Alabama Department of Transportation Testing …

1 REVISED 05/14/03 Testing manual Bureau of Materials and Tests Alabama Dept. of TransportationGeneral InstructionsBureau of Materials and TestsPage 1 of 2 Testing ManualGENERAL INSTRUCTIONSThis manual aids uniform sampling and Testing procedures by the Alabama Department ofTransportation. Compliance with these procedures ensures all materials incorporated in a project can bedocumented as conforming satisfactorily with specification requirements and established Departmentpolicies. Revised or additional schedules and procedures are issued periodically. They should beimmediately placed in the appropriate section of this manual . Note that the primary units used in thisdocument are English. For projects that may be administered in metric units, appropriate metric values havebeen included in parentheses.

2 English and metric units are provided in a manner consistent with the intentof the specifications and may not be exact Sampling and Testing ProgramA copy of the Department 's official sampling and Testing program is for reference and study byproject personnel. It defines their responsibilities for acceptance of materials incorporated in the items are produced or fabricated away from the project site and, inspected and tested by otherDepartment personnel or agencies. Thoroughly study procedure ALDOT-195 before allowing contractorsto incorporate these Sampling and Testing ScheduleTo provide a cost effective sampling and Testing program, schedules contained herein weredeveloped for major projects when materials are produced by previously unused sources.

3 For materialsdelivered to a major project from sources consistently producing quality material, the sampling and testingfrequency may be decreased on a job-by-job basis. The Materials and Tests Engineer must approve thisfrequency decrease. Conversely, the frequency may be increased for a source with a history of supplyingmarginal quality for Testing material may be waived on certain minor projects. Material must bevisually inspected to ensure it is in reasonable close conformance with specifications and will do theintended job. This includes projects with very small materials quantities of a noncritical nature. Examplesare certain intersection improvements, safety projects, etc. Before beginning work, the Divisionrecommends this waiver in writing to the Materials and Tests Engineer.

4 This approval would then be onfile. Form BMT-16 should be completed at the time the materials are incorporated into the project to showa visual inspection of all materials was acceptable. BMT-16 accompanies the Division Materials Certificateand becomes a part of the project contracts requiring miscellaneous material items in quantities smaller than normal lots for testingpurposes, quantities may be accepted by a certified test report from the manufacturer when validated by theTesting Engineer. (Examples are steel fence posts, nuts, bolts, filter fabrics, etc.). For sources consistentlyproducing quality materials, the Division Materials Engineer may authorize project personnel to acceptthese materials following visual inspections. Project personnel will execute Form BMT-16 for materialsaccepted on a visual basis at the time of acceptance and incorporation into the project.

5 State on the reportthe quantity accepted and observed physical characteristics such as dimensions where applicable, generalcondition, workmanship, appearance, Dept. of TransportationGeneral InstructionsBureau of Materials and TestsPage 2 of 2 Testing ManualSampling and Testing ProceduresGenerally, American Association of State Highway and Transportation Officials (AASHTO) orAlabama Department of Transportation Procedures (ALDOT) are used; occasionally, ASTM or otheragencies such as FAA or Corps of Engineers procedures are required. AASHTO, ASTM, or other agencyprocedures are not in this manual . Project personnel may obtain these procedures from the DistrictEngineer's Office, Division Materials Engineer, or Bureau of Materials and is used to determine when or where a sample or test will be taken for normal lot orsublot of material.

6 This procedure provides unbiased samples and tests. If it is apparent that failing materialexists due to segregation, mishandling, or worn equipment, the contractor will be required to rework orreplace the failing portion before taking the acceptance sample or test. All personnel engaged in samplingand Testing duties should thoroughly study this ProvisionsSome AASHTO, ASTM, or Alabama Department of Transportation procedures contain retestprovisions. The following general policy applies for those provisions not contained in the procedure. Foroccasionally failing samples, two additional samples or tests (randomly selected per ALDOT-210), will beobtained for the failing lot. If the two additional tests meet the requirements, the lot may be accepted; ifonly one or none of the samples or tests meet the requirements, the entire lot is rejected until replaced orreworked per the Standard Specifications, Section 106.

7 When more than two failing lots of material aresampled and tested during the same time period, all lots may be rejected without retests. In this event, thesource of material and/or contractor's workmanship should be evaluated before allowing any furthershipments or work to conclusion, project personnel are urged to thoroughly study the individual sampling and testingschedules and procedures before beginning any item of work. Place particular emphasis on results in timely payments to the contractor and rapid clearance of the final Materials Certificate ofConformance (BMT-38). Alabama Dept. of TransportationSampling and Testing ProgramBureau of Materials and TestsPage 1 of 11 Testing ManualINDEXFOREWORD .. 2 SECTION I .. 31. General 32. Types of Samples and 4 SECTION II.

8 And Independent Assurance Samples and Tests .. Testing by the Department .. 5 SECTION Certification .. of Small Quantities of Miscellaneous Materials on the Basis of Visual Inspection orManufacturer 7 SECTION IV .. Reference Laboratory 8 SECTION 91. EXHIBIT A: Certification of Materials and 92. EXHIBIT B: 103. EXHIBIT C: 11 Alabama Dept. of TransportationSampling and Testing ProgramBureau of Materials and TestsPage 2 of 11 Testing ManualFOREWORDS ampling and Testing schedules prepared prior to job (project) construction are general guides forevaluating the quality of materials and workmanship incorporated in a highway or bridge. Accordingly, thismanual contains a general frequency schedule for acceptance sampling and Testing . Select lots or sites forsampling/ Testing under these frequencies per the random number procedure (ALDOT-210) in this test results vary significantly and/or marginal quality of materials or workmanship are noted-developmore frequent schedules of sampling and Testing .

9 Our objective is to ensure acceptance eligibility of anygiven lot of materials or workmanship. Materials from sources consistently producing acceptable materialmay require less frequent Dept. of TransportationSampling and Testing ProgramBureau of Materials and TestsPage 3 of 11 Testing ManualSECTION IGENERAL INFORMATIONThe Bureau of Materials and Tests of the Alabama Department of Transportation is directed by theMaterials and Tests Engineer. He is responsible for evaluation of all materials functions within theDepartment. The Bureau is composed of the following sections: Materials, Central Testing Laboratory, andGeotechnical. Responsibilities of the Materials and Tests Engineer are further executed through DivisionMaterials and Project Laboratories are under the general supervision of the Division MaterialsEngineer.

10 Responsibilities include the quality of all acceptance sampling and Testing of materials fabricatedat or near the project site, , soils and/or aggregate bases, Portland cement concrete, bituminous concretemixes, etc. Duties include the review of the capabilities of all Testing personnel, and their proficiency in andknowledge of the sampling and Testing frequencies/procedures. He is also responsible for frequentcondition checks of Testing equipment used in laboratories under his supervision. When consistent failuresof acceptance samples or tests occur, the Division Materials Engineer initiates an investigation. He reportshis findings and actions taken or recommendations to alleviate further occurrence to the Materials and TestsEngineer. Additionally, the Division Materials Engineer directs periodic reviews of all Testing Manuals inhis area for current additions or Central Testing Laboratory in Montgomery is directed by the Testing include all chemical tests, specialty tests, standardization and uniformity of tests, andquality tests that Division or Project Laboratories are not equipped to perform.