REVISED June 2013

1. STATE MATERIALS OFFICE REVISED June 2013 Materials Certification

2. Goals in this Session To understand: • Why we certify • The Sampling & Testing process • The Project Certification process • The EAR/DDM process • The Project Administrator’s Statement • What an Exception is, and • The Certification process & tools available

3. Why Certify?

4. 23 CFR 637BFederal Aid Policy Guide • Sampling & Testing Program • Material Certification (MM 5.4) • and MM 5.2 for LAP projects • Sampling, Testing & Reporting Guide

5. Remove & Replace Does it meet Specs? No EAR Resolution QC Testing Yes No Do they Compare? Verification Testing Material Accepted Yes Field S & T: An Overview

6. Project Material Certification

7. PA’s Materials Statement Contractor’s Final Certification Contractor’s Monthly Certification Reported Test Results Passing & Verified QC results Approved EAR For failing Material Components Materials Engineer’s Certification

8. Monthly Checklist Items • Verify the area represented contained acceptable material • Verify all material issues are resolved • Verify Exceptions are complete and accurate • Verify the Exceptions match w/ Pay penalties • Verify all supporting certifications for materials accepted by certification are received and meet specifications

9. Engineering Analysis Report EAR

10. What is an EAR? • A report prepared by an approved licensed engineer providing analysis of failing material left in place • Evaluation of affected material, e.g., Analysis of additional samples, Life Cycle Cost Analysis, etc • Reporting structural adequacy with reference to the design criteria • “Disposition of Defective Material” form

11. EAR Processing Non-standard material left is in place Contractor requests PA use Of EAR Use EAR ? Yes PA & DME set up parameters SCE makes final decision PA. authorizes use Of EAR DCE approves disposition DCE forwards package to SCE Contractor submits EAR w/ recommendation to PA Yes Concur ? No DCE prepares recommendation DME reviews EAR and proposes disposition to PA PA forwards a copy of EAR to DME PA sends EAR & disposition to DCE Disposition implemented No

12. Project Administrator’s Materials Statement

13. Financial Project #: • Federal Project #: • Contract #: • County: • All materials incorporated into the referenced project(s) were accepted in accordance with the STRG or pertinent contract documents and met all applicable requirements. • Earthwork density test locations and results are in substantial compliance with the pertinent specification requirements of this project. A spot-check of the project density records indicate substantial compliance with the governing specifications, sampling and testing guides, and procedures. • All Contractor Quality Control (QC) material test results have been verified in accordance with contract requirements. The final disposition of all material represented by QC results has been accurately documented. • All required certifications and/or certified test reports have been received in accordance with contract requirements.

14. Earthwork density test locations and results are in substantial compliance with the pertinent specification requirements of this project. A spot-check of the project density records indicate substantial compliance with the governing specifications, sampling and testing guides, and procedures.

15. All Contractor Quality Control (QC) material test results have been verified in accordance with contract requirements. The final disposition of all material represented by QC results has been accurately documented.

16. All required certifications and/ or certified test reports have been received in accordance with contract requirements.

17. Exceptions

18. What are Exceptions?(to the Certification) Material Not Meeting Standards For CQC Testing: • Asphalt does not meet standards if C.P.F. for a Lot is less than 90% • However, we are noting failing tests, at the request of the Bituminous technical unit • Concrete does not meet standards if “payment tests” do not pass • Earthwork does not meet standards if ‘QC’ tests do not pass and are not verified

19. What are Exceptions?(continued) Material Not Meeting Standards (cont.) For Non-CQC Testing: • Material does not meet standards if ‘V’ test does not pass Testing Frequency • Material not tested, or tested at a frequency, not in conformance with the Specifications and left in-place

20. What are Exceptions?(continued) Qualifications • Sampling and testing performed by unqualified technicians (when specified in the Contract documents) • Testing performed at unqualified laboratories or at qualified laboratories during a time that they were removed from the list of Qualified Laboratories • Materials produced when the production facility was not on the accepted list, and left in-place

21. You have an Exception, how do you report it? Description Location Quantity Resolution (and at what pay) Concurrence…obtained?

22. Example of Format Concrete, Class IV The following Quality Control and Verification samples did not compare within the required tolerance. Resolution was not performed therefore these areas are not verified. Sample Station Result (psi) Quantity (cy) CC4006V 806+77 to 807+97 7983 22.25 CC4006Q ------------------------ 9330 ------- Project personnel recommended leaving the material in-place at full pay based on the QC results. The District Materials and District Construction Engineers concurred.

23. Our Review (the process & tools)

24. Method of Acceptance – What we look at: for all materials that have a paid qty, make sure have proper method of acceptance (examples: sampling and testing or certification) USE: Final pay estimate for Reg. Pay Item Projects *For Design Build and Lump Sum we use the final Job Guide Schedule

25. Open Samples Use: Sample Status Progress Report and Samples Not Tested Report The samples on these reports need follow up. They may need to be processed through LIMS (from receipt to approval)

30. Failing Material USE: Samples with Disposition other than Full Pay per Spec (FS) Report For material not meeting standards. Do we have a DDM documenting resolution and concurrences?

32. Unqualified Personnel and Labs When contracts specify to have qualified technicians and labs Requirements will be under spec book Section 105 for both personnel and labs. Need justification and how accepting material tested by unqualified personnel or labs

33. Material Certifications USE: Required Certification Tracking Report to determine certifications that need to be sent to Gainesville Make sure only those certifications that come to Gainesville are logged in LIMS Others (sampled by PP tested by PP) are scanned into Hummingbird with the project files • Random Sampling Program For more information, see section in the Materials Manual 5.6.15

35. Individual Material Review For example: Earthwork, Concrete, Asphalt, Reinforcing Steel and all other materials Make sure sampling and testing frequency is met per specifications Since, at times the data entry in LIMS is less than adequate (garbage in, garbage out), we need additional information

36. Data for Base LOTS Frequency: One QC test per 8 LOTS One VT test per 16 LOTS (every 2 QC)

37. Data for Structural Concrete LOTS Frequency: One QC test per 50 cy or day’s production One VT test per 4 LOTS (same mix design)

40. Steel Samples • Please submit the steel sample as soon as it is received at the project, do not wait until final acceptance • The SMO Lab will store an unidentified sample for 2 weeks before it is discarded • If your sample is discarded deliver one of the “hold” samples with the appropriate paperwork • Copy of LIMS C22, tag and mill analysis • Do not login a separate LIMS entry for the “hold” sample . The LIMS ID for the original sample will be used for the “hold” sample • LIMS life cycle must be completed

41. Wrap-up We discussed: • Why we certify • The Sampling & Testing process • The Project Certification process • The EAR process • The Project Administrator’s Statement • What an Exception is • The certification review, and • Tools to use

42. Questions • Comments