck mixer (transit-mixed concrete).
D. Mixed completely in a paving mixer.

Agitators may be truck mixers operating at agitating speed or truck agitators. Each mixer and
agitator shall have attached thereto in a prominent place a metal plate or plates on which is
plainly marked the various uses for which the equipment is designed, the manufacturer's
guaranteed capacity of the drum or container in terms of the volume of mixed concrete and the
speed of rotation of the mixing drum or blades.
Truck mixers shall be equipped with electrically or mechanically actuated revolution counters by
which the number of revolutions of the drum or blades may readily be verified.
When shrink-mixed concrete is furnished, concrete that has been partially mixed at a central
plant shall be transferred to a truck mixer and all requirements for transit-mixed concrete shall
apply. No credit in the number of revolutions at mixing speed will be allowed for partial mixing in
a central plant.

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90-6.03 TRANSPORTING MIXED CONCRETE

Mixed concrete may be transported to the delivery point in truck agitators or truck mixers
operating at the speed designated by the manufacturer of the equipment as agitating speed, or
in non-agitating hauling equipment, provided the consistency and workability of the mixed
concrete upon discharge at the delivery point is suitable for adequate placement and
consolidation in place, and provided the mixed concrete after hauling to the delivery point
conforms to the provisions in Section 90-6.01, "General."
Truck agitators shall be loaded not to exceed the manufacturer's guaranteed capacity and shall
maintain the mixed concrete in a thoroughly mixed and uniform mass during hauling.
Bodies of nonagitating hauling equipment shall be constructed so that leakage of the concrete
mix, or any part thereof, will not occur at any time.
Concrete hauled in open-top vehicles shall be protected during hauling against rain or against
exposure to the sun for more than 20 minutes when the ambient temperature exceeds 75 °F.
No water in excess of that in the approved mix design shall be incorporated into the concrete. If
approved by the Engineer, water withheld during batching may be added to the concrete at the
delivery point in one operation before the discharge of more than 1/4 cubic yard. Equipment for
supplying the water shall conform to Section 90-6.06, "Amount of Water and Penetration."
When water is added at the point of delivery, the drum shall be revolved not less than 30
revolutions at mixing speed after the water is added and before discharged is commenced.
The rate of discharge of mixed concrete from truck mixer-agitators shall be controlled by the
speed of rotation of the drum in the discharge direction with the discharge gate fully open.
If a truck mixer or agitator is used for transporting concrete to the delivery point, discharge shall
be completed within 1.5 hours or before 250 revolutions of the drum or blades, whichever
occurs first, after the introduction of the cement to the aggregates. Under conditions
contributing to quick stiffening of the concrete, or if the temperature of the concrete is 85 °F or
above, the time allowed may be less than 1.5 hours. If an admixture is used to retard the set
time, the temperature of the concrete shall not exceed 85 °F, the time limit shall be 2 hours, and
the revolution limitation shall be 300.
If nonagitating hauling equipment is used for transporting concrete to the delivery point,
discharge shall be completed within one hour after the addition of the cement to the aggregates.
Under conditions contributing to quick stiffening of the concrete, or when the temperature of the
concrete is 85 °F or above, the time between the introduction of cement to the aggregates and
discharge shall not exceed 45 minutes.
Each load of concrete delivered at the job site shall be accompanied by a weighmaster
certificate showing the mix identification number, nonrepeating load number, date and time at
which the materials were batched, the total amount of water added to the load, and for transit-
mixed concrete, the reading of the revolution counter at the time the truck mixer is charged with
cement. This weighmaster certificate shall also show the actual scale weights (pounds) for the
ingredients batched. Theoretical or target batch weights shall not be used as a substitute for
actual scale weights.
Weighmaster certificates shall be provided in printed form, or if approved by the Engineer, the
data may be submitted in electronic media. Electronic media shall be presented in a tab-
delimited format on a CD or DVD. Captured data, for the ingredients represented by each batch
shall be "line feed, carriage return" (LFCR) and "one line, separate record" with allowances for
sufficient fields to satisfy the amount of data required by these specifications.

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The Contractor may furnish a weighmaster certificate accompanied by a separate certificate that
lists the actual batch weights or measurements for a load of concrete provided that both
certificates are imprinted with the same nonrepeating load number that is unique to the contract
and delivered to the jobsite with the load.
Weighmaster certificates furnished by the Contractor shall conform to the provisions in Section
9-1.01, "Measurement of Quantities."

90-6.04 TIME OR AMOUNT OF MIXING

Mixing of concrete in paving or stationary mixers shall continue for the required mixing time after
all ingredients, except water and admixture, if added with the water, are in the mixing
compartment of the mixer before any part of the batch is released. Transfer time in multiple
drum mixers shall not be counted as part of the required mixing time.
The required mixing time, in paving or stationary mixers, of concrete used for concrete
structures, except minor structures, shall be not less than 90 seconds or more than 5 minutes,
except that when directed by the Engineer in writing, the requirements of the following
paragraph shall apply.
The required mixing time, in paving or stationary mixers, except as provided in the preceding
paragraph, shall be not less than 50 seconds or more than 5 minutes.
The minimum required revolutions at the mixing speed for transit-mixed concrete shall not be
less than that recommended by the mixer manufacturer, but in no case shall the number of
revolutions be less than that required to consistently produce concrete conforming to the
provisions for uniformity in Section 90-6.01, "General."
When a high range water-reducing admixture is added to the concrete at the job site, the total
number of revolutions shall not exceed 300.

90-6.05 HAND-MIXING
Hand-mixed concrete shall be made in batches of not more than 1/3 cubic yard and shall be
mixed on a watertight, level platform. The proper amount of coarse aggregate shall be
measured in measuring boxes and spread on the platform and the fine aggregate shall be
spread on this layer, the 2 layers being not more than one foot in total depth. On this mixture
shall be spread the dry cementitious materials and the whole mass turned no fewer than 2 times
dry; then sufficient clean water shall be added, evenly distributed, and the whole mass again
turned no fewer than 3 times, not including placing in the carriers or forms.

90-6.06 AMOUNT OF WATER AND PENETRATION

The amount of water used in concrete mixes shall be regulated so that the penetration of the
concrete as determined by California Test 533 or the slump of the concrete as determined by
ASTM Designation: C 143 is within the nominal values shown in the following table. When the
penetration or slump of the concrete is found to exceed the nominal values listed, the mixture of
subsequent batches shall be adjusted to reduce the penetration or slump to a value within the
nominal range shown. Batches of concrete with a penetration or slump exceeding the
maximum values listed shall not be used in the work. If Type F or Type G chemical admixtures

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are added to the mix, the penetration requirements shall not apply and the slump shall not
exceed 9 inches after the chemical admixtures are added.

Type of Work Nominal Maximum

Penetration Slump Penetration Slump
(inches) (inches) (inches) (inches)
Concrete Pavement 0-1 — 1-1/2 —
Non-reinforced concrete facilities 0 – 1-1/2 — 2 —
Reinforced concrete structures
Sections over 12 inches thick 0 – 1-1/2 — 2-1/2 —
Sections 12 inches thick or less 0-2 — 3 —
Concrete placed under water — 6-8 — 9
Cast-in-place concrete piles 2-1/2 – 3-1/2 5-7 4 8

The amount of free water used in concrete shall not exceed 310 pounds per cubic yard, plus 20
pounds for each required 100 pounds of cementitious material in excess of 550 pounds per
cubic yard.
The term free water is defined as the total water in the mixture minus the water absorbed by the
aggregates in reaching a saturated surface-dry condition.
If there are adverse or difficult conditions that affect the placing of concrete, the above specified
penetration and free water content limitations may be exceeded providing the Contractor is
granted permission by the Engineer in writing to increase the cementitious material content per
cubic yard of concrete. The increase in water and cementitious material shall be at a ratio not to
exceed 30 pounds of water per added 100 pounds of cementitious material per cubic yard. Full
compensation for additional cementitious material and water added under these conditions shall
be considered as included in the contract price paid for the concrete work involved and no
additional compensation will be allowed therefor.
The equipment for supplying water to the mixer shall be constructed and arranged so that the
amount of water added can be measured accurately. Any method of discharging water into the
mixer for a batch shall be accurate within 1.5 percent of the quantity of water required to be
added to the mix for any position of the mixer. Tanks used to measure water shall be designed
so that water cannot enter while water is being discharged into the mixer and discharge into the
mixer shall be made rapidly in one operation without dribbling. All equipment shall be arranged
so as to permit checking the amount of water delivered by discharging into measured
containers.

90-7 CURING CONCRETE

90-7.01 METHODS OF CURING
Newly placed concrete shall be cured by the methods specified in this Section 90-7.01 and the
special provisions.

90-7.01A Water Method

The concrete shall be kept continuously wet by the application of water for a minimum curing
period of 7 days after the concrete has been placed.

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Cotton mats, rugs, carpets, or earth or sand blankets may be used as a curing medium to retain
the moisture during the curing period.
If a curing medium consisting of cotton mats, rugs, carpets, polyethylene sheeting, polyethylene
sheeting on burlap, or earth or sand blankets is to be used to retain the moisture, the entire
surface of the concrete shall be kept damp by applying water with a nozzle that so atomizes the
flow that a mist and not a spray is formed, until the surface of the concrete is covered with the
curing medium. The moisture from the nozzle shall not be applied under pressure directly upon
the concrete and shall not be allowed to accumulate on the concrete in a quantity sufficient to
cause a flow or wash the surface. At the expiration of the curing period, the concrete surfaces
shall be cleared of all curing media.
At the option of the Contractor, a curing medium consisting of white opaque polyethylene
sheeting extruded onto burlap may be used to cure concrete structures. The polyethylene
sheeting shall have a minimum thickness of 4-mil, and shall be extruded onto 10-ounce burlap.
At the option of the Contractor, a curing medium consisting of polyethylene sheeting may be
used to cure concrete columns. The polyethylene sheeting shall have a minimum thickness of
10-mil achieved in a single layer of material.
If the Contractor chooses to use polyethylene sheeting or polyethylene sheeting on burlap as a
curing medium, these media and any joints therein shall be secured as necessary to provide
moisture retention and shall be within 3 inches of the concrete at all points along the surface
being cured. When these media are used, the temperature of the concrete shall be monitored
during curing. If the temperature of the concrete cannot be maintained below 140° F, use of
these curing media shall be disallowed.
When concrete bridge decks and flat slabs are to be cured without the use of a curing medium,
the entire surface of the bridge deck or slab shall be kept damp by the application of water with
an atomizing nozzle as specified above, until the concrete has set, after which the entire surface
of the concrete shall be sprinkled continuously with water for a period of not less than 7 days.

90-7.01B Curing Compound Method

Surfaces of the concrete that are exposed to the air shall be sprayed uniformly with a curing
compound.

Curing compounds to be used shall be as follows:

1. Pigmented curing compound conforming to the requirements in ASTM Designation: C

309, Type 2, Class B, except the resin type shall be poly-alpha-methylstyrene.
2. Pigmented curing compound conforming to the requirements in ASTM Designation: C
309, Type 2, Class B.
3. Pigmented curing compound conforming to the requirements in ASTM Designation: C
309, Type 2, Class A.
4. Nonpigmented curing compound conforming to the requirements in ASTM Designation:
C 309, Type 1, Class B.
5. Nonpigmented curing compound conforming to the requirements in ASTM Designation:
C 309, Type 1, Class A.

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6. Nonpigmented curing compound with fugitive dye conforming to the requirements in

ASTM Designation: C 309, Type 1-D, Class A.

The infrared scan for the dried vehicle from curing compound (1) shall match the infrared scan
on file at the Transportation Laboratory.
The loss of water for each type of curing compound, when tested in conformance with the
requirements in California Test 534, shall not be more than 0.28 pounds per square yard in 24
hours.
The curing compound to be used will be specified elsewhere in these specifications or in the
special provisions.
If the use of curing compound is required or permitted elsewhere in these specifications or in the
special provisions and no specific kind is specified, any of the curing compounds listed above
may be used.
Curing compound shall be applied at a nominal rate of one gallon per 150 square feet, unless
otherwise specified.
At any point, the application rate shall be within ±50 square feet per gallon of the nominal rate
specified, and the average application rate shall be within ±25 square feet per gallon of the
nominal rate specified when tested in conformance with the requirements in California Test 535.
Runs, sags, thin areas, skips, or holidays in the applied curing compound shall be evidence that
the application is not satisfactory.
Curing compounds shall be applied using power operated spray equipment. The power
operated spraying equipment shall be equipped with an operational pressure gage and a means
of controlling the pressure. Hand spraying of small and irregular areas that are not reasonably
accessible to mechanical spraying equipment, in the opinion of the Engineer, may be permitted.
The curing compound shall be applied to the concrete following the surface finishing operation,
immediately before the moisture sheen disappears from the surface, but before any drying
shrinkage or craze cracks begin to appear. In the event of any drying or cracking of the surface,
application of water with an atomizing nozzle as specified in Section 90-7.01A, "Water Method,"
shall be started immediately and shall be continued until application of the compound is
resumed or started; however, the compound shall not be applied over any resulting freestanding
water. Should the film of compound be damaged from any cause before the expiration of 7
days after the concrete is placed in the case of structures and 72 hours in the case of
pavement, the damaged portion shall be repaired immediately with additional compound.
At the time of use, compounds containing pigments shall be in a thoroughly mixed condition with
the pigment uniformly dispersed throughout the vehicle. A paddle shall be used to loosen all
settled pigment from the bottom of the container, and a power driven agitator shall be used to
disperse the pigment uniformly throughout the vehicle.
Agitation shall not introduce air or other foreign substance into the curing compound.
The manufacturer shall include in the curing compound the necessary additives for control of
sagging, pigment settling, leveling, de-emulsification, or other requisite qualities of a satisfactory
working material. Pigmented curing compounds shall be manufactured so that the pigment
does not settle badly, does not cake or thicken in the container, and does not become granular
or curdled. Settlement of pigment shall be a thoroughly wetted, soft, mushy mass permitting the
complete and easy vertical penetration of a paddle. Settled pigment shall be easily redispersed,

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with minimum resistance to the sideways manual motion of the paddle across the bottom of the
container, to form a smooth uniform product of the proper consistency.
Curing compounds shall remain sprayable at temperatures above 40 °F and shall not be diluted
or altered after manufacture.
The curing compound shall be packaged in clean 274-gallon totes, 55-gallon barrels or 5-gallon
pails shall be supplied from a suitable storage tank located at the jobsite. The containers shall
comply with "Title 49, Code of Federal Regulations, Hazardous Materials Regulations." The
274-gallon totes and the 55-gallon barrels shall have removable lids and airtight fasteners. The
5-gallon pails shall be round and have standard full open head and bail. Lids with bungholes
will not be permitted. Settling or separation of solids in containers, except tanks, must be
completely redispersed with low speed mixing prior to use, in conformance with these
specifications and the manufacturer's recommendations. Mixing shall be accomplished either
manually by use of a paddle or by use of a mixing blade driven by a drill motor, at low speed.
Mixing blades shall be the type used for mixing paint. On-site storage tanks shall be kept clean
and free of contaminants. Each tank shall have a permanent system designed to completely
redisperse settled material without introducing air or other foreign substances.
Steel containers and lids shall be lined with a coating that will prevent destructive action by the
compound or chemical agents in the air space above the compound. The coating shall not
come off the container or lid as skins. Containers shall be filled in a manner that will prevent
skinning. Plastic containers shall not react with the compound.
Each container shall be labeled with the manufacturer's name, kind of curing compound, batch
number, volume, date of manufacture, and volatile organic compound (VOC) content. The label
shall also warn that the curing compound containing pigment shall be well stirred before use.
Precautions concerning the handling and the application of curing compound shall be shown on
the label of the curing compound containers in conformance with the Construction Safety
Orders and General Industry Safety Orders of the State.
Containers of curing compound shall be labeled to indicate that the contents fully comply with
the rules and regulations concerning air pollution control in the State.
When the curing compound is shipped in tanks or tank trucks, a shipping invoice shall
accompany each load. The invoice shall contain the same information as that required herein
for container labels.
Curing compound will be sampled by the Engineer at the source of supply, at the job site, or at
both locations.
Curing compound shall be formulated so as to maintain the specified properties for a minimum
of one year. The Engineer may require additional testing before use to determine compliance
with these specifications if the compound has not been used within one year or whenever the
Engineer has reason to believe the compound is no longer satisfactory.
Tests will be conducted in conformance with the latest ASTM test methods and methods in use
by the Transportation Laboratory.

90-7.01C Waterproof Membrane Method

The exposed finished surfaces of concrete shall be sprayed with water, using a nozzle that so
atomizes the flow that a mist and not a spray is formed, until the concrete has set, after which

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the curing membrane, shall be placed. The curing membrane shall remain in place for a period
of not less than 72 hours.
Sheeting material for curing concrete shall conform to the requirements in AASHTO
Designation: M 171 for white reflective materials.
The sheeting material shall be fabricated into sheets of such width as to provide a complete
cover for the entire concrete surface. Joints in the sheets shall be securely cemented together
in such a manner as to provide a waterproof joint. The joint seams shall have a minimum lap of
0.33 foot.
The sheets shall be securely weighted down by placing a bank of earth on the edges of the
sheets or by other means satisfactory to the Engineer.
Should any portion of the sheets be broken or damaged before the expiration of 72 hours after
being placed, the broken or damaged portions shall be immediately repaired with new sheets
properly cemented into place.
Sections of membrane that have lost their waterproof qualities or have been damaged to such
an extent as to render them unfit for curing the concrete shall not be used.

90-7.01D Forms-In-Place Method

Formed surfaces of concrete may be cured by retaining the forms in place. The forms shall
remain in place for a minimum period of 7 days after the concrete has been placed, except that
for members over 20 inches in least dimension the forms shall remain in place for a minimum
period of 5 days.
Joints in the forms and the joints between the end of forms and concrete shall be kept moisture
tight during the curing period. Cracks in the forms and cracks between the forms and the
concrete shall be resealed by methods subject to the approval of the Engineer.

90-7.02 BLANK

90-7.03 CURING STRUCTURES

Newly placed concrete for cast-in-place structures, other than highway bridge decks, shall be
cured by the water method, the forms-in-place method, or, as permitted herein, by the curing
compound method, in conformance with the provisions in Section 90-7.01, "Methods of Curing."
The curing compound method using a pigmented curing compound may be used on concrete
surfaces of construction joints, surfaces that are to be buried underground, and surfaces where
only ordinary surface finish is to be applied and on which a uniform color is not required and that
will not be visible from a public traveled way. If the Contractor elects to use the curing
compound method on the bottom slab of box girder spans, the curing compound shall be curing
compound (1).
The top surface of highway bridge decks shall be cured by both the curing compound method
and the water method. The curing compound shall be curing compound (1).
Concrete surfaces of minor structures, as defined in Section 51-1.02, "Minor Structures," shall
be cured by the water method, the forms-in-place method or the curing compound method.

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When deemed necessary by the Engineer during periods of hot weather, water shall be applied
to concrete surfaces being cured by the curing compound method or by the forms-in-place
method, until the Engineer determines that a cooling effect is no longer required. Application of
water for this purpose will be paid for as extra work as provided in Section 4-1.03D, "Extra
Work."

90-7.04 CURING PRECAST CONCRETE MEMBERS

Precast concrete members shall be cured in conformance with any of the methods specified in
Section 90-7.01, "Methods of Curing." Curing shall be provided for the minimum time specified
for each method or until the concrete reaches its design strength, whichever is less. Steam
curing may also be used for precast members and shall conform to the following provisions:

A. After placement of the concrete, members shall be held for a minimum 4-hour
presteaming period. If the ambient air temperature is below 50 °F, steam shall be applied
during the presteaming period to hold the air surrounding the member at a temperature
between 50 °F and 90 °F.
B. To prevent moisture loss on exposed surfaces during the presteaming period, members
shall be covered as soon as possible after casting or the exposed surfaces shall be kept
wet by fog spray or wet blankets.
C. Enclosures for steam curing shall allow free circulation of steam about the member and
shall be constructed to contain the live steam with a minimum moisture loss. The use of
tarpaulins or similar flexible covers will be permitted, provided they are kept in good
repair and secured in such a manner as to prevent the loss of steam and moisture.
D. Steam at the jets shall be at low pressure and in a saturated condition. Steam jets shall
not impinge directly on the concrete, test cylinders, or forms. During application of the
steam, the temperature rise within the enclosure shall not exceed 40 °F per hour. The
curing temperature throughout the enclosure shall not exceed 150 °F and shall be
maintained at a constant level for a sufficient time necessary to develop the required
transfer strength. Control cylinders shall be covered to prevent moisture loss and shall be
placed in a location where temperature is representative of the average temperature of the
enclosure.
E. Temperature recording devices that will provide an accurate, continuous, permanent
record of the curing temperature shall be provided. A minimum of one temperature
recording device per 200 feet of continuous bed length will be required for checking
temperature.
F. Members in pretension beds shall be detensioned immediately after the termination of
steam curing while the concrete and forms are still warm, or the temperature under the
enclosure shall be maintained above 60 °F until the stress is transferred to the concrete.
G. Curing of precast concrete will be considered completed after termination of the steam
curing cycle.

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90-7.05 CURING PRECAST PRESTRESSED CONCRETE PILES

Newly placed concrete for precast prestressed concrete piles shall be cured in conformance
with the provisions in Section 90-7.04, "Curing Precast Concrete Members," except that piles in
a corrosive environment shall be cured as follows:

A. Piles shall be either steam cured or water cured. If water curing is used, the piles shall be
kept continuously wet by the application of water in conformance with the provisions in
Section 90-7.01A, "Water Method."
B. If steam curing is used, the steam curing provisions in Section 90-7.04, "Curing Precast
Concrete Members," shall apply except that the piles shall be kept continuously wet for
their entire length for a period of not less than 3 days, including the holding and steam
curing periods.

90-7.06 CURING SLOPE PROTECTION

Concrete slope protection shall be cured in conformance with any of the methods specified in
Section 90-7.01, "Methods of Curing."
Concreted-rock slope protection shall be cured in conformance with any of the methods
specified in Section 90-7.01, "Methods of Curing," with a blanket of earth kept wet for 72 hours,
or by sprinkling with a fine spray of water every 2 hours during the daytime for a period of 3
days.

90-7.07 CURING MISCELLANEOUS CONCRETE WORK

Exposed surfaces of curbs shall be cured by pigmented curing compounds as specified in
Section 90-7.01B, "Curing Compound Method."
Concrete sidewalks, gutter depressions, island paving, curb ramps, driveways, and other
miscellaneous concrete areas shall be cured in conformance with any of the methods specified
in Section 90-7.01, "Methods of Curing."
Shotcrete shall be cured for at least 72 hours by spraying with water, by a moist earth blanket,
or by any of the methods provided in Section 90-7.01, "Methods of Curing."
Mortar and grout shall be cured by keeping the surface damp for 3 days.
After placing, the exposed surfaces of sign structure foundations, including pedestal portions, if
constructed, shall be cured for at least 72 hours by spraying with water, by a moist earth
blanket, or by any of the methods provided in Section 90-7.01, "Methods of Curing."

90-8 PROTECTING CONCRETE

90-8.01 GENERAL
In addition to the provisions in Section 7-1.16, "Contractor's Responsibility for the Work and
Materials," the Contractor shall protect concrete as provided in this Section 90-8. If required by
the Engineer, the Contractor shall submit a written outline of the proposed methods for
protecting the concrete.

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The Contractor shall protect concrete from damage from any cause, which shall include, but not
be limited to: rain, heat, cold, wind, Contractor's actions, and actions of others.
Concrete shall not be placed on frozen or ice-coated ground or subgrade nor on ice-coated
forms, reinforcing steel, structural steel, conduits, precast members, or construction joints.
Under rainy conditions, placing of concrete shall be stopped before the quantity of surface water
is sufficient to damage surface mortar or cause a flow or wash of the concrete surface, unless
the Contractor provides adequate protection against damage.
Concrete that has been frozen or damaged by other causes, as determined by the Engineer,
shall be removed and replaced by the Contractor at the Contractor's expense.

90-8.02 PROTECTING CONCRETE STRUCTURES

Structure concrete and shotcrete used as structure concrete shall be maintained at a
temperature of not less than 45 °F for 72 hours after placing and at not less than 40 °F for an
additional 4 days.

90-9 COMPRESSIVE STRENGTH

90-9.01 GENERAL
Concrete compressive strength requirements consist of a minimum strength that shall be
attained before various loads or stresses are applied to the concrete and, for concrete
designated by compressive strength, a minimum strength at the age of 28 days or at the age
otherwise allowed in Section 90-1.01, "Description." The various strengths required are
specified in these specifications or the special provisions or are shown on the plans.
The compressive strength of concrete will be determined from test cylinders that have been
fabricated from concrete sampled in conformance with the requirements of California Test 539.
Test cylinders will be molded and initially field cured in conformance with California Test 540.
Test cylinders will be cured and tested after receipt at the testing laboratory in conformance with
the requirements of California Test 521. A strength test shall consist of the average strength of
2 cylinders fabricated from material taken from a single load of concrete, except that, if any
cylinder should show evidence of improper sampling, molding, or testing, that cylinder shall be
discarded and the strength test shall consist of the strength of the remaining cylinder.
When concrete compressive strength is specified as a prerequisite to applying loads or stresses
to a concrete structure or member, test cylinders for other than steam cured concrete will be
cured in conformance with Method 1 of California Test 540. The compressive strength of
concrete determined for these purposes will be evaluated on the basis of individual tests.
When concrete is designated by compressive strength rather than by cementitious material
content, the concrete strength to be used as a basis for acceptance of other than steam cured
concrete will be determined from cylinders cured in conformance with Method 1 of California
Test 540. If the result of a single compressive strength test at the maximum age specified or
allowed is below the specified strength but is 95 percent or more of the specified strength, the
Contractor shall make corrective changes, subject to approval of the Engineer, in the mix
proportions or in the concrete fabrication procedures, before placing additional concrete, and
shall pay to the State $10 for each in-place cubic yard of concrete represented by the deficient
test. If the result of a single compressive strength test at the maximum age specified or allowed
is below 95 percent of the specified strength, but is 85 percent or more of the specified strength,

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the Contractor shall make the corrective changes specified above, and shall pay to the State
$15 for each in-place cubic yard of concrete represented by the deficient test. In addition, such
corrective changes shall be made when the compressive strength of concrete tested at 7 days
indicates, in the judgment of the Engineer, that the concrete will not attain the required
compressive strength at the maximum age specified or allowed. Concrete represented by a
single test that indicates a compressive strength of less than 85 percent of the specified 28-day
compressive strength will be rejected in conformance with the provisions in Section 6-1.04,
"Defective Materials."
If the test result indicates that the compressive strength at the maximum age specified or
allowed is below the specified strength, but is 85 percent or more of the specified strength,
payments to the State as required above shall be made, unless the Contractor, at the
Contractor's expense, obtains and submits evidence acceptable to the Engineer that the
strength of the concrete placed in the work meets or exceeds the specified 28-day compressive
strength. If the test result indicates a compressive strength at the maximum age specified or
allowed below 85 percent, the concrete represented by that test will be rejected, unless the
Contractor, at the Contractor's expense, obtains and submits evidence acceptable to the
Engineer that the strength and quality of the concrete placed in the work are acceptable. If the
evidence consists of tests made on cores taken from the work, the cores shall be obtained and
tested in conformance with the requirements in ASTM Designation: C 42.
No single compressive strength test shall represent more than 320 cubic yards.
If a precast concrete member is steam cured, the compressive strength of the concrete will be
determined from test cylinders that have been handled and stored in conformance with Method
3 of California Test 540. The compressive strength of steam cured concrete will be evaluated
on the basis of individual tests representing specific portions of production. If the concrete is
designated by 28-day compressive strength rather than by cementitious material content, the
concrete shall be considered to be acceptable whenever its compressive strength reaches the
specified 28-day compressive strength provided that strength is reached in not more than the
maximum number of days specified or allowed after the member is cast.
When concrete has a specified 28-day compressive strength greater than 3,600 pounds per
square inch, prequalification of materials, mix proportions, mixing equipment, and procedures
proposed for use will be required prior to placement of the concrete. Prequalification shall be
accomplished by the submission of acceptable certified test data or trial batch reports by the
Contractor. Prequalification data shall be based on the use of materials, mix proportions, mixing
equipment, procedures, and size of batch proposed for use in the work.
Certified test data, in order to be acceptable, shall indicate that not less than 90 percent of at
least 20 consecutive tests exceed the specified strength at the maximum number of days
specified or allowed, and none of those tests are less than 95 percent of specified strength.
Strength tests included in the data shall be the most recent tests made on concrete of the
proposed mix design and all shall have been made within one year of the proposed use of the
concrete.
Trial batch test reports, in order to be acceptable, shall indicate that the average compressive
strength of 5 consecutive concrete cylinders, taken from a single batch, at not more than 28
days (or the maximum age allowed) after molding shall be at least 580 pounds per square inch
greater than the specified 28-day compressive strength, and no individual cylinder shall have a
strength less than the specified strength at the maximum age specified or allowed. Data
contained in the report shall be from trial batches that were produced within one year of the
proposed use of specified strength concrete in the project. Whenever air-entrainment is

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required, the air content of trial batches shall be equal to or greater than the air content
specified for the concrete without reduction due to tolerances.
Tests shall be performed in conformance with either the appropriate California Test methods or
the comparable ASTM test methods. Equipment employed in testing shall be in good condition
and shall be properly calibrated. If the tests are performed during the life of the contract, the
Engineer shall be notified sufficiently in advance of performing the tests in order to witness the
test procedures.

The certified test data and trial batch test reports shall include the following information:

A. Date of mixing.
B. Mixing equipment and procedures used.
C. The size of batch in cubic yards and the weight, type, and source of all ingredients used.
D. Penetration or slump (if the concrete will be placed under water or placed in cast-in-place
concrete piles) of the concrete.
E. The air content of the concrete if an air-entraining admixture is used.
F. The age at time of testing and strength of all concrete cylinders tested.

Certified test data and trial batch test reports shall be signed by an official of the firm that
performed the tests.
When approved by the Engineer, concrete from trial batches may be used in the work at
locations where concrete of a lower quality is required and the concrete will be paid for as the
type of concrete required at that location.
After materials, mix proportions, mixing equipment, and procedures for concrete have been
prequalified for use, additional prequalification by testing of trial batches will be required prior to
making changes that, in the judgment of the Engineer, could result in a strength of concrete
below that specified.
The Contractor's attention is directed to the time required to test trial batches and the Contractor
shall be responsible for production of trial batches at a sufficiently early date so that the
progress of the work is not delayed.
When precast concrete members are manufactured at the plant of an established manufacturer
of precast concrete members, the mix proportions of the concrete shall be determined by the
Contractor, and a trial batch and prequalification of the materials, mix proportions, mixing
equipment, and procedures will not be required.

90-10 MINOR CONCRETE

90-10.01 GENERAL
Concrete for minor structures, slope paving, curbs, sidewalks and other concrete work, when
designated as minor concrete on the plans, in the specifications, or in the contract item, shall
conform to the provisions specified herein.

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The Engineer, at the Engineer's discretion, will inspect and test the facilities, materials and
methods for producing the concrete to ensure that minor concrete of the quality suitable for use
in the work is obtained.
Before using minor concrete or in advance of revising the mix proportions, the Contractor shall
submit in writing to the Engineer a copy of the mix design. When required by the following
table, the Contractor shall include compressive strength test results verifying the minimum
specified compressive strength:

SCM Test Submittal Required

Fly Ash used alone When portland cement content<350 lbs/cy
GGBFS used alone When portland cement content <250 lbs/cy
Natural Pozzolan used alone When portland cement content <350 lbs/cy
More than 1 SCM Always

Tests shall be performed by an ACI certified technician.

90-10.02 MATERIALS
Minor concrete shall conform to the following requirements:

90-10.02A Cementitious Material

Cementitious material shall conform to the provisions in Section 90-1.01, "Description," and 90-
2, "Materials."

90-10.02B Aggregate
Aggregate shall be clean and free from deleterious coatings, clay balls, roots, and other
extraneous materials.
Use of crushed concrete or reclaimed aggregate is acceptable only if the aggregate satisfies all
aggregate requirements.
The Contractor shall submit to the Engineer for approval, a grading of the combined aggregate
proposed for use in the minor concrete. After acceptance of the grading, aggregate furnished
for minor concrete shall conform to that grading, unless a change is authorized in writing by the
Engineer.
The Engineer may require the Contractor to furnish periodic test reports of the aggregate
grading furnished. The maximum size of aggregate used shall be at the option of the
Contractor, but in no case shall the maximum size be larger than 1-1/2-inch or smaller than 3/4
inch.
The Engineer may waive, in writing, the gradation requirements in this Section 90-10.02B, if, in
the Engineer's opinion, the furnishing of the gradation is not necessary for the type or amount of
concrete work to be constructed.

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90-10.02C Water
Water used for washing, mixing, and curing shall be free from oil, salts, and other impurities that
would discolor or etch the surface or have an adverse affect on the quality of the concrete.

90-10.02D Admixtures
The use of admixtures shall conform to the provisions in Section 90-4, "Admixtures."

90-10.03 PRODUCTION
Cementitious material, water, aggregate, and admixtures shall be stored, proportioned, mixed,
transported, and discharged in conformance with recognized standards of good practice that will
result in concrete that is thoroughly and uniformly mixed, that is suitable for the use intended,
and that conforms to requirements specified herein. Recognized standards of good practice are
outlined in various industry publications such as are issued by American Concrete Institute,
AASHTO, or the Department.
The cementitious material content of minor concrete shall conform to the provisions in Section
90-1.01, "Description."
The amount of water used shall result in a consistency of concrete conforming to the provisions
in Section 90-6.06, "Amount of Water and Penetration." Additional mixing water shall not be
incorporated into the concrete during hauling or after arrival at the delivery point, unless
authorized by the Engineer.
Discharge of ready-mixed concrete from the transporting vehicle shall be made while the
concrete is still plastic and before stiffening occurs. An elapsed time of 1.5 hours (one hour in
non-agitating hauling equipment), or more than 250 revolutions of the drum or blades, after the
introduction of the cementitious material to the aggregates, or a temperature of concrete of
more than 90 °F will be considered conditions contributing to the quick stiffening of concrete.
The Contractor shall take whatever action is necessary to eliminate quick stiffening, except that
the addition of water will not be permitted.
The required mixing time in stationary mixers shall be not less than 50 seconds or more than 5
minutes.
The minimum required revolutions at mixing speed for transit-mixed concrete shall be not less
than that recommended by the mixer manufacturer, and shall be increased, if necessary, to
produce thoroughly and uniformly mixed concrete.
When a high range water-reducing admixture is added to the concrete at the job site, the total
number of revolutions shall not exceed 300.
Each load of ready-mixed concrete shall be accompanied by a weighmaster certificate that shall
be delivered to the Engineer at the discharge location of the concrete, unless otherwise directed
by the Engineer. The weighmaster certificate shall be clearly marked with the date and time of
day when the load left the batching plant and, if hauled in truck mixers or agitators, the time the
mixing cycle started.
A Certificate of Compliance conforming to the provisions in Section 6-1.07, "Certificates of
Compliance," shall be furnished to the Engineer, prior to placing minor concrete from a source
not previously used on the contract, stating that minor concrete to be furnished meets contract
requirements, including minimum cementitious material content specified.

April 11,2011 4-310

90-10.04 CURING MINOR CONCRETE

Curing minor concrete shall conform to the provisions in Section 90-7, "Curing Concrete."

90-10.05 PROTECTING MINOR CONCRETE

Protecting minor concrete shall conform to the provisions in Section 90-8, "Protecting Concrete,"
except the concrete shall be maintained at a temperature of not less than 40 °F for 72 hours
after placing.

90-10.06 MEASUREMENT AND PAYMENT

Minor concrete will be measured and paid for in conformance with the provisions specified in the
various sections of these specifications covering concrete construction when minor concrete is
specified in the specifications, shown on the plans, or indicated by contract item in the
Engineer's Estimate.

90-11 MEASUREMENT AND PAYMENT

90-11.01 MEASUREMENT
Portland cement concrete will be measured in conformance with the provisions specified in the
various sections of these specifications covering construction requiring concrete.
For concrete measured at the mixer, the volume in cubic feet shall be computed as the total
weight of the batch in pounds divided by the density of the concrete in pounds per cubic foot.
The total weight of the batch shall be calculated as the sum of all materials, including water,
entering the batch. The density of the concrete will be determined in conformance with the
requirements in California Test 518.

90-11.02 PAYMENT
Portland cement concrete will be paid for in conformance with the provisions specified in the
various sections of these specifications covering construction requiring concrete.
Full compensation for furnishing and incorporating admixtures required by these specifications
or the special provisions will be considered as included in the contract prices paid for the
concrete involved and no additional compensation will be allowed therefor.
Should the Engineer order the Contractor to incorporate any admixtures in the concrete when
their use is not required by these specifications or the special provisions, furnishing the
admixtures and adding them to the concrete will be paid for as extra work as provided in Section
4-1.03D, "Extra Work."
Should the Contractor use admixtures in conformance with the provisions in Section 90-4.05,
"Optional Use of Chemical Admixtures," or Section 90-4.07, "Optional Use of Air-entraining
Admixtures," or should the Contractor request and obtain permission to use other admixtures for
the Contractor's benefit, the Contractor shall furnish those admixtures and incorporate them into
the concrete at the Contractor's expense and no additional compensation will be allowed
therefor.

April 11,2011 4-311

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 91 PAINT
(Issued 05-1-06)

Replace Section 91-3 with:

91-3 PAINTS FOR TIMBER

91-3.01 WOOD PRIMER, LATEX-BASE
Classification:
This specification covers a ready-mixed priming paint for use on unpainted wood or exterior
woodwork. It shall conform with the requirements in the Detailed Performance Standards of the
Master Painters Institute (MPI) for exterior wood primers, and be listed on the Exterior Latex
Wood Primer MPI List Number 6.

91-3.02 PAINT; LATEX-BASE FOR EXTERIOR WOOD, WHITE AND TINTS

Classification:
This specification covers a ready-mixed paint for use on wood surfaces subject to outside
exposures. This paint shall conform to the requirements in the Detailed Performance Standards
of the Master Painters Institute (MPI) for Paint, Latex, Exterior, and shall be listed on the
following MPI Approved Products List:

A. Exterior Latex, Flat MPI Gloss Level 1, MPI List Number 10.
B. Exterior Latex, Semi-Gloss, MPI Gloss Level 5, MPI List Number 11.
C. Exterior Latex, Gloss, MPI Gloss Level 6, MPI List Number 119.

Unpainted wood shall first be primed with wood primer conforming to the provisions in Section
91-3.01, "Wood Primer, Latex-Base."

Replace Section 91-4 with:

April 11,2011 4-312

91-4 MISCELLANEOUS PAINTS

91-4.01 THROUGH 91-4.04 (BLANK)
91-4.05 PAINT; ACRYLIC EMULSION, EXTERIOR WHITE AND LIGHT AND
MEDIUM TINTS
Classification:
This specification covers an acrylic emulsion paint designed for use on exterior masonry. This
paint shall conform to the requirements in the Detailed Performance Standards of the Master
Painters Institute (MPI) for Paint, Latex, Exterior, and shall be listed on the following MPI
Approved Products Lists:

A. Exterior Latex, Flat MPI Gloss Level 1, MPI List Number 10.
B. Exterior Latex, Semi-Gloss, MPI Gloss Level 5, MPI List Number 11.
C. Exterior Latex, Gloss, MPI Gloss Level 6, MPI List Number 119.

This paint may be tinted by using "universal" or "all purpose" concentrates.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 92 ASPHALTS
(Issued 03-21-08)

Replace Section 92 with:

SECTION 92 ASPHALTS

92-1.01 DESCRIPTION
Asphalt is refined petroleum or a mixture of refined liquid asphalt and refined solid asphalt that
are prepared from crude petroleum. Asphalt is:

1. Free from residues caused by the artificial distillation of coal, coal tar, or paraffin
2. Free from water
3. Homogeneous

April 11,2011 4-313

92-1.02 MATERIALS
GENERAL
Furnish asphalt under the Department's "Certification Program for Suppliers of Asphalt." The
Department maintains the program requirements, procedures, and a list of approved suppliers
at:

http://www.dot.ca.gov/hq/esc/Translab/fpm/fpmcoc.htm

Transport, store, use, and dispose of asphalt safely.

Prevent the formation of carbonized particles caused by overheating asphalt during
manufacturing or construction.

GRADES
Performance graded (PG) asphalt binder is:

April 11,2011 4-314

Performance Graded Asphalt Binder

Specification

Grade
Property AASHTO
Test PG PG PG PG PG
Method 58-22 a 64-10 64-16 64-28 70-10
Original Binder
Flash Point, Minimum °C T 48 230 230 230 230 230
Solubility, Minimum % b T 44 99 99 99 99 99
Viscosity at 135°C, c T 316
Maximum, Pa·s 3.0 3.0 3.0 3.0 3.0
Dynamic Shear, T 315
Test Temp. at 10 rad/s, °C 58 64 64 64 70
Minimum G*/sin(delta), kPa 1.00 1.00 1.00 1.00 1.00
RTFO Test, e T 240
Mass Loss, Maximum, % 1.00 1.00 1.00 1.00 1.00
RTFO Test Aged Binder
Dynamic Shear, T 315
Test Temp. at 10 rad/s, °C 58 64 64 64 70
Minimum G*/sin(delta), kPa 2.20 2.20 2.20 2.20 2.20
Ductility at 25°C T 51
Minimum, cm 75 75 75 75 75
PAV f Aging, R 28
Temperature, °C 100 100 100 100 110
RTFO Test and PAV Aged Binder
Dynamic Shear, T 315
Test Temp. at 10 rad/s, °C 22 d 31 d 28 d 22 d 34 d
Maximum G*sin(delta), kPa 5000 5000 5000 5000 5000
Creep Stiffness, T 313
Test Temperature, °C -12 0 -6 -18 0
Maximum S-value, Mpa 300 300 300 300 300
Minimum M-value 0.300 0.300 0.300 0.300 0.300
Notes:
a. Use as asphalt rubber base stock for high mountain and high desert area.
b. The Engineer waives this specification if the supplier is a Quality Supplier as defined by the Department's
"Certification Program for Suppliers of Asphalt."
c. The Engineer waives this specification if the supplier certifies the asphalt binder can be adequately pumped and
mixed at temperatures meeting applicable safety standards.
d. Test the sample at 3°C higher if it fails at the specified test temperature. G*sin(delta) remains 5000 kPa
maximum.
e. "RTFO Test" means the asphaltic residue obtained using the Rolling Thin Film Oven Test, AASHTO Test
Method T 240 or ASTM Designation: D 2872. The residue from mass change determination may be used for
other tests.
f. "PAV" means Pressurized Aging Vessel.

Performance graded polymer modified asphalt binder (PG Polymer Modified) is:

April 11,2011 4-315

Performance Graded Polymer Modified Asphalt Binder a

Specification
Grade
Property AASHTO Test Method
PG PG PG
58-34 PM 64-28 PM 76-22 PM
Original Binder
Flash Point, Minimum °C T 48 230 230 230
Solubility, Minimum % b T 44c 98.5 98.5 98.5
Viscosity at 135°C, d T 316
Maximum, Pa·s 3.0 3.0 3.0
Dynamic Shear, T 315
Test Temp. at 10 rad/s, °C 58 64 76
Minimum G*/sin(delta), kPa 1.00 1.00 1.00
RTFO Test , T 240
Mass Loss, Maximum, % 1.00 1.00 1.00
RTFO Test Aged Binder
Dynamic Shear, T 315
Test Temp. at 10 rad/s, °C 58 64 76
Minimum G*/sin(delta), kPa 2.20 2.20 2.20
Dynamic Shear, T 315
Test Temp. at 10 rad/s, °C Note e Note e Note e
Maximum (delta), % 80 80 80
Elastic Recoveryf, T 301
Test Temp., °C 25 25 25
Minimum recovery, % 75 75 65
PAVg Aging, R 28
Temperature, °C 100 100 110
RTFO Test and PAV Aged Binder
Dynamic Shear, T 315
Test Temp. at 10 rad/s, °C 16 22 31
Maximum G*sin(delta), kPa 5000 5000 5000
Creep Stiffness, T 313
Test Temperature, °C -24 -18 -12
Maximum S-value, MPa 300 300 300
Minimum M-value 0.300 0.300 0.300
Notes:
a. Do not modify PG Polymer Modified using acid modification.
b. The Engineer waives this specification if the supplier is a Quality Supplier as defined by the
Department's "Certification Program for Suppliers of Asphalt."
c. The Department allows ASTM D 5546 instead of AASHTO T 44
d. The Engineer waives this specification if the supplier certifies the asphalt binder can be adequately
pumped and mixed at temperatures meeting applicable safety standards.
e. Test temperature is the temperature at which G*/sin(delta) is 2.2 kPa. A graph of log G*/sin(delta)
plotted against temperature may be used to determine the test temperature when G*/sin(delta) is 2.2
kPa. A graph of (delta) versus temperature may be used to determine delta at the temperature when
G*/sin(delta) is 2.2 kPa. The Engineer also accepts direct measurement of (delta) at the temperature
when G*/sin(delta) is 2.2 kPa.
f. Tests without a force ductility clamp may be performed.
g. "PAV" means Pressurized Aging Vessel.

April 11,2011 4-316

SAMPLING
Provide a sampling device in the asphalt feed line connecting the plant storage tanks to the
asphalt weighing system or spray bar. Make the sampling device accessible between 24 and
30 inches above the platform. Provide a receptacle for flushing the sampling device.
Include with the sampling device a valve:

1. Between 1/2 and 3/4 inch in diameter

2. Manufactured in a manner that a one-quart sample may be taken slowly at any time
during plant operations
3. Maintained in good condition

Replace failed valves.

In the Engineer's presence, take 2 one-quart samples per operating day. Provide round, friction
top, one-quart containers for storing samples.

92-1.03 EXECUTION
If asphalt is applied, you must comply with the heating and application specifications for liquid
asphalt in Section 93, "Liquid Asphalts."

92-1.04 MEASUREMENT
If the contract work item for asphalt is paid by weight, the Department measures asphalt tons by
complying with the specifications for weight determination of liquid asphalt in Section 93, "Liquid
Asphalts."
The Engineer determines the asphalt weight from volumetric measurements if you:

1. Use a partial asphalt load

2. Use asphalt at a location other than a mixing plant and no scales within 20 miles are
available and suitable
3. Deliver asphalt in either of the following:

3.1. A calibrated truck with each tank accompanied by its measuring stick and
calibration card
3.2. A truck equipped with a calibrated thermometer that determines the asphalt
temperature at the delivery time and with a vehicle tank meter complying with the
specifications for weighing, measuring, and metering devices in Section 9-1.01,
"Measurement of Quantities"

If you furnish hot mix asphalt from a mixing plant producing material for only one project, the
Engineer determines the asphalt quantity by measuring the volume in the tank at the project's
start and end provided the tank is calibrated and equipped with its measuring stick and
calibration card.

April 11,2011 4-317

The Engineer determines pay quantities from volumetric measurements as follows:

1. Before converting the volume to weight, the Engineer reduces the measured volume to
that which the asphalt would occupy at 60 °F.
2. The Engineer uses 235 gallons per ton and 8.51 pounds per gallon for the average weight
and volume for PG and PG Polymer Modified asphalt grades at 60 °F.
3. The Engineer uses the Conversion Table in Section 93, "Liquid Asphalts."

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 93 LIQUID ASPHALTS

(Issued 11-03-06)

In Section 93-1.04 replace the 9th paragraph with:

The following Legend and Conversion Table is to be used for converting volumes of liquid
asphalt products, Grades 70 to 3000, inclusive, and paving asphalt Grades PG 58-22, PG 64-
10, PG 64-16, PG 64-28, and PG 70-10, and Grades PG 58-34 PM, PG 64-28 PM, and PG 76-
22 PM.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

SECTION 95 EPOXY
(Issued 06-05-09)

Replace the table in Section 95-2.11 with:

April 11,2011 4-318

Characteristics of Adhesive:
California
Testa Test Requirement
Brookfield Viscosity, No. 3 434, Part 4 0.9 max.
Spindle at 20 rpm, Poise at 77°F
Gel time, minutes 434, Part 1 2 to 15
Slant Shear Strength on Dry 434, Part 5b 3,000 min.
Concrete, psi, after 4 days of cure in
air at 77° F ±2° F
Slant Shear Strength on Wet 434, Part 5b 1,700 min.
Concrete, psi, after 4 days of cure in
air at 77° F ±2° F
Tensile Strength, psi 434, Part 7, except test after 4 days 4,500 min.
of cure at 77° F ±2° F
Elongation, % 434, Part 7, except test after 4 days 10 max.
of cure at 77° F ±2° F
a
The mixing ratio used will be that recommended by the manufacturer.
b
For slant shear strength on concrete, delete Sections B-1 and B-5 of California Test 434, Part 5. For dry concrete,
use Step "2" below only. For wet concrete, use both Steps "1" & "2":

1. Soak blocks in water for 24 hours at 77° F ±2° F. Remove and wipe off excess water.
2. Mix epoxy as described in California Test 434, Part 1, and apply a coat approximately 0.010-inch thick to
each diagonal surface. Place four 0.125-inch square pieces of shim stock 0.012-inch thick on one block to
control final film thickness. Before pressing the coated surfaces together, leave the blocks so that the coated
surfaces are horizontal until the epoxy reacts slightly to prevent excessive flow.

April 11,2011 4-319

5 MODIFICATIONS TO SPECIAL PROVISIONS

District 4 has added the following District Standard Special Provisions. These Standard Special
Provisions shall be used in developing the Special Provisions for this project:

1. Temporary Fence (Type ESA)

2. Remove Yellow Traffic Stripe And Pavement Marking (Hazardous Waste)
3. Relations With California Regional Water Quality Control Board
4. Water Pollution Control (WPCP)
5. Water Pollution Control (SWPPP)
6. Construction Site Management
7. Erosion Control (Sequencing)
8. Rolled Erosion Control Product (Netting)
9. Erosion Control (Hydroseed)
10. Erosion Control (Compost Blanket)
11. Fiber Rolls
12. Cold Plane Asphalt Concrete Pavement
13. Vehicle Sensor Node(S) (Vsn)
14. Long Lead-In Cable Loop Detector (LLLD) Sensor Unit
15. Variable Message Sign (VMS) Assembly
16. General Packet Radio System Wireless Modem Assembly

April 11, 2011 5-1

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. TEMPORARY FENCE (TYPE ESA)

GENERAL
Before start of work, protect the ESA by installing temporary fence (Type ESA).
Summary
This work includes constructing, maintaining, and removing temporary fence (Type ESA).
Temporary fence (Type ESA) provides a visible boundary adjacent to protected areas such as an
environmentally sensitive area.
Signs are not required for temporary fence (Type ESA).

Submittals
Submit a Certificate of Compliance as specified in Section 6-1.07, "Certificates of Compliance" of
the Standard Specifications for:

1. High visibility fabric

2. Safety cap for metal posts

MATERIALS
High Visibility Fabric
High visibility fabric for temporary fence (Type ESA) must consist of one of the following:

1. Polyethylene
2. Polypropylene
3. Combined polyethylene and polypropylene

Sample under ASTM D 4354, Procedure C.

Test under ASTM D 4759. All properties must be based on Minimum Average Roll Value.
Identify, store, and handle under ASTM D 4873.
High visibility fabric must:
1. Contain ultraviolet inhibitors
2. Comply with the following:

April 11, 2011 5-2

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Property Specifications Requirements

Width, inches, Min Measured 48
Opening size inches Measured 1" x 1" (Min)
2" x 2" (Max)
Color Observed Orange
Grab breaking load ASTM D4632 260
1-inch grip, lb, Min. in each
direction
Apparent elongation ASTM D4632 5
percent, Min., in each
direction
Ultraviolet Degradation ASTM D4355 70
percent of original unexposed
grab breaking load 500 hr,
minimum

Posts
Posts must be wood or steel.
Wood posts must be:

1. Untreated fir, redwood, cedar, or pine and cut from sound timber
2. Straight and free of loose or unsound knots and other defects that would render the stakes unfit
for use
3. Pointed on the end to be driven into the ground
4. At least 2" x 2" in size and 6 feet long

Steel posts must:

1. Have a "U," "T," "L," or other cross sectional shape that can resist failure from lateral loads.
2. Be pointed on the end to be driven into the ground.
3. Weigh at least 0.75-pound per foot.
4. Be at least 6 feet long.
5. Have a safety cap attached to the exposed end. The safety cap must be yellow, orange or red
plastic and fit snugly to the metal post.

Signs
If specified, signs must be:

1. Weatherproof and fade-proof and may include plastic laminated printed paper affixed to an
inflexible weatherproof backer board
2. Attached to the high visibility fabric with tie wire or locking plastic fasteners

CONSTRUCTION
General
Install temporary fence (Type ESA):

April 11, 2011 5-3

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. With high visibility fabric, posts, and fasteners as follows:

1.1. If wood posts are used, fasteners must be staples or nails

1.2. If steel posts are used, fasteners must be tie wires or locking plastic fasteners
1.3. Spacing of the fasteners must be no more than 8 inches apart

2. Before clearing and grubbing activities

3. From outside of the protected area
4. With posts spaced 8 feet apart and embedded at least 16 inches in the soil

If specified, signs must be:

1. Attached with the top of the sign panel flush with the top of the high visibility fabric
2. Placed 100 feet apart along the length and at each end of the fence

If trees and other plants need protection, install fence to:

1. Enclose the foliage canopy (drip line) of protected plants

2. Protect visible roots from encroachment

Maintenance
Maintain temporary fence (Type ESA) by:

1. Keeping posts in a vertical position

2. Reattaching fabric to posts
3. Replacing damaged sections of fabric
4. Replacing and securing signs

Removal
When the Department determines that temporary fence (Type ESA) is no longer required, remove and
dispose of it under Section 7-1.13, "Disposal of Material Outside the Highway Right of Way," of the
Standard Specifications.
Backfill and repair ground disturbance caused by the installation and removal of temporary fence
(Type ESA), including holes and depressions, under Section 15-1.02, "Preservation of Property," of the
Standard Specifications.

April 11, 2011 5-4

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

2. REMOVE YELLOW TRAFFIC STRIPE AND PAVEMENT

MARKING (HAZARDOUS WASTE)
GENERAL
Summary
This work includes removing existing yellow thermoplastic and yellow painted traffic stripe and
pavement marking at the locations shown on the plans. The residue from the removal of this material is a
hazardous waste.
Residue from removal of yellow thermoplastic and yellow painted traffic stripe and pavement
marking contains lead chromate. The average lead concentration is greater than or equal to 1000 mg/kg
total lead or 5 mg/l soluble lead. When applied to the roadway, the yellow thermoplastic and yellow
painted traffic stripe and pavement marking contained as much as 2.6 percent lead. Residue produced
from the removal of this yellow thermoplastic and yellow painted traffic stripe and pavement marking
contains heavy metals in concentrations that exceed thresholds established by the Health and Safety Code
and 22 CA Code of Regs. For bidding purposes, assume that the residue is not regulated under the
Federal Resource Conservation and Recovery Act (RCRA), 42 USC § 6901 et seq.. Yellow
thermoplastic and yellow paint may produce toxic fumes when heated.

Submittals
Lead Compliance Plan: Submit a lead compliance plan under Section 7-1.07, "Lead Compliance
Plan," of the Standard Specifications.
Work Plan: Submit a work plan for the removal, containment, storage, and disposal of yellow
thermoplastic and yellow painted traffic stripe and pavement marking for acceptance not less than 15 days
prior to the start of the removal operations. The work plan must include:

1. Objective of the operation

2. Removal equipment
3. Type of hazardous waste storage containers
4. Container storage location and how it will be secured
5. Hazardous waste sampling protocol and QA/QC requirements and procedures
6. Qualifications of sampling personnel
7. Analytical lab that will perform the analyses
8. Certification documentation of the hazardous waste hauler that will transport the hazardous waste
9. Disposal site that will accept the hazardous waste residue

The Department will review the work plan within 5 business days of receipt.
Do not perform work that generates hazardous waste residue until the work plan has been accepted by
the Department. The Department's review and acceptance does not waive any contract requirements and
does not relieve the Design-Builder from complying with Federal, State, and local laws, regulations, and
requirements.
Correct any rejected work plan and resubmit a corrected work plan within 5 business days of
notification by the Department; at which time a new review period of 5 business days will begin.
Analytical Test Results: Submit analytical test results of the residue from removal of yellow
thermoplastic and yellow painted traffic stripe and pavement marking, including chain of custody
documentation, for review and acceptance before:

April 11, 2011 5-5

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. Requesting the Department’s signature on the waste profile requested by the disposal facility
2. Requesting the Department obtain an EPA ID no. for disposal
3. Removing the residue from the site

United States Environmental Protection Agency Identification Number Request: Submit a

request for the U.S. EPA ID no. when the Department accepts analytical test results documenting that
residue from removal of yellow thermoplastic and yellow painted traffic stripe and pavement marking is a
hazardous waste.
Disposal Documentation: Submit receiving landfill documentation of proper disposal within 5
business days of residue transport from the project.

CONSTRUCTION
Where grinding or other approved methods are used to remove yellow thermoplastic and yellow
painted traffic stripe and pavement marking that will produce a hazardous waste residue, the removed
residue, including dust, must be contained and collected immediately. Use a HEPA filter-equipped
vacuum attachment operated concurrently with the removal operations or other equally effective approved
methods for collection of the residue.
Store hazardous waste residue in labeled and covered containers. Labels must comply with the provisions
of 22 CA Code of Regs §§66262.31 and 66262.32. Mark labels with:

1. Date the hazardous waste is generated

2. The words "Hazardous Waste"
3. Composition and physical state of the hazardous waste (for example, asphalt grindings with
thermoplastic or paint)
4. The word "Toxic"
5. Name, address, and telephone no. of the Engineer
6. Contract no.
7. Contractor or subcontractor name

Use metal containers approved by the U.S. Department of Transportation for the transportation and
temporary storage of the removed residue. Handle the containers such that no spillage occurs. Store
containers in a secured enclosure. Acceptable secure enclosures include a locked chain link fenced area
or a lockable shipping container located within the project limits until disposal as approved.
Make necessary arrangements to test the yellow thermoplastic and yellow paint hazardous waste
residue as required by the disposal facility and these special provisions. Testing must include, at a
minimum:

1. Total lead by EPA Method 6010C

2. Total chromium by US EPA Method 7000 series
3. Soluble lead by California Waste Extraction Test
4. Soluble chromium by California Waste Extraction Test
5. Soluble lead by Toxicity Characteristic Leaching Procedure
6. Soluble chromium by Toxicity Characteristic Leaching Procedure

April 11, 2011 5-6

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

From the 1st 220 gallons of hazardous waste or portion thereof if less than 220 gallons of hazardous
waste are produced, a minimum of 4 randomly selected samples must be taken and analyzed individually.
Samples must not be composited. From each additional 880 gallons of hazardous waste or portion thereof
if less than 880 gallons are produced, a minimum of 1 additional random sample must be taken and
analyzed. Use chain of custody procedures consistent with Chapter 9 of U.S. EPA Test Methods for
Evaluating Solid Waste, Physical/Chemical Methods (SW-846) while transporting samples from the
project to the laboratory. Each sample must be homogenized before analysis by the laboratory
performing the analyses. A sample aliquot sufficient to cover the amount necessary for the total and the
soluble analyses must then be taken. This aliquot must be homogenized a 2nd time and the total and
soluble analyses run on this aliquot. The homogenization process must not include grinding of the
samples. Submit the name and location of the disposal facility that will be accepting the hazardous waste
and the analytical laboratory along with the testing requirements not less than 5 business days before the
start of removal of yellow thermoplastic and yellow painted traffic stripe and pavement marking. The
analytical laboratory must be certified by the CA Department of Public Health Environmental Laboratory
Accreditation Program for all analyses to be performed.
After the Department accepts the analytical test results, dispose of yellow thermoplastic and yellow
paint hazardous waste residue at a Class 1 disposal facility located in CA under the requirements of the
disposal facility operator within 30 days after accumulating 220 pounds of residue and dust.
If less than 220 pounds of hazardous waste residue and dust is generated in total, it must be disposed
of within 30 days after the start of accumulation of the residue and dust.
Use a hazardous waste manifest and a transporter registered with the CA Department of Toxic
Substance Control. The Department will obtain the U.S. EPA ID no. and will sign all manifests as the
generator within 2 business days of receiving and accepting the analytical test results and receiving your
request for the U.S. EPA ID no.
If analytical test results demonstrate that the residue is a non–hazardous waste and the Department
agrees, dispose of the residue at an appropriately permitted Class II or Class III facility under Section 7-
1.13, "Disposal of Material Outside the Highway Right of Way," of the Standard Specifications.

April 11, 2011 5-7

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

3. RELATIONS WITH CALIFORNIA REGIONAL WATER QUALITY

CONTROL BOARD
This project lies within the boundaries of the San Francisco Regional Water Quality Control Board
(RWQCB).
The State Water Resources Control Board (SWRCB) has issued to the Department a permit that
governs storm water and non-storm water discharges from the Department's properties, facilities, and
activities. The Department's permit is entitled "Order No. 99 - 06 - DWQ, NPDES No. CAS000003,
National Pollutant Discharge Elimination System (NPDES) Permit, Statewide Storm Water Permit and
Waste Discharge Requirements (WDRs) for the State of California, Department of Transportation
(Caltrans)." Copies of the Department's permit are available for review from the SWRCB, Division of
Water Quality, 1001 "I" Street, P.O. Box 100, Sacramento, California 95812-0100, Telephone fax:
(916) 341-5463 and may also be obtained at:

http://www.waterboards.ca.gov/water_issues/programs/stormwater/caltrans.shtml

The Design-Builder shall know and comply with provisions of Federal, State, and local regulations
and requirements that govern the Design-Builder's operations and storm water and non-storm water
discharges from the project site and areas of disturbance outside the project limits during construction.
Attention is directed to Sections 7-1.01, "Laws to be Observed," 5-1.18, "Property and Facility
Preservation," 7-1.12, "Indemnification and Insurance," and 9-1.07E(5), "Penalty Withholds," of the
Standard Specifications.
The Design-Builder shall notify the Department immediately upon request from the regulatory
agencies to enter, inspect, sample, monitor, or otherwise access the project site or the Design-Builder's
records pertaining to water pollution control work. The Design-Builder and the Department shall provide
copies of correspondence, notices of violation, enforcement actions, or proposed fines by regulatory
agencies to the requesting regulatory agency.

April 11, 2011 5-8

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

4. WATER POLLUTION CONTROL (WPCP)

GENERAL
Summary
Work activities must not disturb 1 or more acres of soil. Manage work activities to reduce the
discharge of pollutants to surface waters, groundwater, or municipal separate storm sewer systems
including the work item shown in the verified Bid Item List for Prepare Water Pollution Control Program.
WPCP preparation includes obtaining WPCP approval, amending the WPCP, and monitoring and
inspecting WPC practices at the job site.

Do not start work until:

1. WPCP is approved
2. WPCP review requirements have been fulfilled. If the RWQCB requires time for WPCP review,
allow 30 days for the RWQCB to review the WPCP as specified under "Submittals" of these
technical provisions.

Definitions and Abbreviations

active and inactive areas: (1) Active areas have soil disturbing work activities occurring at least
once within 14 days, and (2) Inactive areas are areas that have not been disturbed for at least 15
days.
BMPs: Best Management Practices are water pollution control practices.
construction phase: Construction phases are (1) Highway Construction including work activities for
building roads and structures, (2) Plant Establishment including maintenance on vegetation
installed for final stabilization, and (3) Suspension where work activities are suspended and areas
are inactive.
Preparation Manual: The Department's "Storm Water Pollution Prevention Plan and Water
Pollution Control Program Preparation Manual."
NPDES: National Pollutant Discharge Elimination System.
NOI: Notice of Intent.
QSD: Qualified SWPPP Developer.
QSP: Qualified SWPPP Practitioner.
RWQCB: Regional Water Quality Control Board.
SWPPP: Storm Water Pollution Prevention Plan.
SWRCB: State Water Resources Control Board.
WPC: Water Pollution Control.
WPC Manager: Water Pollution Control Manager. The WPC Manager implements water pollution
control work described in the WPCP and oversees revisions and amendments to the WPCP.
WPCP: Water Pollution Control Program.

Submittals
Within 7 days after NTP1, start the following process for WPCP approval:

1. Submit 2 copies of the WPCP and allow 15 days for the Department's review. If revisions are
required, the Department provides comments and specifies the date that the review stopped.
2. Change and resubmit the WPCP within 7 days of receipt of the Department's comments. The
Department's review resumes when the complete WPCP is resubmitted.

April 11, 2011 5-9

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

3. When the Department approves the WPCP, submit an electronic and 3 printed copies of the
approved WPCP.
4. If the RWQCB reviews the approved WPCP, the Department submits one copy of the approved
WPCP to the RWQCB for their review and comment. RWQCBs requiring time to review
WPCPs include:

4.1. Lahontan for projects in the Lake Tahoe Hydrologic Unit and the Mammoth Lakes
Hydrologic Unit

5. If the Department requests changes to the WPCP based on RWQCB comments, amend the WPCP
within 3 days.

Submit:

1. Stormwater training records including training dates and subject for employees and
subcontractors. Include dates and subject for ongoing training, including tailgate meetings.
2. Employee training records:

2.1. Within 5 days of WPCP approval for existing employees

2.2. Within 5 days of training for new employees
2.3. At least 5 days before subcontractors start work for subcontractor's employees

Submit as required:

1. BMP Status Report

2. Inspection Reports

At least 5 days before operating any construction support facility, submit:

1. A plan showing the location and quantity of WPC practices associated with the construction
support facility
2. A copy of the NOI approved by the RWQCB and the WPCP approved by the RWQCB if you will
be operating a batch plant or a crushing plant under the General Industrial Permit

Quality Control and Assurance

Training
Provide storm water training for:

1. Project managers
2. Supervisory personnel
3. Employees involved with WPC work

Train all employees, including subcontractor’s employees, in the following subjects:

April 11, 2011 5-10

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. WPC rules and regulations

2. Implementation and maintenance for:

2.1. Temporary Soil Stabilization

2.2. Temporary Sediment Control
2.3. Tracking Control
2.4. Wind Erosion Control
2.5. Material pollution prevention and control
2.6. Waste management
2.7. Non-storm water management
2.8. Identifying and handling hazardous substances
2.9. Potential dangers to humans and the environment from spills and leaks or exposure to toxic
or hazardous substances

Employees must receive initial WPC training before working on the project.
Conduct weekly training meetings covering:

1. WPC BMP deficiencies and corrective actions

2. BMPs that are required for work activities during the week
3. Spill prevention and control
4. Material delivery, storage, use, and disposal
5. Waste management
6. Non-storm water management procedures

You may obtain copies of the Preparation Manual from the Publication Distribution Unit. The mailing
address for the Publication Distribution Unit is:

State of California
Department of Transportation
Publication Distribution Unit
1900 Royal Oaks Drive
Sacramento, California 95815
Telephone: (916) 445-3520

The Preparation Manual and other WPC references are available at the Department's "Construction
Storm Water and Water Pollution Control" Web site. For the Web site, go to:

http://www.dot.ca.gov/hq/construc/stormwater/stormwater1.htm

If you operate construction support facilities, protect storm water systems or receiving waters from
the discharge of potential pollutants by using WPC practices.
Construction support facilities include:

April 11, 2011 5-11

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. Staging areas
2. Storage yards for equipment and materials
3. Mobile operations
4. Batch plants for PCC and HMA
5. Crushing plants for rock and aggregate
6. Other facilities installed for your convenience such as haul roads

If you operate a batch plant to manufacture PCC, HMA, or other material; or a crushing plant to
produce rock or aggregate; obtain coverage under the General Industrial Permit. You must be covered
under the General Industrial Permit for batch plants and crushing plants located:

1. Outside of the job site

2. Within the job site that serve one or more contracts

Discharges from manufacturing facilities such as batch plants must comply with the general waste
discharge requirements for Order No. 97-03-DWQ, NPDES General Permit No. CAS000001, issued by
the SWRCB for "Discharge of Stormwater Associated with Industrial Activities Excluding Construction
Activities." For the General Industrial Permit, go to:

http://www.waterboards.ca.gov/

Water Pollution Control Manager

Assign one WPC Manager to implement the WPCP. You may assign a different QSP to prepare the
WPCP.
The WPC Manager must comply with the Permit (Order No. 2009-0009-DWQ, NPDES No.
CAS000002) for a QSP by having at least one of the following qualifications:

1. Certified Erosion, Sediment and Storm Water Inspector (CESSWI)™ registered through Enviro
Cert International, Inc.
2. Certified Inspector of Sediment and Erosion Control (CISEC) registered through CISEC, Inc.
3. Qualifications described in the Permit for a QSD
4. Department approved storm water management training described in the Department's
"Construction Storm Water and Water Pollution Control" Web site

At the job site, the WPC Manager must:

1. Be responsible for WPC work

2. Be the primary contact for WPC work
3. Oversee the maintenance of WPC practices
4. Oversee and enforce hazardous waste management practices
5. Have the authority to mobilize crews to make immediate repairs to WPC practices
6. Ensure that all employees have current water pollution control training
7. Implement the approved WPCP and amend the WPCP when required

April 11, 2011 5-12

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

WPC Manager must oversee:

1. Inspections of WPC practices identified in the WPCP

2. Inspections for visual monitoring

WATER POLLUTION CONTROL PROGRAM

WPCP work includes preparing a WPCP, obtaining WPCP approval, amending the WPCP, and
reporting on WPC practices at the job site. The WPCP must comply with the Preparation Manual. The
WPCP is required by the provisions in Section 7-1.01G, "Water Pollution," of the Standard
Specifications.
You may request, or the Department may order, changes to the WPC work. Changes may include the
addition of new WPC practices. Additional WPC work will be paid for as extra work under Section 4-
1.03D, "Extra Work," of the Standard Specifications.
The WPCP must include WPC practices:

1. For storm water and non-stormwater from areas outside of the job site related to project work
activities such as:

1.1. Staging areas

1.2. Storage yards
1.3. Access roads

2. For activities or mobile operations related to Design-Builder obtained NPDES permits

3. Construction support facilities

The WPCP must include a copy of permits obtained by the Department such as Fish & Game permits,
US Army Corps of Engineers permits, RWQCB 401 Certifications, and RWQCB Waste Discharge
Requirements for Aerially Deposited Lead Reuse.

WPCP Amendments
You must amend the WPCP when:

1. Changes in work activities could affect the discharge of pollutants

2. WPC practices are added by change order work
3. WPC practices are added at your discretion

If you amend the WPCP, follow the same process specified for WPCP approval.
Retain a printed copy of the approved WPCP at the job site.

WPCP Schedule
The WPCP schedule must:

April 11, 2011 5-13

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. Describe when work activities will be performed that could cause the discharge of pollutants in
storm water
2. Describe WPC practices associated with each construction phase
3. Identify soil stabilization and sediment control practices for disturbed soil areas

IMPLEMENTATION REQUIREMENTS
WPCP Implementation
Monitor the National Weather Service Forecast Office on a daily basis. For forecasts, go to:

http://www.srh.noaa.gov/forecast

Whenever you or the Department identifies a deficiency in the implementation of the approved
WPCP:

1. Correct the deficiency immediately, unless the Department agrees to a later date for making the
correction
2. Correct the deficiency before precipitation occurs

If you fail to correct the deficiency by the agreed date or before the onset of precipitation, the
Department may correct the deficiency and deduct the cost of correcting the deficiency from payment.
Continue WPCP implementation during any temporary suspension of work activities.
Install WPC practices within 15 days or before predicted precipitation, whichever occurs first.
If actions for your convenience disturb 1 or more acres of soil, you must pay all costs and be
responsible for all delays associated with submitting a SWPPP.

Inspection
The WPC Manager must oversee inspections for WPC practices identified in the WPCP:

1. Before a forecasted storm

2. After precipitation that causes site runoff
3. At 24-hour intervals during extended precipitation
4. On a predetermined schedule, a minimum of once a week

The WPC Manager must oversee daily inspections of:

1. Storage areas for hazardous materials and waste

2. Hazardous waste disposal and transporting activities
3. Hazardous material delivery and storage activities
4. WPC practices specified under "Construction Site Management" of these special provisions

The WPC Manager must use the Storm Water Site Inspection Report provided in the Preparation
Manual.

April 11, 2011 5-14

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

The WPC Manager must prepare BMP status reports that include the following:

1. Location and quantity of installed WPC practices

2. Location and quantity of disturbed soil for the active or inactive areas

Within 24 hours of finishing the weekly inspection, the WPC Manager must submit:

1. Copy of the completed site inspection report

2. Copy of the BMP status report

Reporting Requirements
If the following occur, notify the Department within 6 hours:

1. You identify discharges into receiving waters or drainage systems causing or potentially causing
pollution
2. The project receives a written notice or order from a regulatory agency

No later than 48 hours after the conclusion of a storm event resulting in a discharge, a non-stormwater
discharge, or receiving the notice or order, submit:

1. Date, time, location, and nature of the activity, type of discharge and quantity, and the cause of
the notice or order
2. WPC practices used before the discharge, or before receiving the notice or order
3. Description of WPC practices and corrective actions taken to manage the discharge or cause of
the notice

April 11, 2011 5-15

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

5. WATER POLLUTION CONTROL (SWPPP)

GENERAL
Summary
Discharges of storm water from the project must comply with NPDES General Permit for "Storm
Water Discharges Associated with Construction and Land Disturbance Activities" (Order No. 2009-0009-
DWQ, NPDES No. CAS000002) hereinafter called the "Permit." Manage work activities to reduce the
discharge of pollutants to surface waters, groundwater, or municipal separate storm sewer systems
including work items shown in the Bid Item List for:

1. Prepare Storm Water Pollution Prevention Plan. SWPPP preparation includes obtaining SWPPP
approval, amending the SWPPP, preparing a CSMP and a SAP, and monitoring and inspecting
WPC practices at the job site.
2. Storm Water Annual Report. Storm Water Annual Report preparation includes certifications,
monitoring and inspection results, and obtaining Storm Water Annual Report acceptance.
3. Storm Water Sampling and Analysis Day. Storm Water Sampling and Analysis Day includes
reporting of storm water quality per qualifying rain event. If specified for the risk level, the work
includes preparation, collection, analysis, and reporting of storm water samples for turbidity, pH,
and other constituents.
4. Rain Event Action Plan. If specified for the project risk level, REAP preparation includes
preparing and submitting REAP forms and monitoring weather forecasts.

Do not start work until:

1. SWPPP is approved.
2. WDID is issued.
3. SWPPP review requirements have been fulfilled. If the RWQCB requires time for SWPPP
review, allow 30 days for the RWQCB to review the SWPPP as specified under "Submittals" of
these special provisions.

This project is Risk Level 1.

Definitions and Abbreviations

April 11, 2011 5-16

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Preparation Manual: The Department's "Storm Water Pollution Prevention Plan and Water
Pollution Control Program Preparation Manual."
QSD: Qualified SWPPP Developer.
QSP: Qualified SWPPP Practitioner.
qualified rain event: A qualified rain event is a storm that produces at least 0.5 inch of precipitation
with a 48 hour or greater period between storms.
REAP: Rain Event Action Plan.
RWQCB: Regional Water Quality Control Board.
SAP: Sampling and Analysis Plan.
SSC: Suspended Sediment Concentration.
SWRCB: State Water Resources Control Board.
SWPPP: Storm Water Pollution Prevention Plan.
WDID: Waste Discharge Identification Number.
WPC: Water Pollution Control.
WPC Manager: Water Pollution Control Manager. The WPC Manager implements water pollution
control work described in the SWPPP and oversees revisions and amendments to the SWPPP.

Submittals
Within 20 days after NPT2, start the following process for SWPPP approval:

1. Submit 3 copies of the SWPPP and allow 20 days for the Department's review. If revisions are
required, the Department provides comments and specifies the date that the review stopped.
2. Change and resubmit the SWPPP within 15 days of receipt of the Department's comments. The
Department's review resumes when the complete SWPPP is resubmitted.
3. When the Department approves the SWPPP, submit an electronic and 4 printed copies of the
approved SWPPP.
4. If the RWQCB reviews the approved SWPPP, the Department submits one copy of the approved
SWPPP to the RWQCB for their review and comment. RWQCBs requiring time to review
SWPPPs include:

4.1. Lahontan for projects in the Lake Tahoe Hydrologic Unit and the Mammoth Lakes
Hydrologic Unit

5. If the Department requests changes to the SWPPP based on RWQCB comments, amend the
SWPPP within 10 days.

Submit:

1. Storm water training records including training dates and subjects for employees and
subcontractors. Include dates and subjects for ongoing training, including tailgate meetings.
2. Employee training records:

2.1. Within 5 days of SWPPP approval for existing employees

2.2. Within 5 days of training for new employees
2.3. At least 5 days before subcontractors start work for subcontractor's employees

April 11, 2011 5-17

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Prepare a Storm Water Annual Report for the reporting period from July 1st to June 30th. For the
prior reporting period, submit the report no later than July 15th if construction occurs from July 1st
through June 30th or within 15 days after contract acceptance if construction ends before June 30th.
Submit the Storm Water Annual Report as follows:

1. Submit 2 copies of the Storm Water Annual Report and allow 10 days for the Department's
review. If revisions are required, the Department provides comments and specifies the date that
the review stopped.
2. Change and resubmit the Storm Water Annual Report within 5 days of receipt of the
Department's comments. The Department's review resumes when the complete Storm Water
Annual Report is resubmitted.
3. When the Department accepts the Storm Water Annual Report, insert the WPC Manager's signed
certification and the Department's signed certification.

Submit one electronic copy and 2 printed copies of the accepted Storm Water Annual Report.
Submit as required:

1. NAL Exceedance Reports

2. NEL Exceedance Reports
3. Visual Monitoring Reports
4. Inspection Reports
5. BMP Status Report

At least 5 days before operating any construction support facility, submit:

1. A plan showing the location and quantity of WPC practices associated with the construction
support facility
2. A copy of the NOI approved by the RWQCB and the SWPPP approved by the RWQCB if you
will be operating a batch plant or a crushing plant under the General Industrial Permit

Quality Control and Assurance

Training
Provide storm water training for:

1. Project managers
2. Supervisory personnel
3. Employees involved with WPC work

Train all employees, including subcontractor's employees, in the following subjects:

1. WPC rules and regulations

2. Implementation and maintenance for:

April 11, 2011 5-18

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

2.1. Temporary Soil Stabilization

Employees must receive initial WPC training before working on the job site.
Conduct weekly training meetings covering:

1. WPC BMP deficiencies and corrective actions

Training for personnel to collect water quality samples must include:

1. SAP review
2. Health and safety review
3. Sampling simulations

If you operate a batch plant to manufacture PCC, HMA, or other material; or a crushing plant to
produce rock or aggregate; obtain coverage under the General Industrial General Permit. You must be
covered under the General Industrial Permit for batch plants and crushing plants located:

1. Outside of the job site

2. Within the job site that serve one or more contracts

April 11, 2011 5-19

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

http://www.waterboards.ca.gov/

You may obtain copies of the Preparation Manual from the Publication Distribution Unit. The mailing
address for the Publication Distribution Unit is:

State of California
Department of Transportation
Publication Distribution Unit
1900 Royal Oaks Drive
Sacramento, California 95815
Telephone: (916) 445-3520

The Preparation Manual and other WPC references are available at the Department's "Construction
Storm Water and Water Pollution Control" Web site. For the Web site, go to:

http://www.dot.ca.gov/hq/construc/stormwater/stormwater1.htm

Water Pollution Control Manager

Assign one WPC Manager to implement the SWPPP. The WPC Manager must comply with the
Permit qualifications for a QSP and a QSD. You may assign a different QSD to prepare the SWPPP.
The QSD must have the following qualifications:

1. Department approved storm water management training described in the Department's

"Construction Storm Water and Water Pollution Control" web site
2. Registration or certification described in the Permit

The QSP must meet the qualifications of the QSD or have the following certifications:

1. Department approved storm water management training described in the Department's

"Construction Storm Water and Water Pollution Control" web site
2. Certification described in the Permit

At the job site, the WPC Manager must:

April 11, 2011 5-20

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. Be responsible for WPC work

WPC Manager must oversee:

1. Inspections of WPC practices identified in the SWPPP

2. Inspections and reports for visual monitoring
3. Preparation and implementation of REAPs
4. Sampling and analysis
5. Preparation and submittal of:

5.1. NAL exceedance reports

5.2. NEL exceedance reports
5.3. SWPPP annual certification
5.4. Annual reports
5.5. BMP status reports

STORM WATER POLLUTION PREVENTION PLAN (SWPPP)

General
SWPPP work includes preparing a SWPPP including a CSMP, obtaining SWPPP approval, amending
the SWPPP, inspecting and reporting on WPC practices at the job site. The SWPPP must comply with
the Preparation Manual and the Permit. The SWPPP must be submitted in place of the water pollution
control program under Section 7-1.01G, "Water Pollution," of the Standard Specifications.
You may request, or the Department may order, changes to the WPC work. Changes may include the
addition of new WPC practices. Additional WPC work will be paid for as extra work under Section 4-
1.03D, "Extra Work," of the Standard Specifications.
The SWPPP must include sections as specified for the project risk level as follows:

1. For risk level 1:

1.1. Schedule
1.2. CSMP

2. For risk level 2:

2.1. Schedule
2.2. CSMP
2.3. Adherence to Effluent Standards for NALs
2.4. REAP

3. For risk level 3:

April 11, 2011 5-21

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

3.1. Schedule
3.2. CSMP
3.3. Adherence to Effluent Standards for NALs and NELs
3.4. REAP

The SWPPP must include WPC practices for:

1. Storm water and non-stormwater from areas outside of the job site related to project work
activities such as:

1.1. Staging areas

1.2. Storage yards
1.3. Access roads

2. Activities or mobile operations related to Design-Builder obtained NPDES permits

3. Construction support facilities

The SWPPP must include a copy of permits obtained by the Department such as Fish & Game
permits, US Army Corps of Engineers permits, RWQCB 401 Certifications, and RWQCB Waste
Discharge Requirements for Aerially Deposited Lead Reuse.
Amend the SWPPP annually and resubmit it by July 15th.
Amend the SWPPP if:

1. Changes in work activities could affect the discharge of pollutants

2. WPC practices are added by change order work
3. WPC practices are added at your discretion
4. Changes in the amount of disturbed soil are substantial
5. Objectives for reducing or eliminating pollutants in storm water discharges have not been
achieved
6. There is a Permit violation

Whenever you amend the SWPPP, follow the same process specified for SWPPP approval.
Retain a printed copy of the approved SWPPP at the job site.

SWPPP Schedule
The SWPPP schedule must:

1. Describe when work activities will be performed that could cause the discharge of pollutants into
storm water
2. Describe WPC practices associated with each construction phase
3. Identify soil stabilization and sediment control practices for disturbed soil areas

April 11, 2011 5-22

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Construction Site Monitoring Program (CSMP)

General
The QSD must prepare a CSMP as part of the SWPPP. The CSMP must be developed before starting
work and be revised to reflect current construction activities as necessary.
The CSMP must include sections for the project risk level as follows:

1. For risk level 1:

1.1. Visual Monitoring

1.2. SAP for Non-Visible Pollutants

2. For risk level 2:

2.1. Visual Monitoring

2.2. SAP for Non-Visible Pollutants
2.3. SAP for sediment and turbidity
2.4. SAP for pH

3. For risk level 3:

3.1. Visual Monitoring

3.2. SAP for Non-Visible Pollutants
3.3. SAP for sediment and turbidity
3.4. SAP for pH
3.5. SAP for receiving waters
3.6. SAP for temporary active treatment systems

Visual Monitoring
The WPC Manager must oversee the performance of visual inspections for qualifying rain events.
For each qualifying rain event, perform visual inspections and record observations during normal
working hours as follows:

1. Record the time, date, and rain gauge reading

2. Observe:

2.1. Within 2 days before the storm:

2.1.1. Drainage areas for spills, leaks, or uncontrolled pollutants

2.1.2. Proper implementation of WPC practices
2.1.3. Storm water storage areas for leaks and adequate freeboard

2.2. Every 24 hours during the storm:

2.2.1. WPC practices for effective operation

2.2.2. WPC practices needing maintenance and repair

April 11, 2011 5-23

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

2.3. Within 2 days after the storm event:

2.3.1. Discharge locations

2.3.2. WPC practices to evaluate the design, implementation, and effectiveness
2.3.3. To identify where additional WPC practices may be needed

Perform non-stormwater discharge visual inspections as follows:

1. At least once during each of the following periods:

1.1. January through March

1.2. April through June
1.3. July through September
1.4. October through December

2. Observe flowing and contained storm water for the presence of floating and suspended materials,
sheen on the surface, discoloration, turbidity, odors, and sources of observed pollutants
3. Observe the job site for the presence of authorized and unauthorized non-stormwater discharges
and their sources

The WPC Manager must prepare visual inspection reports that include the following:

1. Name of personnel performing the inspection, inspection date, and date inspection report
completed
2. Storm and weather conditions
3. Locations and observations
4. Corrective actions taken

Maintain visual inspections reports at the job site as part of the SWPPP.

Sampling and Analysis Plan (SAP)

General
Include a SAP in the CSMP to monitor the effectiveness of WPC practices.
The SAP must comply with the Preparation Manual.
Assign trained personnel to collect water quality samples. Document their training in the SAP.
Describe the following water quality sampling procedures in the SAP:

1. Sampling equipment
2. Sample preparation
3. Collection
4. Field measurement methods
5. Analytical methods
6. Quality assurance and quality control

April 11, 2011 5-24

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

7. Sample preservation and labeling

8. Collection documentation
9. Sample shipping
10. Chain of custody
11. Data management and reporting
12. Precautions from the construction site health and safety plan
13. Laboratory selection and certifications

Whenever assigned field personnel take samples, comply with the equipment manufacturer's
recommendation for collection, analysis methods, and equipment calibration.
Samples taken for laboratory analysis must follow water quality sampling procedures and be analyzed
by a State-certified laboratory under 40 CFR Part 136, "Guidelines Establishing Test Procedures for the
Analysis of Pollutants."
The SAP must identify the State-certified laboratory, sample containers, preservation requirements,
holding times, and analysis method. For a list of State-certified laboratories, go to:

http://www.cdph.ca.gov/certlic/labs/Pages/ELAP.aspx

Include procedure for sample collection during precipitation.

Retain water quality sampling documentation and analytical results with the SWPPP at the job site.
Show pollutant sampling locations on SWPPP drawings.
If discharges or sampling locations change because of changed work activities or knowledge of site
conditions, amend the SAP.
If the project is risk level 2 or risk level 3, include procedures for collecting and analyzing at least 3
samples for each day of each qualifying rain event. Describe the collection of effluent samples at all
locations where the storm water is discharged off-site.

Analytical Results and Evaluation

Submit an electronic copy (in file format .xls, .txt, .csv, .dbs, or .mdb) and a printed copy of water
quality analytical results, and quality assurance and quality control within 48 hours of field analysis
sampling, and within 30 days for laboratory analysis. Also provide an evaluation of whether the
downstream samples show levels of the tested parameter that are higher than the control sample.
Electronic water quality analysis results must have the following information:

1. Sample identification number

2. Contract number
3. Constituent
4. Reported value
5. Analytical method
6. Method detection limit
7. Reported limit

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SAP for Non-Visible Pollutants

The SAP must include a description of the sampling and analysis strategy for monitoring non-visible
pollutants.
The SAP must identify potential non-visible pollutants present at the job site associated with any of
the following:

1. Construction materials and waste

2. Existing contamination due to historical site usage
3. Application of soil amendments, including soil stabilization materials, with the potential to
change pH or contribute toxic pollutants to storm water

SWPPP drawings must show the locations planned for storage and use of potential non-visible
pollutants.
The SAP must include sampling procedures for the following conditions when observed during a
storm water visual inspection. For each of the following, collect at least one sample for each qualifying
storm event:

1. Materials or waste containing potential non-visible pollutants that are not stored under watertight
conditions
2. Materials or waste containing potential non-visible pollutants that are stored under watertight
conditions, but a breach, leakage, malfunction, or spill is observed; the leak or spill has not been
cleaned up before precipitation; and material or waste could discharge non-visible pollutants to
surface waters or drainage system
3. Chemical applications, including fertilizer, pesticide, herbicide, methyl methacrylate concrete
sealant, or non-pigmented curing compound used during precipitation or within 24 hours
preceding precipitation, and could discharge pollutants to surface waters or drainage system
4. Applied soil amendments, including soil stabilization materials that could change pH levels or
contribute toxic pollutants to storm water runoff and discharge pollutants to surface waters or
drainage system, unless available independent test data indicates acceptable concentrations of
non-visible pollutants in the soil amendment
5. Storm water runoff from an area contaminated by historical usage of the site that could discharge
pollutants to surface waters or drainage systems

The SAP must provide sampling procedures and schedule for:

1. Sample collection during the first 2 hours of each rain event that generate runoff
2. Sample collection during normal working hours
3. Each non-visible pollutant source
4. Uncontaminated control sample

The SAP must identify locations for sampling downstream and control samples, and reasons for
selecting those locations. Select control sample locations where the sample will not come in contact with
materials, waste, or areas associated with potential non-visible pollutants or disturbed soil areas.

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SAP for Sediment and Turbidity

If the project is risk level 2 or risk level 3, sample and analyze for turbidity:

Parameter Test Method Detection Unit

Limit (Min)
Turbidity Field test with calibrated 1 NTU
portable instrument

If the project is risk level 3 and the turbidity NEL has been exceeded, sample and analyze for SSC:

Parameter Test Method Detection Unit

Limit (Min)
SSC ASTM Method D3977-97 5 Mg/L

SAP for pH
If the project is risk level 2 or risk level 3, sample and analyze for pH:

Parameter Test Method Detection Unit

Limit (Min)
pH Field test with calibrated 0.2 pH units
portable instrument

SAP for Receiving Waters

If the project is risk level 3, describe procedures for obtaining samples from representative and
accessible locations:

1. Upstream of the discharge point

2. Downstream of the discharge point

Show receiving water sampling locations on SWPPP drawings.

If there are several discharge points, describe procedures for obtaining samples from a single
upstream and a single downstream location.

Rain Event Action Plan (REAP)

REAP work includes preparing and submitting REAP forms and monitoring weather forecasts. The
WPC Manager must submit a REAP to protect the job site at least 48 hours before a predicted rain event.
Prepare a REAP when the National Weather Service is predicting at least a 50 percent probability of
precipitation within 72 hours.
For the REAP, use approved forms and include:

1. Site location

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2. Risk level
3. Contact information including 24-hour emergency phone numbers for:

3.1. WPC Manager

3.2. Erosion and sediment control providers or subcontractors
3.3. Storm water sampling providers or subcontractors

4. Storm Information
5. Construction phase information for:

5.1. Highway Construction including active and inactive areas for work activities for building
roads and structures
5.2. Plant Establishment including maintenance on vegetation installed for final stabilization
where areas are inactive
5.3. Suspension where work activities are suspended and areas are inactive

6. Construction phase information including:

6.1. Construction activities

6.2. Subcontractors and trades on the job site
6.3. Pre-storm activities including:

6.3.1. Responsibilities of the WPC Manager

6.3.2. Responsibilities of the crew and crew size
6.3.3. Stabilization for active and inactive disturbed soil areas
6.3.4. Stockpile management
6.3.5. Corrective actions taken for deficiencies identified during pre-storm visual
inspection

6.4. Activities to be performed during storm events including:

6.4.1. Responsibilities of the WPC Manager

6.4.2. Responsibilities of the crew and crew size
6.4.3. BMP maintenance and repair

6.5. Description of flood contingency measures

You must have the REAP onsite at least 24 hours before a predicted rain event. A printed copy of
each REAP must be at the job site as part of the SWPPP.
Implement the REAP including mobilizing crews to complete activities no later than 24 hours before
precipitation occurs.

IMPLEMENTATION REQUIREMENTS
SWPPP Implementation
Obtain, install, and maintain a rain gauge at the job site. Observe and record daily precipitation.
Monitor the National Weather Service Forecast Office on a daily basis. For forecasts, go to:

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Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
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http://www.srh.noaa.gov/forecast

Whenever you or the Department identifies a deficiency in the implementation of the approved
SWPPP:

1. Correct the deficiency immediately, unless the Department agrees to a later date for making the
correction
2. Correct the deficiency before precipitation occurs

If you fail to correct the deficiency by the agreed date or before the onset of precipitation, the
Department may correct the deficiency and deduct the cost of correcting the deficiency from payment.
Continue SWPPP implementation during any temporary suspension of work activities.
Install WPC practices within 15 days or before predicted precipitation, whichever occurs first.

Numeric Action Levels (NALs)

If the project is risk level 2 or risk level 3, then it is subject to NALs:

Parameter Test Method Detection Unit Numeric Action Level

Limit (Min)
pH Field test with calibrated 0.2 pH units Lower NAL = 6.5
portable instrument Upper NAL = 8.5

Turbidity Field test with calibrated 1 NTU 250 NTU

portable instrument

Numeric Effluent Limits (NELs)

If the project is risk level 3, then it is subject to NELs:

Parameter Test Method Detection Unit Numeric Effluent Limit

Limit (Min)
pH Field test with calibrated 0.2 pH units Lower NEL = 6.0
portable instrument Upper NEL = 9.0

Turbidity Field test with calibrated 1 NTU 500 NTU

portable instrument

The storm event daily average for storms up to the 5-year, 24-hour storm, must not exceed the NEL
for turbidity.
The daily average sampling results must not exceed the NEL for pH.

Storm Water Sampling and Analysis Day

Storm Water Sampling and Analysis Day work includes preparation, collection, analysis, and
reporting of storm water samples for turbidity, pH, and other constituents. If the project is risk level 2 or

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risk level 3, and there is a qualified rain event that produces runoff, comply with the project's SAP for
preparation, collection, analysis, and reporting of storm water samples. Collect:

1. Samples for each non-visible pollutant source and a corresponding uncontaminated control
sample
2. Samples for turbidity, pH, and other constituents as specified
3. At least 3 samples for each day of each qualifying rain event
4. Samples for all locations where the storm water is discharged off-site

Perform sample collection during:

1. First 2 hours of each qualified rain event that produces runoff

2. Normal working hours

If the project is risk level 3, obtain receiving water samples.

You are not required to physically collect samples during dangerous weather conditions such as
flooding or electrical storms.
If downstream samples show increased levels, assess WPC practices, site conditions, and surrounding
influences to determine the probable cause for the increase.

Inspection
The WPC Manager must oversee inspections for WPC practices identified in the SWPPP:

1. Before a forecasted storm

2. After precipitation that causes site runoff
3. At 24-hour intervals during extended precipitation
4. On a predetermined schedule, a minimum of once a week

The WPC Manager must oversee daily inspections of:

1. Storage areas for hazardous materials and waste

The WPC Manager must use the Storm Water Site Inspection Report provided in the Preparation
Manual.
The WPC Manager must prepare BMP status reports that include the following:

1. Location and quantity of installed WPC practices

2. Location and quantity of disturbed soil for the active or inactive areas

Within 24 hours of finishing the weekly inspection, the WPC Manager must submit:

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1. Copy of the completed site inspection report

2. Copy of the BMP status report

REPORTING REQUIREMENTS
Storm Water Annual Report
Storm Water Annual Report work includes certifications, monitoring and inspection results, and
obtaining Storm Water Annual Report acceptance. The WPC Manager must prepare a Storm Water
Annual Report. The report must:

1. Use an approved report format

2. Include project information including description and location
3. Include storm water monitoring information including:

3.1. Summary and evaluation of sampling and analysis results including laboratory reports
3.2. Analytical methods, reporting units, detections limits for analytical parameters
3.3. Summary of corrective actions
3.4. Identification of corrective actions or compliance activities that were not implemented
3.5. Summary of violations
3.6. Names of individuals performing storm water inspections and sampling
3.7. Logistical information for inspections and sampling including location, date, time, and
precipitation
3.8. Visual observations and sample collection records

4. Include documentation on training for:

4.1. Individuals responsible for NPDES permit compliance

4.2. Individuals responsible for BMP installation, inspection, maintenance, and repair
4.3. Individuals responsible for preparing, revising, and amending the SWPPP

NAL Exceedance Report

If the project is risk level 2 or risk level 3 and an effluent sample exceeds a NAL, notify the
Department and submit a NAL Exceedance Report no later than 48 hours after the conclusion of the
storm event. The report must:

1. Include the following field sampling results and inspections:

1.1. Analytical methods, reporting units, and detection limits

1.2. Date, location, time of sampling, visual observation and measurements
1.3. Quantity of precipitation of the storm event

2. Description of BMPs and corrective actions taken to manage NAL exceedance

NEL Violation Report

If the project is risk level 3 and an NEL is exceeded, notify the Department and submit a NEL
Violation Report within 6 hours. The report must:

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1. Include the following field sampling results and inspections:

1.1. Analytical methods, reporting units, and detection limits

1.2. Date, location, time of sampling, visual observations and measurements
1.3. Quantity of precipitation of the storm event

2. Description of BMPs and corrective actions taken to manage NEL exceedance

If the project is risk level 2 or risk level 3, submit all sampling results to the Department no later than
48 hours after the conclusion of a storm event.

PAYMENT
For each failure to submit a completed Storm Water Annual Report, the Department withholds
$10,000. This withhold is in addition to other withholds under Section 9-1.07E(3) "Performance Failure
Withholds," of the Standard Specifications.
Each failure to comply with any part of these special provisions and each failure to implement water
pollution control practices are considered separate performance failures.

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6. CONSTRUCTION SITE MANAGEMENT

GENERAL
Summary
This work includes controlling potential sources of water pollution before they come in contact with
storm water systems or watercourses.
Control material pollution and manage waste and non-stormwater at the job site by implementing
effective handling, storage, use, and disposal practices.
For information on documents specified in these special provisions, refer to the Department's
Preparation Manual, Dewatering Guide, and BMP Manual.
Preparation Manual, Dewatering Guide, and BMP Manual are available from the Department's
Construction Storm Water and Water Pollution Control web site at:

http://www.dot.ca.gov/hq/construc/stormwater/stormwater1.htm

Definitions and Abbreviations

active and inactive areas: (1) Active areas have soil disturbing work activities occurring at least
once within 14 days, and (2) Inactive areas are areas that have not been disturbed for at least 15
days.
BMP Manual: The Department's Construction Site Best Management Practices (BMP) Manual.
CDPH: California Department of Public Health
Dewatering Guide: The Department's Field Guide to Construction Site Dewatering.
ELAP: Environmental Laboratory Accreditation Program
minor spills: Small quantities of oil, gasoline, paint, or other material that are small enough to be
controlled by a first responder upon discovery of the spill.
MSDS: Material Safety Data Sheet
Preparation Manual: The Department's Storm Water Pollution Prevention Plan (SWPPP) and
Water Pollution Control Program (WPCP) Preparation Manual.
semi-significant spills: Spills that can be controlled by a first responder with help from other
personnel.
significant or hazardous spills: Spills that cannot be controlled by construction personnel.
WPC: Water Pollution Control
WPC Manager: Water Pollution Control Manager as defined under "Water Pollution Control" of
these special provisions.

Submittals
Submit the following:

1. MSDS at least 5 days before material is used or stored

2. Monthly inventory records for material used or stored
3. Copy of written approval to discharge into a sanitary sewer system at least 5 days before
beginning discharge activities

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CONSTRUCTION
Spill Prevention and Control
Implement spill and leak prevention procedures for chemicals and hazardous substances stored at the
job site. If you spill or leak chemicals or hazardous substances at the job site, you are responsible for all
associated cleanup costs and related liability.
As soon as it is safe, contain and clean up spills of petroleum products, sanitary and septic waste
substances listed under CFR Title 40, Parts 110, 117, and 302.

Minor Spills
Clean up minor spills using the following procedures:

1. Contain the spread of the spill

2. Recover the spilled material by absorption
3. Clean the contaminated area
4. Dispose of the contaminated material promptly and properly

Semi-significant Spills
Clean up semi-significant spills immediately by the following procedures:

1. Contain the spread of the spill

2. Recover the spilled material using absorption whenever a spill occurs on a paved surface or an
impermeable surface
3. Contain the spill with an earthen dike and dig up the contaminated soil for disposal whenever a
spill occurs on soil
4. If the spill occurs during precipitation, cover the spill with plastic or other material to prevent
contaminated runoff
5. Dispose of the contaminated material promptly and properly

Significant or Hazardous Spills

Immediately notify qualified personnel of significant or hazardous spills. Do not let construction
personnel attempt to clean up the spill until qualified staff have arrived. Do the following:

1. Notify the Engineer and follow up with a written report

2. Obtain the services of a spills contractor or hazardous material team immediately
3. Notify the local emergency response team by dialing 911 and county officials at the emergency
phone numbers kept at the job site
4. Notify the Governor's Office of Emergency Services Warning Center at (805) 852-7550
5. Notify the National Response Center at (800) 424-8802 regarding spills of Federal reportable
quantities under CFR Title 40, Parts 110, 119, and 302
6. Notify other agencies as appropriate, including:

6.1. Fire Department

6.2. Public Works Department

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6.3. Coast Guard

6.4. Highway Patrol
6.5. City Police or County Sheriff Department
6.6. Department of Toxic Substances
6.7. California Division of Oil and Gas
6.8. Cal OSHA
6.9. Regional Water Resources Control Board

Report minor, semi-significant, and significant spills to the WPC Manager. The WPC Manager must
notify the Engineer immediately. The WPC Manager must oversee and enforce proper spill prevention
and control measures.
Prevent spills from entering storm water runoff before and during cleanup. Do not bury spills or
wash spills with water.
Keep material or waste storage areas clean, well organized, and equipped with enough cleanup
supplies for the material being stored.

Material Management
General
Material must be delivered, used, and stored for this job in a way that minimizes or eliminates
discharge of material into the air, storm drain systems, and watercourses.
Implement the practices described under "Material Management" of these special provisions while
taking delivery of, using, or storing any of the following materials:

1. Hazardous chemicals including acids, lime, glues, adhesives, paints, solvents, and curing
compounds
2. Soil stabilizers and binders
3. Fertilizers
4. Detergents
5. Plaster
6. Petroleum materials including fuel, oil, and grease
7. Asphalt components and concrete components
8. Pesticides and herbicides

Employees trained in emergency spill cleanup procedures must be present during the unloading of
hazardous materials or chemicals.
If practicable, use less hazardous materials.

Material Storage
Use the following material storage procedures:

1. Store liquids, petroleum materials, and substances listed in CFR Title 40, Parts 110, 117, and 302
as specified by the Department, and place them in secondary containment facilities.

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2. Secondary containment facilities must be impervious to the materials stored there for a minimum
contact time of 72 hours.
3. Cover secondary containment facilities during non-working days and when precipitation is
predicted. Secondary containment facilities must be adequately ventilated.
4. Keep secondary containment facility free of accumulated rainwater or spills. After precipitation,
or in the event of spills or leaks, collect accumulated liquid and place into drums within 24 hours.
Handle these liquids as hazardous waste under "Hazardous Waste" of these special provisions
unless testing determines them to be nonhazardous.
5. Do not store incompatible materials, such as chlorine and ammonia, in the same secondary
containment facility.
6. Store materials in the original containers with the original material labels maintained in legible
condition. Replace damaged or illegible labels immediately.
7. Secondary containment facilities must have the capacity to contain precipitation from a 24-hour-
long, 25-year storm, and 10 percent of the aggregate volume of all containers, or entire volume of
the largest container within the facility, whichever is greater.
8. Store bagged or boxed material on pallets. Protect bagged or boxed material from wind and rain
during non-working days and while precipitation is predicted.
9. Provide sufficient separation between stored containers to allow for spill cleanup or emergency
response access. Storage areas must be kept clean, well organized, and equipped with cleanup
supplies appropriate for the materials being stored.
10. Repair or replace perimeter controls, containment structures, covers, and liners as necessary.
Inspect storage areas before and after precipitation, and at least weekly during other times.

Stockpile Management
Use the following stockpile management procedures:

1. Reduce or eliminate potential water pollution from stockpiled material including soil, paving
material, and pressure treated wood.
2. Locate stockpiles:

2.1. If within the floodplain, at least 100 feet from concentrated flows of storm water, drainage
courses, and inlets unless approved
2.2. If outside the floodplain, at least 50 feet from concentrated flows of storm water, drainage
courses, and inlets unless approved

Install WPC practices within 15 days or before predicted precipitation, whichever occurs first.
Active and inactive soil stockpiles must be:

1. Covered with soil stabilization measures, plastic sheeting, or geosynthetic fabric

2. Surrounded with a linear sediment barrier

Portland cement concrete rubble, AC, HMA, AC and HMA rubble, aggregate base or aggregate sub-
base stockpiles must be:

1. Covered with plastic sheeting, or geosynthetic fabric

2. Surrounded with a linear sediment barrier

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Pressure treated wood stockpiles must be:

1. Placed on pallets
2. Covered with impermeable material

Cold mix asphalt concrete stockpiles must be:

1. Placed on impervious surface

2. Covered with impermeable material
3. Protected from run-on and runoff

Control wind erosion year round under Section 14-9.02, "Dust Control" of the Standard
Specifications.
Repair or replace linear sediment barriers and covers as needed to keep them functioning properly. If
sediment accumulates to 1/3 of the linear sediment barrier height, remove the sediment.

Waste Management
Solid Waste
Do not allow litter or debris to accumulate anywhere at the job site, including storm drain grates, trash
racks, and ditch lines. Pick up and remove trash and debris from the job site at least once a week. The
WPC Manager must monitor solid waste storage and disposal procedures at the job site.
If practicable, recycle nonhazardous job site waste and excess material. If recycling is not
practicable, disposal must comply with Section 7-1.13, "Disposal of Material Outside the Highway Right
of Way" of the Standard Specifications.
Furnish enough closed-lid dumpsters of sufficient size to contain any solid waste generated by work
activities. When the refuse reaches the fill line, empty the dumpsters. Dumpsters must be watertight. Do
not wash out dumpsters at the job site. Furnish additional containers and pick up dumpsters more
frequent during the demolition phase of construction.
Solid waste includes:

1. Brick
2. Mortar
3. Timber
4. Metal scraps
5. Sawdust
6. Pipe
7. Electrical cuttings
8. Non-hazardous equipment parts
9. Styrofoam and other packaging materials
10. Vegetative material and plant containers from highway planting
11. Litter and smoking material, including litter generated randomly by the public
12. Other trash and debris

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Furnish and use trash receptacles at the job site yard, field trailers, and locations where workers
gather for lunch and breaks.

Hazardous Waste
Use hazardous waste management practices if waste is generated at the job site from the following
substances:

1. Petroleum products
2. Asphalt products
3. Concrete curing compound
4. Pesticides
5. Acids
6. Paints
7. Stains
8. Solvents
9. Wood preservatives and treated posts
10. Roofing tar
11. Road flares
12. Lime
13. Glues and adhesives
14. Materials classified as hazardous by California Code of Regulations, Title 22, Division 4.5; or
listed in CFR Title 40, Parts 110, 117, 261, or 302

The WPC Manager must oversee and enforce hazardous waste management practices. Minimize the
production of hazardous materials and hazardous waste at the job site. If damaged, repair or replace
perimeter controls, containment structures, and covers.
If hazardous material levels are unknown, use a laboratory certified by ELAP under CDPH to sample
and test waste to determine safe methods for storage and disposal.
Separate potentially hazardous waste from nonhazardous waste at the job site. Hazardous waste must
be handled, stored, and disposed of under California Code of Regulations, Title 22, Division 4.5, Section
66262.34; and in CFR Title 49, Parts 261, 262, and 263.
Store hazardous waste in sealed containers constructed and labeled with the contents and date
accumulated under California Code of Regulations, Title 22, Division 4.5; and in CFR Title 49, Parts 172,
173, 178, and 179. Keep hazardous waste containers in temporary containment facilities under "Material
Storage" of these special provisions.
Furnish containers with adequate storage volume at convenient locations for hazardous waste
collection. Do not overfill hazardous waste containers. Do not mix hazardous waste. Do not allow
potentially hazardous waste to accumulate on the ground. Store containers of dry waste that are not
watertight on pallets. Store hazardous waste away from storm drains, watercourses, moving vehicles, and
equipment.
Clean water based or oil based paint from brushes or equipment within a contained area and in a way
that does not contaminate soil, watercourses, and storm drain systems. Handle and dispose of the
following as hazardous waste: paints, thinners, solvents, residues, and sludges that cannot be recycled or

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reused. When thoroughly dry, dispose of the following as solid waste: dry, latex paint and paint cans,
used brushes, rags, absorbent materials, and drop cloths.
Dispose of hazardous waste within 90 days of being generated. Use a licensed hazardous waste
transporter to take hazardous waste to a Class I Disposal Site. Submit a copy of uniform hazardous waste
manifest forms within 24 hours of transporting hazardous waste.
The WPC Manager must inspect the following daily:

1. Storage areas for hazardous materials and waste

2. Hazardous waste disposal and transporting activities
3. Hazardous material delivery and storage activities

Contaminated Soil
Identify contaminated soil from spills or leaks by noticing discoloration, odors, or differences in soil
properties. Soil with evidence of contamination must be sampled and tested by a laboratory certified by
ELAP.
If levels of contamination are found to be hazardous, handle and dispose of the soil as hazardous
waste.
Prevent the flow of water, including ground water, from mixing with contaminated soil by using one
or a combination of the following measures:

1. Berms
2. Cofferdams
3. Grout curtains
4. Freeze walls
5. Concrete seal course

If water mixes with contaminated soil and becomes contaminated, sample and test the water using a
laboratory certified by ELAP. If levels of contamination are found to be hazardous, handle and dispose of
the water as hazardous waste.

Concrete Waste
Use practices that will prevent the discharge of portland cement concrete, AC, or HMA waste into
storm drain systems or watercourses.
Collect and dispose of portland cement concrete, AC, or HMA waste at locations where:

1. Concrete material, including grout, is used

2. Concrete dust and debris result from demolition
3. Sawcutting, coring, grinding, grooving, or hydro-concrete demolition of portland cement
concrete, AC, or HMA creates a residue or slurry
4. Concrete truck or other concrete-coated equipment is cleaned at the job site

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Sanitary and Septic Waste

Do not bury or discharge wastewater from sanitary or septic systems within Department right-of-way.
The WPC Manager must inspect sanitary or septic waste storage and monitor disposal procedures at least
weekly. Sanitary facilities that discharge to the sanitary sewer system must be properly connected and
free from leaks. Place sanitary facilities at least 50 feet away from storm drains, watercourses, and flow
lines.
Obtain written approval from the local health agency, city, county, and sewer district before
discharging from a sanitary or septic system directly into a sanitary sewer system, and submit a copy to
the Engineer. Comply with local health agency provisions while using an on-site disposal system.

Liquid Waste
Use practices that will prevent job site liquid waste from entering storm drain systems or
watercourses. Liquid waste includes the following:

1. Drilling slurries or fluids

2. Grease-free or oil-free wastewater or rinse water
3. Dredgings, including liquid waste from drainage system cleaning
4. Liquid waste running off a surface including wash or rinse water
5. Other non-stormwater liquids not covered by separate permits

Hold liquid waste in structurally sound, leak proof containers such as:

1. Roll-off bins
2. Portable tanks

Liquid waste containers must be of sufficient quantity and volume to prevent overflow, spills and
leaks.
Store containers:

1. At least 50 feet from moving vehicles and equipment

2. If within the floodplain, at least 100 feet from concentrated flows of storm water, drainage
courses, watercourses, and storm drain inlets unless approved
3. If outside the floodplain, at least 50 feet from concentrated flows of storm water, drainage
courses, watercourses, and storm drain inlets unless approved

Remove and dispose of deposited solids from sediment traps under "Solid Waste" of these special
provisions unless the Engineer approves another method.
Liquid waste may require testing to determine hazardous material content before disposal.
Drilling fluids and residue must be disposed of outside the highway right-of-way.
If an approved location is available within the job site, fluids and residue exempt under California
Code of Regulations, Title 23, Section 2511(g) may be dried by evaporation in a leak proof container.
Dispose of remaining solid waste under "Solid Waste" of these special provisions.

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Non-Storm Water Management

Water Control and Conservation
Manage water used for work activities to prevent erosion or discharge of pollutants into storm drain
systems or watercourses. Obtain approval before washing anything at the job site with water that could
discharge into a storm drain system or watercourse. Report discharges immediately.
If water is used at the job site, implement water conservation practices. Inspect irrigation areas.
Adjust watering schedules to prevent erosion, excess watering, or runoff. Shut off water source to broken
lines, sprinklers, or valves, and repair breaks within 24 hours. If possible, reuse water from waterline
flushing for landscape irrigation. Sweep and vacuum paved areas; do not wash them with water.
Direct job site water runoff, including water from water line repair, to areas where it can infiltrate into
the ground and not enter storm drain systems or watercourses. Do not allow spilled water to escape water
truck filling areas. If possible, direct water from off-site sources around the job site. Minimize the
contact of off-site water with job site water.

Illegal Connection and Discharge Detection and Reporting

Inspect the job site and the site perimeter before starting work for evidence of illegal connections,
discharges, or dumping. After starting work, inspect the job site and perimeter on a daily schedule.
Whenever illegal connections, discharges, or dumping are discovered, notify the Engineer
immediately. Take no further action unless ordered by the Engineer. Assume unlabeled or unidentifiable
material is hazardous.
Look for the following evidence of illegal connections, discharges, or dumping:

1. Debris or trash piles

2. Staining or discoloration on pavement or soils
3. Pungent odors coming from drainage systems
4. Discoloration or oily sheen on water
5. Stains or residue in ditches, channels or drain boxes
6. Abnormal water flow during dry weather
7. Excessive sediment deposits
8. Nonstandard drainage junction structures
9. Broken concrete or other disturbances near junction structures

Vehicle and Equipment Cleaning

Limit vehicle and equipment cleaning or washing at the job site except what is necessary to control
vehicle tracking or hazardous waste. Notify the Engineer before cleaning vehicles and equipment at the
job site with soap, solvents, or steam. Contain and recycle or dispose of resulting waste under "Liquid
Waste" or "Hazardous Waste" of these special provisions, whichever is applicable. Do not use diesel to
clean vehicles or equipment, and minimize the use of solvents.
Clean or wash vehicles and equipment in a structure equipped with disposal facilities. If using a
structure is not possible, clean or wash vehicles and equipment in an outside area. The outside area must
be:

1. Paved with AC, HMA, or concrete paving

April 11, 2011 5-41

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

2. Surrounded by a containment berm

3. Equipped with a sump to collect and dispose of wash water
4. If within the floodplain, located at least 100 feet from concentrated flows of storm water,
drainage courses, watercourses, and storm drain inlets unless approved
5. If outside the floodplain, located at least 50 feet from concentrated flows of storm water, drainage
courses, watercourses, and storm drain inlets unless approved

When washing vehicles or equipment with water, use as little water as possible. Hoses must be
equipped with a positive shutoff valve.
Discharge liquid from wash racks to a recycle system or to another approved system. Remove liquids
and sediment as necessary.
The WPC Manager must inspect vehicle and equipment cleaning facilities:

1. Daily if vehicle and equipment cleaning occurs daily

2. Weekly if vehicle and equipment cleaning does not occur daily

Vehicle and Equipment Fueling and Maintenance

If practicable, perform maintenance on vehicles and equipment off the job site.
If fueling or maintenance must be done at the job site, designate a site, or sites, and obtain approval
before using. Minimize mobile fueling or maintenance.
If vehicle and equipment fueling and maintenance must be done at the job site, areas for the following
activities must be:

1. On level ground
2. Protected from storm water run-on
3. If within the floodplain, located at least 100 feet from concentrated flows of storm water,
drainage courses, watercourses, and storm drain inlets unless approved
4. If outside the floodplain, located at least 50 feet from concentrated flows of storm water, drainage
courses, watercourses, and storm drain inlets unless approved

Use containment berms or dikes around the fueling and maintenance area. Keep adequate quantities
of absorbent spill cleanup material and spill kits in the fueling and maintenance area and on fueling
trucks. Dispose of spill cleanup material and kits immediately after use. Use drip pans or absorbent pads
during fueling or maintenance.
Fueling or maintenance activities must not be left unattended. Fueling nozzles must be equipped with
an automatic shutoff control. Vapor recovery fueling nozzles must be used where required by the Air
Quality Management District. When not in use, nozzles must be secured upright. Do not top-off fuel
tanks.
Recycle or properly dispose of used batteries and tires.
The WPC Manager must inspect vehicle and equipment maintenance and fueling areas:

1. Daily when vehicle and equipment maintenance and fueling occurs daily
2. Weekly when vehicle and equipment maintenance and fueling does not occur daily

April 11, 2011 5-42

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

The WPC Manager must inspect vehicles and equipment at the job site for leaks and spills on a daily
schedule. Operators must inspect vehicles and equipment each day of use.
If leaks cannot be repaired immediately, remove the vehicle or equipment from the job site.

Material and Equipment Used Over Water

Place drip pans and absorbent pads under vehicles or equipment used over water. Keep an adequate
supply of spill cleanup material with the vehicle or equipment. If the vehicle or equipment will be idle for
more than one hour, place drip pans or plastic sheeting under the vehicle or equipment on docks, barges,
or other surfaces over water.
Furnish watertight curbs or toe boards on barges, platforms, docks, or other surfaces over water to
contain material, debris, and tools. Secure material to prevent spills or discharge into water due to wind.

Structure Removal Over or Adjacent to Water

Do not allow demolished material to enter storm water systems or watercourses. Use approved
covers and platforms to collect debris. Use attachments on equipment to catch debris on small demolition
activities. Empty debris catching devices daily and handle debris under "Waste Management" of these
special provisions.
The WPC Manager must inspect demolition sites within 50 feet of storm water systems or
watercourses daily.

Paving, Sealing, Sawcutting, Grooving, and Grinding Activities

Prevent the following materials from entering storm drain systems or water courses:

1. Cementitious material
2. Asphaltic material
3. Aggregate or screenings
4. Grinding grooving, or sawcutting residue
5. Pavement chunks
6. Shoulder backing
7. Methacrylate

Cover drainage inlets and use linear sediment barriers to protect downhill watercourses until paving,
sealing, sawcutting, grooving, or grinding activities are completed and excess material has been removed.
Cover drainage inlets and manholes during the application of seal coat, tack coat, slurry seal, or fog seal.
If precipitation is predicted, limit paving, sawcutting, and grinding to places where runoff can be
captured.
Do not start seal coat, tack coat, slurry seal, or fog seal activities if precipitation is predicted during
the application or curing period. Do not excavate material from existing roadways during precipitation.
Use a vacuum to remove slurry immediately after slurry is produced. Do not allow slurry to run onto
lanes open to traffic or off the pavement.

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Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Collect residue from portland cement concrete grinding and grooving activities with a vacuum
attachment on the grinding machine. Do not leave any residue on the pavement or allow the residue to
flow across the pavement.
If approved, material excavated from existing roadways may be stockpiled under "Stockpile
Management" of these special provisions.
Do not coat asphalt trucks and equipment with substances that contain soap, foaming agents, or toxic
chemicals.
When paving equipment is not in use, park over drip pans or plastic sheeting with absorbent material
to catch drips.

Thermoplastic Striping and Pavement Markers

Thermoplastic striping and preheating equipment shutoff valves must work properly at all times. Do
not preheat, transfer, or load thermoplastic within 50 feet of drainage inlets or watercourses. Do not fill a
preheating container above a level that is 6 inches below the top. Truck beds must be cleaned daily of
scraps or melted thermoplastic.
Do not unload, transfer, or load bituminous material for pavement markers within 50 feet of drainage
inlets or watercourses. Release all pressure from a melting tank before removing the lid to fill or service.
Do not fill a melting tank above a level that is 6 inches below the top.
Collect bituminous material from the roadway after marker removal.

Pile Driving
Keep spill kits and cleanup material at pile driving locations. Pile driving equipment must be parked
over drip pans, absorbent pads, or plastic sheeting with absorbent material. If precipitation is predicted,
protect pile driving equipment by parking on plywood and covering with plastic.
Store pile driving equipment when not in use. Stored pile driving equipment must be:

1. Kept on level ground

2. Protected from storm water run-on
3. If within the floodplain, at least 100 feet from concentrated flows of storm water, drainage
courses, watercourses, and storm drain inlets unless approved
4. If outside the floodplain, at least 50 feet from concentrated flows of storm water, drainage
courses, watercourses, and storm drain inlets unless approved

If practicable, use vegetable oil instead of hydraulic fluid.

The WPC Manager must inspect the pile driving area for leaks and spills:

1. Daily when pile driving occurs daily

2. Weekly when pile driving does not occur daily

April 11, 2011 5-44

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Concrete Curing
Do not overspray chemical curing compound. Minimize the drift by spraying as close to the concrete
as possible. Cover drainage inlets before applying the curing compound.
Minimize the use and discharge of water by using wet blankets or similar methods to maintain
moisture while curing concrete.

Concrete Finishing
Collect and dispose of water and solid waste from high-pressure water blasting. Cover drainage inlets
within 50 feet before sandblasting. Minimize drift of dust and blast material by keeping the nozzle close
to the surface of the concrete. The blast residue may contain hazardous material.
Inspect concrete finishing containment structures for damage before each day of use and before
predicted precipitation. Remove liquid and solid waste from containment structures after each work shift.

Sweeping
Sweeping must be done using hand or mechanical methods such as vacuuming.
Monitor paved areas and roadways within the job site for sediment and debris generating activities
such as:

1. Clearing and grubbing

2. Earthwork
3. Trenching
4. Roadway structural section work
5. Vehicles entering and leaving the job site
6. Soil disturbing work
7. Work that causes offsite tracking of material

If sediment or debris is observed, perform sweeping:

1. Within:

1.1. 8 hours of predicted rain

1.2. 24 hours unless the Engineer approves a longer period

2. On paved roads at job site entrances and exit locations

3. On paved areas within the job site that flow to storm drains or receiving waters

You may stockpile collected material at the job site. Remove collected material including sediment
from paved shoulders, drain inlets, curbs and dikes, and other drainage areas. If stockpiled, dispose of
collected material at least once per week.
You may dispose of sediment within the job site that you collected during sweeping activities.
Protect disposal areas against erosion.
Remove and dispose of trash collected during sweeping under Section 7-1.13, "Disposal of Material
Outside the Highway Right of Way" of the Standard Specifications.

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Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Dewatering
Dewatering consists of discharging accumulated storm water, ground water, or surface water from
excavations or temporary containment facilities.
If dewatering and discharging activities are specified under a work item such as "Temporary Active
Treatment System" or "Dewatering and Discharge," perform dewatering work as specified in the section
involved.
If dewatering and discharging activities are not specified under a work item and you will be
performing dewatering activities, you must:

1. Submit a Dewatering and Discharge Plan under Section 5-1.02, "Plans and Working Drawings,"
of the Standard Specifications and "Water Pollution Control" of these special provisions at least
10 days before starting dewatering activities. The Dewatering and Discharge Plan must include:

1.1. Title sheet and table of contents

1.2. Description of dewatering and discharge activities detailing locations, quantity of water,
equipment, and discharge points
1.3. Estimated schedule for dewatering and discharge (start and end dates, intermittent or
continuous)
1.4. Discharge alternatives such as dust control or percolation
1.5. Visual monitoring procedures with inspection log

2. Conduct dewatering activities under the Departments' s "Field Guide for Construction
Dewatering."
3. Ensure that any dewatering discharge does not cause erosion, scour, or sedimentary deposits that
could impact natural bedding materials.
4. Discharge the water within the project limits. Dispose of the water in the same way as specified
for material in Section 7-1.13 "Disposal of Material Outside the Highway Right of Way" of the
Standard Specification if it cannot be discharged within project limits due to site constraints.
5. Do not discharge storm water or non-stormwater that has an odor, discoloration other than
sediment, an oily sheen, or foam on the surface. Notify the Engineer immediately upon
discovering any such condition.

The WPC manager must inspect dewatering activities:

1. Daily when dewatering work occurs daily

2. Weekly when dewatering work does not occur daily

April 11, 2011 5-46

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

7. EROSION CONTROL (SEQUENCING)

Place erosion control treatments in the following sequence for each erosion control type identified:

Erosion Control (Type 1)

Erosion Control (Compost Blanket)
Rolled Erosion Control Product (Netting)
Erosion Control (Hydroseed)

Erosion Control (Type 2)

Erosion Control (Compost Blanket)
Erosion Control (Hydroseed)

April 11, 2011 5-47

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

8. ROLLED EROSION CONTROL PRODUCT (NETTING)

GENERAL
Summary
This work includes installing rolled erosion control product (netting).

Definitions
Rolled erosion control product (RECP): A long-term degradable material manufactured or fabricated into
rolls designed to reduce soil erosion and assist in the growth, establishment and protection of vegetation.
Open weave textile (OWT): A degradable RECP composed of processed natural yarns woven into a matrix,
used to provide erosion control and vegetation establishment.

Submittals
Submit a Certificate of Compliance under Section 6-1.07, "Certificates of Compliance" of the Standard
Specifications for:

1. Netting
2. Fastener

MATERIALS
Netting
Netting must comply with the following:

1. Netting must be a OWT RECP.

2. Netting Type: C6.
3. Machine-made mats provided in rolled strips.
4. Minimum thickness: 0.30 inch.
5. Minimum width: 72 inches.
6. U.V. Stability under ASTM D 4355 (500 hours exposure): 80%
7. Physical properties in Table A:

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Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Table A
Type Number Net Matrix Maximum Minimum Functional Minimum
Of Type "C" Sheer Longevity Tensile
Nets Factor 1 Stress 2 (months) Strength 3
A4 Single Ne Organic 100% Woven C 0.25 3 36 125
(Coconut Fiber)
B5 Single Ne Organic 100% Woven C 0.25 4.4 36 125
(Coconut Fiber)
C6 Single Ne Organic 100% Woven C 0.25 4.6 36 125
(Coconut Fiber)
Notes:
1
Universal Soil Loss Equation (USLE) C-Factor for a 1.5:1 (H:V) unvegetated slope.
2
lb/ft2 under ASTM D 6460.
3
lb/ft under ASTM D 5035.
4
Average open area of 65%, with a tolerance of ± two percent. Minimum weight of 11.8 ounces per s
yard under ASTM D 3776.
5
Average open area of 48%, with a tolerance of ± two percent. Minimum weight of 20 ounces per squ
yard under ASTM D 3776.
6
Average open area of 38%, with a tolerance of ± two percent. Minimum weight of 26 ounces per squ
yard under ASTM D 3776.

Fasteners
Fasteners must be 11 gauge, 6-inch U-shaped staples with 6-inch legs, and 1-inch crown.

April 11, 2011 5-49

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

9. EROSION CONTROL (HYDROSEED)

GENERAL
Summary
This work includes removing and disposing of weeds, applying erosion control materials, seed, fiber, straw,
and tackifier to erosion control (Hydroseed) areas shown on the plans.
Comply with Section 20-3, "Erosion Control," of the Standard Specifications.
If the slope on which the erosion control to be placed is finished during the rainy season as specified under "Water
Pollution Control" of these special provisions, apply erosion control to the slope immediately.
The Department will designate the ground location of all erosion control (Hydroseed) areas in increments of one
acre or smaller by directing the placing of stakes or other suitable markers. Furnish all tools, labor, materials, and
transportation required to adequately indicate the various erosion control (Hydroseed) locations.

MATERIALS

Seed
Seed not required to be labeled under the California Food and Agricultural Code must be tested for purity and
germination by a seed laboratory certified by the Association of Official Seed Analysts or by a seed technologist
certified by the Society of Commercial Seed Technologists. Measure and mix individual seed species in the
presence of the Department.
Seed must contain at most 1.0 percent total weed seed by weight.
Deliver seed to the job site in unopened separate containers with the seed tag attached. Containers without a seed
tag attached are not accepted. The Department takes a sample of approximately one ounce or 0.25 cup of seed for
each seed lot greater than 2 pounds.
Seed must comply with the following:

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Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Seed
Botanical Name Percent Germination Pounds Pure Live Seed Per Acre
(Common Name) (Minimum) (Slope Measurement)
Bromus carinatus var Maritimu 40 7
(Coastal California Brome)
1 50 10
Leymus triticoides var Rio
(Hybrid Sterile Wheatgrass)
Hordeum brachyantherum 40 5
(Meadow Barley)
1 40 5
Festuca rubra var. Molate
(Molate Red Fescue)
Nassella pulchra 50 10
(Purple Needlegrass)
Vulpia microstachys 35 5
(Three week fescue)
Total 42
Applicable when numbers below are shown after a Botanical Name/(Common Name) above:
1
Seed produced in California only.

Seed Sampling Supplies

At the time of seed sampling, provide the Department a glassine lined bag and custody seal tag for each seed lot
sample.

Organic Fertilizer
Must be a pelleted or granular form and must be one of the following:

Organic Fertilizer
Guaranteed Chemi
Products Analysis Company
(N-P-K) (%)
Biosol Mix - Granular 7-2-3 Rocky Mountains Bioproducts
Edwards, CO

Fertil-Fibers™ 6-4-1 Quattro Environmental

Coronado, CA

Sustane 5-2-4 Natural Fertilizer of America

Cannon Falls, MN

Approved Equal1 (N) 5 to 7

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Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

(P) 1 to 5
• (K) 2 to 1

1
Approved equal must be within the ranges shown for N-P-K. The cumulative (N) release rate must b
more than 70 percent the first 70 days after incubation (86° F) with 100 percent at 350 days or more.

Straw
Straw must be Rice.
Straw must be free of plastic, glass, metal, rocks, and refuse or other deleterious material.

Tackifier
Tackifier must be:

1. Guar (Plant Based)

Tackifier must comply with the following:

1. Nonflammable
2. Nontoxic to aquatic organisms
3. Free from growth or germination inhibiting factors
4. Either a plant-based product or a polymeric-emulsion blend

Tackifier classified as a plant based product must comply with the following:

1. A natural high molecular weight polysaccharide

2. A high viscosity hydrocolloid that is miscible in water
3. Functional for at least 180 days
4. Labeled as either guar, psyllium, or starch

Guar:

1. A guar gum based product derived from the ground endosperm of the guar plant, cyanmopsis
tetragonolobus
2. Treated with dispersant agents for easy mixing
3. Able to be diluted at the rate of 1 to 5 pounds per 100 gallons of water

Psyllium:

1. Made of the finely ground muciloid coating of plantago ovata or plantago ispaghula seeds
2. Able to dry and form a firm but rewettable membrane

Starch:

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Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

1. A non-ionic, water-soluble granular material derived from corn, potato, or other plant-based source.

Fiber
Fiber must be:
1. A combination of Wood, Cellulose, or Alternate

Fiber must comply with the following:

1. Free from lead paint, printing ink, varnish, petroleum products, seed germination inhibitors, or chlorine
bleach
2. Free from synthetic or plastic materials
3. At most 7 percent ash

Wood Fiber must comply with the following:

1. Long strand, whole wood fibers, thermo-mechanically processed from clean, whole wood chips
2. Not made from sawdust, cardboard, paper, or paper byproducts
3. At least 25 percent of fibers 3/8 inch long
4. At least 40 percent held on a No. 25 sieve

Cellulose Fiber must comply with the following:

1. Made from natural or recycled pulp fiber, such as wood chips, sawdust, newsprint, chipboard, corrugated
cardboard, or a combination of these materials

Alternate Fiber must comply with the following:

1. Long strand, whole natural fibers made from clean straw, cotton, corn, or other natural feed stock
2. At least 25 percent of fibers 3/8 inch long
3. At least 40 percent held on a No. 25 sieve

Coloring Agent
Use a biodegradable, nontoxic coloring agent free from copper, mercury, and arsenic.

CONSTRUCTION
Site Preparation
Immediately prior to applying seed to erosion control (Hydroseed) areas, trash and debris and weeds must be
removed.
Removed weeds must be disposed of in conformance with the provisions in Section 7-1.13, "Disposal of
Material Outside the Highway Right of Way," of the Standard Specifications.

April 11, 2011 5-53

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Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Application
Apply erosion control (Hydroseed) materials in separate applications in the following sequence:

1. Apply the following mixture with hydroseeding equipment at the rates indicated within 60 minutes after
the seed has been added to the mixture:

Material Pounds Per Acre

(Slope Measuremen
Seed 42
Fiber 285
Organic Fertilizer 500

2. Apply straw at the rate of 2 tons per acre based on slope measurements. Incorporation of straw will not
be required. Distribute straw evenly without clumping or piling.
3. Apply the following mixture with hydro-seeding equipment at the corresponding rates:

Material Pounds Per Acre

(Slope Measuremen
Fiber 285
Tackifier 125

The ratio of total water to total tackifier in the mixture must be as recommended by the manufacturer.
Seed may be dry applied at the total rate specified in the preceding table for small areas not accessible by the
hydro-seeding equipment, when approved in writing by the Department. Dry applied seed must be incorporated
into the soil a maximum depth of 1/4 inch by raking or dragging.
Hydraulic application of erosion control (Hydroseed) materials for rolled erosion control product (Netting)
areas must be applied by hose, from the ground. Erosion control (Hydroseed) materials must be applied onto the
slope face such that the materials are well integrated into the rolled erosion control product (Netting) and in
contact with ground surface. Application must be perpendicular to the slope face such that rolled erosion control
product (Netting) materials are not damaged or displaced.
Once straw work is started in an area, complete tackifier applications in that area on the same working day.
The Department may change the rates of erosion control (Hydroseed) materials to meet field conditions.
For any area where erosion control (Hydroseed) materials are to be applied, the application of all erosion
control (Hydroseed) materials to be applied to that area must be completed within 72 hours from when the first
materials were applied.

April 11, 2011 5-54

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

10. EROSION CONTROL (COMPOST BLANKET)

GENERAL
Summary
This work includes removing and disposing of weeds, applying compost to erosion control (Compost
Blanket) areas shown on the plans.
Comply with Section 20-3, "Erosion Control," of the Standard Specifications.
The Department will designate the ground location of all erosion control (Compost Blanket) areas in
increments of one acre or smaller by directing the placing of stakes or other suitable markers. Furnish all tools,
labor, materials, and transportation required to adequately indicate the various erosion control (Compost Blanket)
locations.

MATERIALS
Compost
The compost producer must be fully permitted as specified under the California Integrated Waste
Management Board, Local Enforcement Agencies and any other State and Local Agencies that regulate Solid
Waste Facilities. If exempt from State permitting requirements, the composting facility must certify that it
follows guidelines and procedures for production of compost meeting the environmental health standards of Title
14, California Code of Regulations, Division 7, Chapter 3.1, Article 7.
The compost producer must be a participant in United States Composting Council's Seal of Testing Assurance
program.
Compost may be derived from any single, or mixture of the following feedstock materials:

1. Green material consisting of chipped, shredded, or ground vegetation, or clean processed recycled wood
products
2. Biosolids
3. Manure
4. Mixed food waste

Compost feedstock materials to reduce weed seeds, pathogens and deleterious materials as specified under
Title 14, California Code of Regulations, Division 7, Chapter 3.1, Article 7, Section 17868.3.
Compost must not be derived from mixed municipal solid waste and must be reasonably free of visible
contaminates. Compost must not contain paint, petroleum products, pesticides or any other chemical residues
harmful to animal life or plant growth. Compost must not possess objectionable odors.
Metal concentrations in compost must not exceed the maximum metal concentrations listed under Title 14,
California Code of Regulations, Division 7, Chapter 3.1, Section 17868.2.
Compost must comply with the following:

April 11, 2011 5-55

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Physical/Chemical Requirements
Property Test Method Requirement
pH *TMECC 04.11-A 6.0–8.0
Elastometric pH 1:5 Slurry Method
pH Units
Soluble Salts TMECC 04.10-A 0-10.0
Electrical Conductivity 1:5 Slurry Method
dS/m (mmhos/cm)
Moisture Content TMECC 03.09-A 30-60
Total Solids & Moisture at 70+/- 5 deg C
% Wet Weight Basis
Organic Matter TMECC 05.07-A 30–65
Content Loss-On-Ignition Organic Matter Method (LOI)
% Dry Weight Basis
Maturity TMECC 05.05-A
Germination and Vigor
Seed Emergence 80 or Above
Seedling Vigor 80 or Above
% Relative to Positive Control
Stability TMECC 05.08-B
Carbon Dioxide Evolution Rate
mg CO2-C/g OM per day 8 or below
Particle Size TMECC 02.02-B 100% Passing, 3 inch
Sample Sieving for Aggregate Size Classification 90-100% Passing, 1 inc
% Dry Weight Basis 65-100% Passing, 3/4 in
0 - 75% Passing, 1/4 inc

Maximum length 6 inch

Pathogen TMECC 07.01-B
Fecal Coliform Bacteria Pass
< 1000 MPN/gram dry wt.
Pathogen TMECC 07.01-B
Salmonella Pass
< 3 MPN/4 grams dry wt.
Physical Contaminants TMECC 02.02-C
Man Made Inert Removal and Classification: Combined Total:
Plastic, Glass and Metal < 1.0
% > 4mm fraction
Physical Contaminants TMECC 02.02-C
Man Made Inert Removal and Classification:
Sharps (Sewing needles, straight pins and hypodermic needle None Detected
% > 4mm fraction
*TMECC refers to "Test Methods for the Examination of Composting and Compost," published by the United States
Department of Agriculture and the United States Compost Council (USCC).

Before compost application, provide the Department with a copy of the compost producer's compost
technical data sheet and a copy of the compost producer's Seal of Testing Assurance certification.
The compost technical data sheet must include:

1. Laboratory analytical test results

2. List of product ingredients

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Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Before compost application, provide the Department with a Certificate of Compliance under
Section 6-1.07, "Certificates of Compliance," of the Standard Specifications.

CONSTRUCTION
Site Preparation
Immediately prior to applying compost to erosion control (Compost Blanket) areas remove trash,
debris and weeds.
Removed weeds must be disposed of in conformance with the provisions in Section 7-1.13, "Disposal
of Material Outside the Highway Right of Way," of the Standard Specifications.

Application
Apply compost to a uniform thickness.
Erosion control (Compost Blanket) must extend to the edge of retaining sidewalks, walls, curbs,
dikes, paving, and to within 4 feet from the flow line of paved and unpaved drainage ditches.

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11. FIBER ROLLS

GENERAL
Summary
This work includes installing fiber rolls.
At the option of the Design-Builder, fiber rolls shall be Type 1 or Type 2.

MATERIALS
Fiber Roll
Fiber roll shall be either:

1. Constructed with a premanufactured blanket consisting of wood excelsior, rice or wheat straw, or coconut
fibers or a combination of these materials. The blanket shall be between 6 feet and 8 feet in width and
between 65 feet and 95 feet in length. Wood excelsior shall be individual fibers, of which 80 percent
shall be 6 inches or longer in length. The blanket shall have a biodegradable jute, sisal, or coir fiber
netting on at least one side. The blanket shall be rolled along the width and secured with jute twine
spaced 6 feet apart along the full length of the roll and placed 6 inches from the ends of each roll. The
finished roll shall be between 8 inches and 10 inches in diameter, a minimum of 20 feet in length, and
shall weigh a minimum of 0.5 pound per linear foot. More than one blanket may be required to achieve
the finished roll diameter. When more than one blanket is required, blankets shall be jointed
longitudinally with an overlap of 6 inches along the length of the blanket.
2. A premanufactured roll of rice or wheat straw, wood excelsior, or coconut fiber encapsulated within a
biodegradable jute, sisal, or coir fiber netting. The netting shall have a minimum durability of one year
after installation. The netting shall be secured tightly at each end of the roll. Rolls shall be between
8 inches and 12 inches in diameter. Rolls between 8 inches and 10 inches in diameter shall have a
minimum weight of 1 pound per linear foot and a minimum length of 20 feet. Rolls between 10 inches
and 12 inches in diameter shall have a minimum weight of 3 pounds per linear foot and a minimum length
of 10 feet.

Stakes
Wood stakes shall be a minimum of 1" x 1" x 24" in size for Type 1 installation, or a minimum of
1" x 2" x 24" in size for Type 2 installation. Wood stakes shall be untreated fir, redwood, cedar, or pine
and cut from sound timber. They shall be straight and free of loose or unsound knots and other defects
which would render them unfit for the purpose intended. Metal stakes shall not be used.

Rope
Rope shall be biodegradable, such as sisal or manila, with a minimum diameter of 1/4 inch.

CONSTRUCTION
Installation
Fiber rolls shall be installed as follows:

1. Fiber rolls (Type 1): Furrows shall be constructed to a depth between 2 inches and 4 inches, and to a
sufficient width to hold the fiber roll. Stakes shall be installed 24 inches apart along the length of the

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fiber rolls and stopped at 12 inches from each end of the rolls. Stakes shall be driven to a maximum of
2 inches above, or flush with the top of the roll.
2. Fiber rolls (Type 2): Rope and notched stakes shall be used to restrain the fiber rolls against the slope.
Stakes shall be driven into the slope until the notch is even with the top of the fiber roll. Rope shall be
knotted at each stake and laced between stakes. After installation of the rope, stakes shall be driven into
the slope such that the rope will hold the fiber roll tightly to the slope. Furrows will not be required.
3. Fiber rolls shall be placed 10 feet apart along the slope for slope inclination (horizontal: vertical) of 2:1
and steeper, 15 feet apart along the slope for slope inclination between 2:1 and 4:1, 20 feet apart along the
slope for slope inclination between 4:1 and 10:1, and a maximum of 50 feet apart along the slope for
slope inclination of 10:1 and flatter.
4. The bedding area for the fiber rolls shall be cleared of obstructions including rocks, clods, and debris
greater than one inch in diameter before installation.
5. Fiber rolls shall be installed approximately parallel to the slope contour.

If the intended function of the fiber rolls to disperse concentrated water runoff and to reduce runoff
velocities is impaired, the Design-Builder shall take action to repair or replace the fiber rolls. Split, torn,
or unraveling rolls shall be repaired or replaced. Broken or split stakes shall be replaced. Sagging or
slumping fiber rolls shall be repaired with additional stakes or replaced. Locations where rills and other
evidence of concentrated runoff have occurred beneath the rolls shall be corrected. Fiber rolls shall be
repaired or replaced within 24 hours of identifying the deficiency.

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12. COLD PLANE ASPHALT CONCRETE PAVEMENT

GENERAL
Summary
This work includes cold planing existing asphalt concrete pavement.

Sequencing and Scheduling

Schedule cold planing activities to ensure hot mix asphalt (HMA) is placed over cold planed area
during the same work shift before opening to traffic. If you cannot place HMA over the entire cold
planed area before opening it to traffic:

1. Construct a temporary HMA taper to the level of the existing pavement.

2. Place HMA during the next lane or shoulder closure for that area.
3. Submit a corrective action plan that shows that you are able to cold plane and place HMA in the
same work shift. Do not perform cold planing work until the Engineer approves the corrective
action plan.

MATERIALS
HMA for temporary tapers must be of the same quality as the HMA used elsewhere on the project or
comply with "Minor Hot Mix Asphalt" of these special provisions.

CONSTRUCTION
General
Perform planing of asphalt concrete pavement without the use of a heating device to soften the
pavement.

Cold Planing Equipment

Cold planing machine must be:

1. Equipped with a cutter head width that matches the planing width. If the only available cutter
head width is wider than the cold plane area shown, submit to the Engineer a request for using a
wider cutter head. Do not cold plane until the Engineer approves your request.
2. Equipped with automatic controls to control the longitudinal grade and transverse slope of the
cutter head and:

2.1. If a ski device is used, it must be at least 30 feet long, rigid, and 1 piece unit. The entire
length must be used in activating the sensor.
2.2. If referencing from existing pavement, the cold planing machine must be controlled by a
self-contained grade reference system. The system must be used at or near the centerline of
the roadway. On the adjacent pass with the cold planing machine, a joint matching shoe
may be used.

3. Equipped to effectively control dust generated by the planing operation.

4. Operated so that no fumes or smoke is produced.

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Replace broken, missing, or worn machine teeth.

Grade Control and Surface Smoothness

Furnish, install, and maintain grade and transverse slope references.
The depth, length, width, and shape of the cut must be as shown or as ordered. The final cut must
result in a neat and uniform surface. Do not damage remaining surface.
The completed surface of the planed asphalt concrete pavement must not vary more than 0.02 foot
when measured with a 12-foot straightedge parallel with the centerline. The transverse slope of the
planed surface must not vary more than 0.03 foot from the straightedge when placed at right angles to the
centerline.
A drop-off of more than 0.15 foot is not allowed between adjacent lanes open to public traffic.

Temporary HMA Tapers

If a drop-off between the existing pavement and the planed area at transverse joints cannot be avoided
before opening to traffic, construct a temporary HMA taper. HMA for temporary taper must be:

1. Placed to the level of the existing pavement and tapered on a slope of 30:1 (Horizontal: Vertical)
or flatter to the level of the planed area
2. Compacted by any method that will produce a smooth riding surface
3. Completely removed before placing the permanent surfacing. The removed material must be
disposed of outside the highway right of way in conformance with the provisions in Section 7-
1.13, "Disposal of Material Outside the Highway Right of Way," of Book 3, Section 4 -
Modifications to Caltrans Standard Specifications.

Disposal of Planed Material

Remove cold planed material concurrent with planing activities, within 50 feet of the planer or as
ordered.
Dispose of planed material and under Section 7-1.13, "Disposal of Material Outside the Highway
Right of Way," of Book 3, Section 4 - Modifications to Caltrans Standard Specifications.

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13. VEHICLE SENSOR NODE(S) (VSN)

Each VSN shall be manufactured by Sensys Networks, Inc., 2560 Ninth Street, Suite 211, Berkeley,
CA 94709, telephone (510) 548-4620. Arrangements have been made to ensure that the Design-Builder
can obtain these components and related materials directly from the manufacturer. The unit price quoted
by the manufacturer for each component is as follows, not including sales tax or shipping. It is the
Design-Builder responsibility to verify that the prices are current at the time of order. The Department
shall not be held liable for any price fluctuations.

Sensys Part Number Component Quantity 1-9 10-49 50-99 100-149 150-299 300+
900-240-015-13-000 AP240-E-12V Access Point $ 2,534 $ 2,504 $ 2,401 $ 2,268 $2134 $1,963
900-240-021-0-000 RP240-B-LL Repeater $1,205 $1,195 $1,145 $1,090 $1,020 $940
900-240-015-y-010 AP / RP Mounting Bracket $145 $143 $135 $128 $120 $110
900-240-015-y-003 Power over Ethernet Injector $145 $143 $135 $128 $120 $110

Sensys Part Number Quantity 1-99 100-499 500-999 1000- 1500- 3000+
1499 2999
900-240-100-0-000 VSN240F Flush Mount Sensor $447 $438 $415 $392 $369 $339
900-240-100-0-005 Sealant $68 $67 $64 $60 $57 $52

Vehicle Sensor Nodes

Each vehicle sensor nodes (VSN) shall consist of a magnetometer sensor, a microprocessor with
firmware in non-volatile memory, a wireless transceiver and a battery within a single housing.
The magnetometer sensor shall detect the presence of a vehicle by a change in the vertical component
of the earth’s magnetic field within the detection zone corresponding to a 6-foot by 6-foot Type A
inductive loop, with the VSN at the center. Each VSN shall continuously report the presence of the
vehicle until the vehicle leaves the detection zone, whereupon the VSN shall report the absence of
presence within 5 +/- 1 millisecond.
The housing shall be fully encapsulated to provide a minimum of 8 years of operation, over a
temperature range of -34 °F to 165 °F.
Each VSN shall be individually addressable with a unique identifier, and capable of transmitting its
data to the Access Point (AP) directly or via a Repeator (RP). Each VSN shall also be capable of
receiving detector parameters, microprocessor firmware and other commands from the AP directly or via
a RP without loss of data.

Sealant
The sealant for the installation of each VSN shall be a two-component, 100% solids, polyurea-based
joint sealant and approved by the manufacturer of the VSN. It shall be a self-leveling joint sealant
applied at a minimum temperature of 32 °F.
Physical Properties:

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Tensile Strength (PSI) ASTM D412 2950

Elongation (%) ASTM D412 350
Hardness (Shore A) ASTM D2240 95A
Flexibility 1/8” Mandrel ASTM D1737 Pass
Taber Abrasion (mg loss) ASTM D4060 25
CS18 Wheel 1 kg per 1000 cycles

Gel Time Minutes 2

Tack Free Time Minutes 5
Open to Traffic Minutes 15

PRE-CONSTRUCTION SITE ANALYSIS

1. The Design-Builder shall ensure that each VSN shall be installed such that each operates
independently and does not interfere with similar components at another site or other equipment
in the vicinity of the site.
2. The Design-Builder shall ensure that each VSN shall be installed within range of its
corresponding AP or RP. All VSN assigned to either an RP or AP shall be located within a +/-
60-degree horizontal cone, measured from perpendicular. The maximum distances between a
VSN and the AP or RP are as follows:

AP / RP mounting height Maximum distance from VSN

12 feet 75 feet
18 feet 105 feet
24 feet 150 feet

3. The Design-Builder shall configure and demonstrate successful communication between each
VSN, the RP (if necessary) and the AP to the Department prior to the installation of any
component.

Installation and Calibration

All necessary software and equipment needed for the calibration of each Vehicle Sensor Node to its
corresponding AP or RP shall be provided by the Design-Builder. All software shall operate on a laptop
computer running Windows 2000 or Windows XP.

1. The Design-Builder shall not proceed with the installation of any component without the written
approval from the Department of the Pre-construction Site Analysis.
2. The Design-Builder shall provide personnel skilled in the installation and calibration of Vehicle
Sensor Node and its corresponding AP or RP.
3. Prior to installation, the Design-Builder shall record the VSN ID, its lane number and lane
position on the required documentation.
4. The Design-Builder shall install each VSN in the roadway per manufacturer’s recommendations
and as shown on the plans. Holes cored in the pavement shall be cleaned and thoroughly dried
before installing VSN. Residue resulting from core drilling shall not be permitted to flow across
shoulders or lanes occupied by public traffic and shall be removed from the pavement surface by
vacuuming or other approved method before any residue flows off of the pavement surface.

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Residue from core drilling shall be disposed of as provided in Section 7-1.13, “Disposal of
Material outside the Highway Right-of-Way”, of the Standard Specifications. The cored
pavement shall be back-filled per manufacturer’s recommendations. The Design-Builder shall
remove any excess epoxy from the roadway without the use of solvents and disposed of as
provided in Section 7-1.13, “Disposal of Material outside the Highway Right-of-Way”, of the
Standard Specifications.
5. After installation of both VSN in a lane, the Design-Builder shall record the center-to-center
spacing between the VSN on the required documentation.
6. After installation of all components, the Design-Builder shall re-configure and demonstrate
successful communication between each VSN, the RP (if necessary) and the AP to the
Department.

Acceptance Testing
The Design-Builder shall notify the Department 15 working days before the Vehicle Sensor Node is
ready for acceptance testing. Acceptance testing shall be scheduled to be conducted in the presence of the
Department during a normal work day (M-F 0800 to 1600). The Design-Builder shall demonstrate the
operation of each Vehicle Sensor Node satisfying the functional requirements of these special provisions.
The Department has the right to reject the Vehicle Sensor Node if the demonstration fails.
All necessary software and equipment, including documentation, needed for the acceptance testing of
each Vehicle Sensor Node shall be provided by the Design-Builder. All software shall operate on a
laptop computer running Windows 2000 or Windows XP.
The Department will review the results from the acceptance testing and accept or reject the results
within 7 days. Determination of any vehicle anomalies or unusual occurrences will be decided by the
Department. Data or counts that are not agreed upon by the Department shall be considered errors and
count against the unit’s calibration. If the Department determines that the Vehicle Sensor Node does not
meet the performance requirements, the Design-Builder will have seven days to re-calibrate and re-test
the unit and re-submit new test data. Following three failed attempts, the Design-Builder shall replace the
Vehicle Sensor Node with new one.
Repair, replacement, and retesting of Vehicle Sensor Node components due to failure or rejection
shall be at the Design-Builder’s expense.

Warranty
The Design-Builder shall provide the manufacturer’s written warranty against defects in material and
workmanship for the Vehicle Sensor Node, for a period of 24 months after acceptance. After final
acceptance of the Vehicle Sensor Node, all replacement assemblies covered under warranty shall be
provided within 10 days after receipt of failed units at no cost to the State, except the cost of shipping.
All warranty documentation shall be given to the Department prior to installation. All replacement
Vehicle Sensor Node shall be delivered to Caltrans Maintenance Electrical Shop at 30 Rickard St., San
Francisco, CA 94134.
Standard updates to the VSN, RP and AP software shall be available from the manufacturer without
charge to the State during the warranty period.

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14. LONG LEAD-IN CABLE LOOP DETECTOR (LLLD) SENSOR

UNIT
General
Each Long Lead-in cable Loop Detector (LLLD) sensor unit shall comply with the following:

1. Chapter 5 of the Transportation Electrical Equipment Specifications (TEES),

2. Section 86-5.01 of the Standard Specifications.
3. The enhancements as specified in this specification.

Each LLLD sensor unit shall have 2 channels and shall be capable of detecting Agency licensed
vehicles on a single Type A or E loop with a 3000 feet lead-in-cable.

Sensitivity
Each LLLD sensor unit channel shall have a sensitivity based on delta L threshold rather than delta L
(only). There shall be 8 threshold levels corresponding to 8 nH, 16 nH, 32 nH, 64 nH, 128 nH, 256 nH,
512 nH and 1024 nH.

Variations
Each LLLD sensor unit channel shall be permitted the following exceptions to the TEES and
Standard Specifications:

1. Three frequency settings minimum.

2. The operating frequency of 40 kHz is not required as long as the sensor unit adheres to all other
FCC rules.
3. The minimum Q requirement of 5 is not required if all other functional requirements are met.
4. Pulse mode requirements may vary from TEES but are subject to the approval of the Engineer.

Certificate of Compliance
The Design-Builder shall provide the Department with a Certificate of Compliance from the
manufacturer in accordance with the provisions of Section 6-1.07, “Certificates of Compliance” of the
Standard Specifications for each LLLD sensor unit furnished.

Warranty
Each LLLD sensor unit shall have a complete manufacturer's warranty of at least 1 year parts.

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15. VARIABLE MESSAGE SIGN (VMS) ASSEMBLY

GENERAL
Each Variable Message Sign (VMS) assembly shall include one sign panel, one sign controller
assembly including enclosure, and one sign interface cable.
Each VMS assembly shall operate at a frequency of 60 +/- 3 Hz AC line over a voltage ranging from
90 to 135 Volts AC voltage fluctuations shall cause no visible flicker or change in pixel luminous
intensity. The rated voltage for measurements shall be 120 Volts AC.
Each VMS assembly shall include voltage surge protection to withstand high repetition noise
transient as stated in section 2.1.6 of NEMA Standard TS-2, 1992.
Each VMS assembly shall meet Federal Communications Commission (FCC) Title 47, SubPart B,
Section 15 regulations concerning the emission of electronic noise.
All wiring shall be No. 22 AWG or larger, and shall be color-coded per TEES Section 1.13.3.6. All
wiring shall be bundled, wrapped, and permanently labeled.

SIGN PANEL
The maximum dimensions of each sign panel shall be 114" in length, 63" in height and 10” in depth.
Each sign panel shall not weigh more than 400 lbs.
Each sign panel shall have internal power supplies to fully operate the sign. The sign panel power
factor shall be greater than 90 percent, and current total harmonic distortion shall be less than 25 percent.
The maximum power consumption of each sign panel shall be 150 W.
Each sign panel shall have dimming capability to fully operate the sign, using one or more
photosensors installed inside the housing to measure ambient light level.

Housing
Each sign panel shall be constructed with an extruded aluminum frame. One 0.25 inch reinforcing
plate shall be added at the top and bottom of the frame. Two 0.5625 inch diameter holes shall be drilled
through both the reinforcing plate and the housing at the top and bottom of the panel, with each hole
centered 2 inches from the rear of the housing and 30 inches off the panel vertical centerline.
The rear, sides, top and bottom of the housing shall consist of 0.0625 inch minimum sheet aluminum,
with a high gloss textured black finish powder coat paint meeting the color standards of Federal
specifications 595b, 17038, applied to both internal and external surfaces.
The front face shall have a 6 inch wide border on the top, bottom and both sides to frame the pixel
array. The border shall consist of 0.0625 inch minimum sheet aluminum, with a high gloss textured black
finish powder coat paint meeting the color standards of Federal specifications 595b, 17038, applied to
both internal and external surfaces. The front face shall be constructed with a transparent anti-glare
polycarbonate or hardened acrylic panel mounted behind the border.
The front face shall be hinged to allow access to the interior of the panel. The sign panel shall be
provided with devices to retain the front face in a fully open mode. The housing shall be made rain-tight
with a closed-cell neoprene gasket.
The housing shall be vented on the bottom and shall be provided with an interior temperature-
controlled ventilation fan. Additional ventilation shall be provided such as to ensure the interior of the
housing remains below 55°C without compromising the rain-tight integrity. Each vent shall have a
removable filter installed in a frame.

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The housing shall have fully welded seams. All interior and exterior hardware shall be either
stainless steel or cadmium-plated steel.
Each sign panel shall have the manufacturer's name and trademark permanently marked on its side.
Each sign panel shall be identified with a model, serial number and shipping date stamped on a tag
attached to its side for warranty purposes. The lettering shall be a minimum of 9/32-inch high. The
information may be either depressed or raised, and shall be legible and durable.

Pixel Module
Each sign panel shall have a full matrix of pixels, with a minimum of 56 pixels wide by 25 pixels
high. The pixels shall be uniformly arranged in multiple modules, with minimum horizontal and vertical
pitch of 1.75 inch.
Each pixel module shall be fabricated from 0.0625 inch minimum thick aluminum sheet. After
fabrication, each pixel module shall be treated with a high gloss textured black finish powder coat paint
meeting the color standards of Federal specifications 595b, 17038.
Each pixel module shall have the manufacturer’s name, trademark, model number, serial number
permanently marked on the back of the panel. Rated voltage, current, power consumption and Volt-
Amperes (VA) per pixel shall also be identified.
Each pixel module shall be identical to and interchangeable with other modules.
Each pixel module shall be 100 percent solid-state design with no moving parts or switches.
Each pixel module shall be secured to the sign panel frame at each corner by one metal roundhead
screw.

Pixels
Each pixel shall consist of high-intensity ultra-bright Aluminum Indium Gallium Phosphide
(AlInGaP) LEDs. Each LED shall be rated for 100,000 hours of continuous operation from -37°C to
+74°C. The color of each LED shall be yellow (592 +/- 5 nm). Each LED in a pixel shall be from the
same manufacturer and color bin. Each LED shall be UV-stabilized.
Each pixel shall be designed such that a catastrophic failure of one LED will result in the loss of not
more than 40 percent of the total LEDs for that pixel.
Each pixel shall have a maximum LED array size of 1 inch diameter (if circular array) or 1 inch
square (if square array). The LEDs shall be evenly distributed throughout the pixel.
Each pixel shall have a viewing angle of 30 degrees. Each pixel shall have an initial nominal
luminous intensity of 9.5 cd on the maximum setting. Each pixel shall be rated for a minimum useful life
of 48 months and shall maintain not less than 85 percent of the minimum intensity while operating
throughout the temperature range of -37°C to +74°C.
The measured chromatic coordinates of each pixel shall conform to the chromaticity requirements of
section 5.3.2.1 and Figure C of the Equipment and Materials Standards of the Institute of Transportation
Engineers ITE Publication ST-017A.
Each pixel shall have a removable black plastic visor to enhance resistance to sun phantom.
Each pixel shall be encapsulated for water resistance.

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SIGN CONTROLLER ASSEMBLY

General
Each sign controller assembly shall consist of one sign controller, one power supply, one standard
IBM PC-compatible keyboard, and one multi-line LCD display mounted inside one enclosure.
Sign Controller
Each sign controller shall have one EIA-232 communication interface for remote communications.
Each sign controller shall have the necessary interface to control 2 beacons.
Each sign controller shall have firmware that allows the user to create, edit and save a minimum of 50
messages and 99 pages. These shall be stored in non-volatile memory and shall remain unaltered for a
minimum of 30 days without AC power to the sign controller.
The firmware shall interact with the sign panel through a menu-driven interface. The firmware shall
be accessible via either the keyboard or through the EIA-232 port.
Access to the firmware shall be protected by multi-level password control.
The firmware shall be NTCIP (National Transportation Communication for ITS Protocol) compliant
including, but not limited to, the following standards:

A. Device Data Dictionary: NTCIP 1201 – Global Object Definitions, all mandatory objects of
all mandatory conformance groups;
B. Device Data Dictionary: NTCIP 1203 – Object Definitions for Dynamic Message Signs;
C. Application Profile Level: NTCIP 1101 – Simple Transportation Management Framework
(STMF) – and shall meet Conformance Level 1;
D. Sub-network Profile Level: NTCIP 2103 – SP PPP / RS-232 and
E. Transport Profile Level: NTCIP 2201, TP – Transportation Transport Profile.

The firmware shall support the following Tags as defined in NTCIP 1203, v02.31a:

A. Flash;
B. Font;
C. Graphic;
D. Justification – Line;
E. Justification – Page;
F. New Line;
G. New Page;
H. Page Time; and
I. Spacing Character.

The firmware shall support 2 beacons with opposed flashing.

Dimming Control
The sign controller shall automatically adjust the intensity of all pixels by means of photo sensors
installed in the sign housing. There shall be a minimum of three adjustable levels of luminance:
100 percent, 60 percent, and 30 percent luminance.

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A single-throw “Dim Test” switch shall be provided to override the automatic intensity selection and
force each activated pixel to 30 percent luminance.

Enclosure
The enclosure shall include the sign controller assembly, power supply, operational display of the
controller, keyboard and a disconnect switch. Enclosure shall be partitioned with a continuous stainless
steel hinge panel. In the back of this panel, install the sign controller assembly, and power supply. In
front of this panel, install the display, key board, and disconnect switch. This panel shall be secured with
thumbscrews when it is closed.
The enclosure shall be fabricated from galvanized sheet steel, or shall be fabricated from sheet steel
and zinc- or cadmium-plated after fabrication, or shall be fabricated from aluminum. The enclosure shall
conform to the provisions for a NEMA Type 3R enclosure.
The enclosure door shall have a handheld latch to keep the door closed. Padlock hasps with a 7/16
inch hole shall be welded to the enclosure and door to enable the installation of a padlock which will be
furnished by others.
Each enclosure shall have the manufacturer's name and trademark permanently marked on its side.
Each enclosure shall be identified with a model, serial number and shipping date stamped on a tag
attached to its side for warranty purposes. The lettering shall be a minimum of 9/32-inch high. The
information may be either depressed or raised, and shall be legible and durable.

Sign Operating Software (SOS)

The sign operating software shall enable a PC laptop to interact with sign controller via an on-board
communications port. This port may be either Ethernet or EIA-232.
The manufacturer shall supply the State free of charge one copy of the SOS in CD-ROM format for
each VMS Assembly delivered in the contract, up to a maximum of 5 copies.

SIGN INTERFACE CABLE

The sign interface cable shall connect the sign panel to sign controller assembly and shall be
continuous without splicing. The cable shall be fabricated by the sign manufacturer. The manufacturer
identification shall be printed in white ink every foot along the surface of the cable. The cable shall meet
all specifications for outdoor use. The cable length shall be a minimum of 50 feet.
The Design-Builder shall furnish a EIA-232 to EIA 422 converter for each fix camera installed in this
contract. EIA-422 shall be crew terminal type connection. EIA-232 shall be DE9 female connector type
connection.

PRE-FABRICATION APPROVAL
Complete shop drawings for the VMS Assembly shall be submitted to the Department for testing,
evaluation and approval, a minimum of 30 days before ordering or fabrication of equipment.

MANUALS
Two copies of the Manual shall be submitted to the Department for evaluation and approval. Upon
approval by the Department, two copies of the Manual for each VMS Assembly delivered in the contract,
up to a maximum of 30 manuals, shall be provided.

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All pages in the manual shall be securely fastened together between protective covers (loose-leaf ring
binding is acceptable). No page shall be subject to fading from exposure to any normal source of ambient
lighting (ozalid-reproduced pages are non acceptable).
Each manual shall contain but not limited to the following sections and sub-sections:

General

a. List of applicable subassemblies that comprise the specified equipment.

b. Overall description of the equipment design features (including any modification if applicable),
performance, and applications.
c. Equipment specifications summary.
d. Equipment installation instructions.

Operations

a. Theory of operation of the standard equipment, with unique or unusual circuitry described in
detail.
b. Theory of operation reflecting any modification to the standard equipment.
c. Operation of the VMS and controller assembly

Service and Maintenance

a. Recommended test equipment and fixtures, or minimum operational and performance

requirements for appropriate test equipment.
b. Trouble shooting information, resetting instruction/process and charts.
c. Removal and installation procedures for replacing assemblies and subassemblies, if not obvious
or if improper sequencing of steps may result in damage.
d. Service of the VMS components and controller assembly

Replacement parts

a. Equipment replacement parts list including electrical parts, mechanical parts and assemblies,
with each semiconductor device identified by the supplier's numbers and by JEDEC numbers if
applicable.

Diagrams

a. Schematic diagrams(s) identifying all circuit components and showing normal test voltages and
levels.
b. Overall functional block diagram.
c. Detailed interconnecting diagram(s) showing wiring between modules, circuit boards and major
components.
d. Pictorial circuit board layout diagram(s) showing both component placement and printed wiring
detail.

April 11, 2011 5-70

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

e. Diagram(s) showing location of circuit boards and other subassemblies.

f. Exploded view diagram(s) of complex mechanical assemblies.

PERFORMANCE WARRANTY
The manufacturer shall provide a written warranty against defects in materials and workmanship. All
warranty documentation must be submitted to the Department before installation. The manufacturer shall
replace or repair any sign panel or sign controller that exhibits failure due to workmanship or material
defects within 48 months of delivering the VMS Assembly to the State or the date of acceptance
whichever is later. Replacement must be provided within 15 days after receipt of failed parts at your
expense. The State pays for shipping the failed parts to you. Replacement of failed parts must be
delivered to State Maintenance Electrical Shop at 30 Rickard Street, San Francisco, CA 94134, phone
(415) 330-6500.
The manufacturer shall replace or repair any pixel module that contains a pixel that exhibits light
degradation greater than 50 percent within the first 36 months of operation, or if more than 20 percent of
its LEDs fail during that same period.

TESTING
Each VMS Assembly shall be inspected and tested by the California Department of Transportation,
Transportation Laboratory Electrical Testing Branch. Quality Assurance (QA) inspection and acceptance
testing shall be at the manufacturer's facility. Two copies of the Manuals and two copies of the shop
drawings, showing the mechanical and electrical systems and circuits, shall be delivered to the
Department's Electrical Testing Branch engineer prior to acceptance testing. It is the responsibility of the
Design-Builder to make arrangements with the Electrical Testing Branch to schedule an inspection date.
This date shall be agreed upon no fewer than 15 calendar days prior to the inspection date.
Each VMS assembly shall be inspected and tested by the Department's Electrical Testing Branch
engineer for mechanical and electrical specification compliance and quality of workmanship. In addition
to factory testing, the following functional testing shall be done by a qualified representative of the sign
manufacturer in the presence of the Department's Electrical Testing Branch engineer. The State may
reject any unit, which is not in compliance with the specifications.
A minimum of 5 different messages composed of text and graphics display shall be performed. Any
others tests recommended by the manufacturer shall also be conducted.

April 11, 2011 5-71

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

16. GENERAL PACKET RADIO SYSTEM WIRELESS MODEM

ASSEMBLY
The General Packet Radio System (GPRS) Wireless Modem Assembly shall be furnished and
configured with the following major components:

A. Modem
B. Power supply
C. Modem mounting bracket and hardware
D. Serial communication cable
E. Antenna

MODEM
All modems shall be configurable remotely through the wireless network and through the
modem serial port. The Design-Builder shall configure all modems prior to acceptance. The
Design-Builder shall provide the Department with the modem serial, SIM and IMEI numbers 30
days prior to requiring the PDP context. The Department will make available the PDP context
comprising the IP (assigned) and APN (obtained from service provider ). All modems shall be
complete with all cables, conductors, hardware, antenna and other equipment as required to make
the system completely operational. Location and mounting of the equipment shall be directed by
the Engineer and details shown on the plans. The modems shall be fully compliant with PCCA
STD-101.

Environmental Requirements
The operating temperature of the modem shall range from –30°C to +70°C, with humidity
from 5 percent to 95 percent (non-condensing) and have transmissions at 10 percent duty cycle
above 60°C.

Physical Characteristics
The modem shall weigh less than 2 lbs and shall have overall dimensions of less than 7 1/8 inches × 3
1/2 inches × 1 1/8 inches. The housing shall be constructed of anodized aluminum.
The modem shall have the following status indicators:

1. Power (on).
2. Channel acquired.
3. Link status.
4. Network registration.
5. Received signal strength indicator.
6. Transmit and receive data.
7. Block errors.

Operational Parameters
The modem shall operate in a dynamic IP addressing environment of GPRS Networks at 1900/850
MHz and meet the following operational parameters:

April 11, 2011 5-72

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

Transmit power at antenna 1.0 W for 1900 MHz

port 0.8 W for 850 MHz
Receiver sensitivity -107 dBm (2.439 % bit error rate)
Input voltage 10 VDC to 28 VDC
Input current 40 mA to 200 mA

Application Interfaces
The modem shall have the following standard interfaces:

1. The AT command serial character stream uses TCP/IP.

2. Host communicates with modem using either UDP or TCP packet modes.
3. Computer terminal platform using Windows XP/7 and Dial-Up Networking communicates with
the modem using PPP.

Features
The modem shall have the following features:

1. 53.6 kbps raw data transfer rate minimum.

2. Full duplex transceiver.
3. 1900/850 MHz dual band networking.
4. Integrated TCP/IP protocol stack with UDP.
5. Security such to prevent unauthorized access.
6. Includes a DC power cable at least 40 inches in length with a connector compatible with the
modem power connector.
7. Packet buffering and forwarding feature that provides discipline to the output of the serial port.
The packet forwarding time interval shall be configurable from a rate of 0 (undisciplined ) to
400ms in increments of 100ms or less.
8. Choice of "Friends Only" access mode.

System Compliance
The modem and associated firmware, software, hardware, protocol, and other features shall be fully
and completely compatible with the existing GPRS network currently in use. The existing GPRS network
utilizes the AT&T Wireless (now Cingular) cellular system (band compatible with this modem), the
AirLink Raven GPRS modem, and the AirLink Gateway. The Design-Builder shall demonstrate the
compatibility to the Department by actual installation demonstration or by other means approved by the
Department.

Installation
The installation of the modem shall be according to the plans, the manufacturer’s instructions, and
adjusted per field conditions with the Department's approval.

April 11, 2011 5-73

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

POWER SUPPLY

The power supply shall be vertically mountable on a 19-inch standard rack rail using two machine
screws and two wing nuts. The power supply shall have provisions to attach the modem power cable
securely without the need for modifying the modem power cable.
The power supply shall meet the following requirements:

Power Cord Standard 120 V(ac), 3 prong cord, at least 40 inches in length
(may be added by Contractor)
Type Switching mode type
Power Rated 40 W minimum with no minimum load required
Operating Temperature Range From -30°C to +70°C
Operating Humidity Range From 5 percent to 95 percent non-condensing
Input Voltage From 85 V (ac) to 264 V (ac) or 120 V (dç) to 370 V (dc)
Input Frequency From 47 Hz to 63 Hz
Inrush Current Cold start, 25 A at 115 V
Output Voltage 12 V (dc), adjustable over a ±10 percent range
Overload Protection From 105 percent to 150 percent in output pulsing mode
Over Voltage Protection From 115 percent to 135 percent of output voltage
Setup, Rise, Hold Up Time 800 ms, 50 ms,15 ms at 115 V (ac)
Withstand Voltage I/P-0/P:3 kV, I/P-FG:1.5 kV, for 60 seconds
Working Temperature* 70 °C@30%
Safety Standards UL 1012, TUV EN60950
EMC Standards EN55022 Class B, EN61000-4-2, 3, 4, 5 and EN61000-3-2, 3

• Note: A substitute may be proposed by the Design-Builder which meets the 70°C
environmental rating at a lower load percentage as long as the temperature rating is
maintained at the maximum modem load and all other electrical specifications are met.

MODEM MOUNTING BRACKET AND HARDWARE

The mounting bracket and hardware shall be stainless steel. The mounting bracket shall securely hold
the modem in a vertical attitude with all cables and conductors installed. The mounting bracket shall
contain the modem using a method that allows the removal of the modem without tools or without
removing the bracket from its attachment to the cabinet frame.

COMMUNICATION SERIAL CABLE – TYPE D

Where the modem is designed to interface with a Model 170E controller, the Design-Builder shall
provide a communication cable known as the C2 cable. The C2 cable shall interface the Model 170E
controller C2 connector and the GPRS modem and include all conductors and connectors required for that
purpose. The GPRS modem connector shall meet EIA RS-232 standard using a 9 pin Type D connector.
The Model 170E controller end connector shall comply with AMP 201360-2-ND or equivalent. All pins
in both connectors shall be gold plated. The cable shall have four No. 20 AWG conductors with (UL)
Type CM shielded or AWM 2464 80C 300 Volts – C (UL) CMG. The cable shall be at least 3 feet long.
The cable wiring shall comply with the following:

April 11, 2011 5-74

Modifications To Special Provisions
Department of Transportation Book 3 – San Mateo 101, Ramp Metering Systems
E.A. 04-2A7904
Project ID 0400000843

AMP 201360-2-ND -L to DB9-P - 2

AMP 201360-2-ND -K to DB9-P - 3
AMP 201360-2-ND -N to DB9-P - 5
AMP 201360-2-ND -D to AMP 201360-2-ND - H
AMP 201360-2-ND -J to AMP 201360-2-ND - M

ANTENNA
The antenna shall be the low profile disc type, and shall adhere to the cabinet using a factory installed
double-sided waterproof acrylic foam adhesive. The coax cable shall be at least 40 inches in length and
shall have a 50 Ω TNC connector on the modem end. In addition, the antenna shall meet the following
requirements:

VSWR (at resonant point) 2:1 or less

Frequency 1850-1990 MHz and
824-894 MHz
Nominal Impedance 50 Ω
Gain 2 dB
Radiation Pattern Omni-directional
Polarization Vertical
Ground Plane Required Yes, see note below

Ground plane requirements: The antenna shall require a reflective ground plane to function properly.
The required ground plane shall extend beyond the antenna at least 8 inches in all directions.

Warranty
The manufacturer shall provide a written warranty against defects in materials and workmanship for
modems and power supplies for a period of 12 months after installation for parts and labor. Replacement
modems and power supplies shall be provided within 5 days after receipt of failed modem and power
supply at no cost to the State, except the cost of shipping the failed modem and power supply. All
warranty documentation shall be given to the Department prior to installation. Replacement modems and
power supplies shall be delivered to Caltrans Maintenance Electrical Shop at 30 Rickard Street, San
Francisco, CA 94134, phone (415) 330-6500.

April 11, 2011 5-75

Modifications To Special Provisions

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