Category:123 Federal-Aid Highway Program: Difference between revisions

123.1 Discussion

The Federal Highway Administration (FHWA) is one of the key partners with MoDOT in delivering the highway program in the State of Missouri. Federal funding of highway projects is an essential part of planning, design, construction, and preventive maintenance activities undertaken by MoDOT. The FHWA is one of the agencies under the U.S. Department of Transportation and is responsible for administering the Federal-Aid Highway Program nationwide. In addition to the Washington Headquarters office and Resource Centers, the FHWA has a division office in each state to provide direct assistance and guidance to the individual state highway departments. The primary sources of guidance on the Federal-Aid Program are available in Title 23, United States Code - Highways, 23 Code of Federal Regulations (CFR), the current federal highway act,and the Federal-Aid Policy Guide (FAPG). These documents provide current regulations, policies and procedural guidance.

To ensure projects qualify for federal funding and obtain the maximum participation, compliance with federal laws, regulations and FHWA policies and procedures is necessary. This is accomplished through a close partnership arrangement with MoDOT and has included innovative methods and practices to enhance program implementation. FHWA and MoDOT have entered into an oversight agreement that allows MoDOT to discharge some responsibilities traditionally performed by FHWA for projects not on the Interstate highway system. This agreement documents the roles and responsibilities of both FHWA and MoDOT in carrying out the Federal-Aid Highway Program. This includes identification of the type of projects that will require full oversight by FHWA, or are exempt from FHWA oversight. All Federal-Aid projects, regardless of whether MoDOT has responsibility for administration, must comply with all applicable federal regulations in order to receive federal-aid funding. Specific guidance and assistance in implementing the Federal-Aid Program is available from the FHWA Missouri Division office in Jefferson City.

To further reinforce this close partnership, FHWA will be given the opportunity to participate in task forces and other quality improvement teams established to review existing processes and procedures to improve implementation of the MoDOT transportation program.

123.1.1 FHWA Oversight - National Highway System

The National Highway System (NHS) includes the entire interstate system and other urban and

rural principal arterials along with major highway network connectors. The FHWA has the responsibility to ensure the safety, appropriate design, and national continuity of the NHS. This is accomplished through the oversight agreement. The following briefly describes the oversight role of FHWA:

Full Oversight Projects. Individual projects that require approval by FHWA for all project actions (full oversight) are:

• All interstate system projects with estimated construction cost equal to or greater than $1 million including traffic control plans.

• All Intelligent Transportation System (ITS) projects. ITS projects are those that provide for development of ITS software, implementation of ITS features or any project that utilizes ITS technology including traffic signal integration.

• All major bridge projects on the NHS. FHWA defines major bridges as new, complex designs involving unique design or operational features, unusual geotechnical features or unusual hydraulic features. This includes major structures with span lengths greater than 200 ft. (60 m) or a total length greater than 1000 ft. (300 m).

123.1.2 Federal Appropriations

Current legislation provides for the appropriation of federal funds from the Highway Trust Fund for the purposes of carrying out the provisions of Title 23, U.S.C. Funds are divided among the various states by an apportionment process. These funds are subject to mandatory limitations established by the U.S. Congress each fiscal year to help control spending and drawdown of the Highway Trust Fund. A certain percentage of the apportioned funds are directly allocated to urbanized areas with a population over 200,000 and are subject to the control of a metropolitan planning organization (MPO). In Missouri, the urbanized areas over 200,000 in population are St. Louis, Kansas City and Springfield. The cities of St. Joseph, Joplin, Columbia, and the City of Jefferson also have MPO's but do not receive a direct allocation of funds. Other major funding categories are:

Interstate Maintenance (IM). IM funds can be used for resurfacing, restoration, and rehabilitation, but not for the construction of new travel lanes unless they are high occupancy vehicle (HOV) or auxiliary lanes.

National Highway System (NHS). NHS funds may be used for a variety of projects on the NHS including construction, reconstruction, resurfacing, restoration, and rehabilitation, operational and safety improvements, start-up costs for traffic management and control systems, fringe and corridor parking facilities, carpool and vanpool projects, and bicycle and pedestrian facilities.

Surface Transportation Program (STP). These funds may be used for any highways, including the NHS, that are not functionally classified as local or rural minor collectors. Eligible items of work are similar to those under the NHS. However, 10% must be used for transportation enhancements and 62.5% of the remaining funds are sub-allocated to areas of the state based on population.

Highway Bridge Replacement and Rehabilitation Program (HBRRP). Eligible projects for HBRRP funding include replacement or rehabilitation of a structurally deficient or functionally obsolete highway bridge, replacement of ferryboat operations and low water crossings, bridge painting, calcium magnesium acetate applications, and seismic retrofitting. Additionally, not less than 15% will be spent on off-system bridges.

123.1.3 Programming

To insure coordination of intergovernmental planning and before any federal-aid programs are approved by FHWA, all projects must be cleared under the Missouri State and Local Review System. Briefly, this is described as:

State Clearinghouse The State Clearinghouse, after notifying other state agencies, certifies to MoDOT that these agencies have been informed of the project and have indicated whether the proposed work conflicts with their programs.

Regional and Metropolitan Clearinghouses Similar clearance must be received from regional and metropolitan clearinghouses who notify appropriate local governments and other regional agencies in the area. These clearinghouses provide comments to the MoDOT on proposed projects. Any adverse comments received from the clearinghouses must be resolved. In order for any proposed project to be eligible for federal funding, it must be included on the Statewide Transportation Improvement Program (STIP). Before any work is performed for which federal reimbursement is expected, FHWA must provide approval. MoDOT district offices will notify the Design Division as soon as possible if any proposed work is identified that is not on the approved STIP. For projects to be constructed in stages, a separate item will be shown on the STIP for each stage.

123.1.4 Federal Authorization

Authorization to proceed with a federal-aid project can be given only after applicable requirements of federal laws and regulations have been satisfied, including the planning and programming items noted above. For construction projects, additional requirements must be completed such as an approved environmental document, right-of-way clearance, and submission of a request to FHWA by MoDOT to authorize construction with the obligation of funds. Authorization to proceed is considered a contractual obligation of the Federal Government under 23 U.S.C. 106 and federal funds will not participate in costs incurred prior to the date of authorization.

123.2 Construction Requirements

123.2.1 General Procedures

On Federal-Aid highway projects, the terms of federal participation are established by oversight agreement between the department and the FHWA. This agreement provides for the work to be done in accordance with predetermined criteria contained in the plans and specifications, in approved standard drawings, and in special provisions required by the nature of the project.

The Missouri Highway and Transportation Commission will award a construction contract for the project with the concurrence of the FHWA. Supervision of construction is a function of the MoDOT’s engineers and inspectors. FHWA representatives may make periodic inspections of these projects and will complete a final inspection and final acceptance.

123.2.2 The FHWA - MoDOT Relationship

The relationship between the FHWA and MoDOT does not directly involve the contractor. FHWA representatives inspect the project to review MoDOT’s procedures for assuring the project is built according to commitments contained in project documents, MoDOT/FHWA agreements and to assure that the contractor follows proper construction practices. Any deficiencies noted by the FHWA representative shall be documented and conveyed to MoDOT’s engineer or inspector. MoDOT will work directly with the contractor to resolve these deficiencies.

MoDOT employees are expected to cooperate with FHWA representatives in their inspections. Note their comments in the diary. Promptly refer to the resident engineer matters that require their attention. Should a FHWA representative give instructions to a MoDOT employee which appears to be in conflict with MoDOT policy, the FHWA representative should be courteously informed that the employee has no authority to carry out such instruction but will refer the matter to the appropriate supervisor.

The MoDOT inspector, as directed by the resident engineer, will inform FHWA representatives of necessary extra work and of any proposed changes on full oversight projects. All major changes must have concurrence of the FHWA before any of the work is started.

An oversight agreement signed by MoDOT and FHWA, outlines the specific procedures which the Construction and Materials Division together with the district must follow in the administration of a project. MoDOT will complete a final inspection and final acceptance on projects exempt from FHWA full oversight. The FHWA reserves the right to observe a project under MoDOT responsibility, including those conducted by a Local Public Agency (LPA) at any time.

123.3 Materials Requirements

123.3.1 Independent Assurance Samples and Tests (IAS)

The following information establishes procedures for sampling, testing and reporting Independent Assurance Samples (IAS) for all Federal-Aid projects. Federal-Aid projects are Interstate, Primary and Secondary projects awarded and administered by the Missouri Department of Transportation, and Off-System and Surface Transportation Program-Urban projects awarded and administered by a county, city, or the Missouri Department of Transportation. These procedures do not change normal job control procedures for any projects. The term “FAST” contained in these procedures is interpreted as:

• Federal-Aid Acceptance Sampling and Testing (FAST) of aggregates performed by Construction and Materials personnel, or
• Samples and tests performed by project personnel for project control.

123.3.1.1 General Procedures

The frequency at which IAS are to be taken on Federal-Aid projects should generally conform to established guidelines for various types of construction. This frequency may vary for individual projects or phases of projects in accordance with the level of control for the quality of materials or work.

It is not intended that IAS for any work be taken at predetermined uniform intervals. A reasonable effort to avoid concentration of a large part of the prescribed number of IAS in one area or time period should be made.

For each type of construction or material shown in the established guidelines, the quantity to be used for determining the minimum number of IAS is the total quantity of that type within the project limits, except, IAS are not to be taken for bituminous mixtures or aggregate bases used for temporary construction which is to be maintained by the contractor and removed before final acceptance.

Small quantities of materials accepted by construction, county, or city, on the basis of visual inspection or producer certification of compliance are not to be sampled and tested for Independent Assurance. If the contract specifications waive specific requirements and allow acceptance by certification, visual inspection, etc., IAS are not required. If a test is shown in the established guidelines but not required by the project contract, the IAS test is not required.

Each inspector assigned to Independent Assurance Sampling is to be fully equipped or have ready access to the equipment necessary to perform all field tests listed in the guidelines, except nuclear density tests, asphalt binder content with a nuclear gauge, asphalt binder content with binder ignition oven, gyratory compactor and maximum specific gravity testing equipment. This equipment is to be used on a portion of the tests performed. As a guide, it is recommended that approximately 80 percent of each type of field test specified be performed by the Independent Assurance Sampler using equipment other than that assigned to project personnel, except when nuclear density testing, asphalt binder content by nuclear method, asphalt binder content by binder ignition method, gyratory compactor operation and maximum specific gravity testing are used. On the remaining tests to be made, the IAS inspector may perform the test, or participate in the sampling and testing, or witness the sampling and testing. When possible, the IAS inspector and the inspector being reviewed should not report to the same immediate supervisor.

When nuclear density testing methods are used for project job control, the IAS inspector is not required to perform any of those tests. However, designation of the location for the test, witnessing the test, checking calculations, and reporting is required. In addition, the IAS inspector is to review the daily standardization check for the machine being used if the checks are required by policy. The report needs to state that the standardization check was examined. If the standardization check has not been performed as required, please note that in the remarks.

When asphalt binder content, for normal job control, is determined by nuclear gauge or binder ignition oven, the IAS inspector is not required to perform any of those tests. However, observing the sample preparation, testing, checking calculations, and reporting are required. When the nuclear gauge is used, the IAS inspector is to review the statistical stability test records and the daily background check for the nuclear gauge being used. The report is to state that the statistical stability test and the background check were reviewed and found current and satisfactory, or not. The asphalt content by nuclear gauge or binder ignition oven is to be reported on the appropriate test in SiteManager. The frequency of IAS is shown in the established guidelines. If a plant is producing the same mixture for more than one project at a time, the IAS for asphalt binder content is to be credited to each of the projects receiving that mixture that day. Reports to the individual project will be required.

When a gyratory compactor is used for normal job control, the IAS inspector is not required to perform any of those tests. However, observing the sample preparation, testing, and reporting are required. When a gyratory compactor is used, the IAS inspector is to review the calibration records for the gyratory compactor being used. The report is to state that the calibration records were reviewed and found current and satisfactory, or not. The frequency of IAS is shown in the established guidelines. If a plant is producing the same mixture for more than one project at a time, the IAS for the gyratory compactor is credited to each of the projects receiving that mixture that day. Reports to the individual projects will be required.

Independent Assurance tests may be performed in the field, the district laboratory, or the Central Laboratory in Jefferson City as condition and need dictates, unless shown otherwise in the established guidelines.

Test results are to be rounded for reporting in conformance with the procedures established in Reporting Test Results.

All IAS aggregate gradation tests are to be "washed" and are to include each sieve specified. The size of sample and method of sieve analysis of fine and coarse aggregate is to be in accordance with 1002 Aggregate for Asphaltic Concrete, except:

• the size of hot bin gradation samples for bituminous mixtures shall be as shown in Articles 401 Bituminous Base and Pavement, 402 Bituminous Surface Leveling and 403 Asphaltic Concrete Pavement and
• for coarse aggregate, the nominal maximum size of particle is to be considered as the largest sieve size on which material is retained.

The sample size of fine aggregate may have to be adjusted in order to comply with the requirement in 1002 Aggregate for Asphaltic Concrete, i.e., the fraction retained on any sieve at the completion of the sieving operation shall not exceed 4 grams per square inch (6 kg/m2) of sieving surface. As a guide only, it is suggested approximately 400 grams be used as a sample size for fine aggregate for portland cement concrete (Specification 1005.3) and approximately 100-150 grams for all other fine aggregate gradations.

IAS requirements for gradation, PI, or liquid limit tests on aggregates and base materials are to be fulfilled by obtaining the sample by one of the following methods.

• By the FAST inspector taking a sample in the presence of the IAS inspector and then furnishing one-half of that sample to the IAS inspector. The FAST inspector is to perform the required tests and report the results as a Federal-Aid Acceptance Sample and Test (FAST) in SiteManager. The IAS inspector would perform the required IAS tests on the other one-half sample, recording the results in SiteManager.
• By the IAS inspector taking a sample and furnishing one-half of the sample to the FAST inspector currently assigned to that plant or location, who will then perform the required tests and report the results as a FAST. The IAS inspector would perform the required IAS tests on the other one-half sample.

SiteManager samples sent to the Central Laboratory are to be designated “Proj. IAS” in the Sample Type field. The sample record is to contain the prescribed information regarding the location and shall indicate the person designating the location and performing or witnessing the sampling.

123.3.1.2 Specific Procedures

123.3.1.2.1 Grading

The location of tests, for both embankment and subgrade preparation are to include the approximate distance below final earthwork grade in addition to the station number and distance right or left of centerline. In the case of dual construction, outer roadway, or other construction, the roadway is also to be identified.

The frequency shown in the established guidelines is total cubic yards (meters) within the project limits or accumulation of length in miles (kilometers) of individual embankments regardless of the number of pavement lanes on the embankment.

IAS density tests, other than nuclear, are to be located in the very near vicinity of the FAST density test performed by project personnel and are to be performed by the same method used by project personnel.

If density tests are not taken due to material being too rocky to test, a notation to that effect is to be noted on the IAS summary.

123.3.1.2.2 Aggregate, Sand-Soil, Soil-Cement, or Soil-Lime Bases

IAS density tests, other than nuclear, are to be located in the very near vicinity of the FAST density test performed by project personnel and are to be performed by the same method used by project personnel.

Care should be taken to show the location of IAS tests by roadway, station, distance right or left of centerline or of the edge of pavement, number and nominal thickness of the lift or lifts identified shall be shown.

Samples of material for gradation or PI are to be obtained at a point just prior to use, i.e., stockpile, pugmill, spreader, belt feeder or bin discharge. The place of sampling and the approximate roadway station number where the material is laid is to be shown on the report. The samples are to be taken by one of the methods described in section 123.3.1.1.

123.3.1.2.3 Crushed Stone or Gravel Surfacing

Samples for gradation are to be taken at a point just prior to use. The samples are to be taken by one of the methods described in section 123.3.1.1.

IAS are not required for Temporary Surfacing, Specification 104.8.

The report is to show the roadway, approximate station number where the aggregate is placed and the place of sampling.

123.3.1.2.4 Bituminous Mixtures

The asphalt plant inspector may obtain the IAS samples for gradation provided the IAS inspector observes the sampling. The sample is to be split and the IAS test performed on one-half the sample. Project personnel test the other half of the sample for acceptance purposes (FAST). The IAS inspector may perform the IAS test at the project using equipment other than project equipment, except, scales that have been calibrated within the immediate past 12 months may be used by both inspectors, or the IAS test may be performed in the district laboratory, reporting results through SiteManager.

Hot mix gradation samples are to be reported in SiteManager.

Road mix gradation samples of aggregate shall be taken at a point just prior to use and shall be reported in SiteManager.

The FAST inspector may obtain the IAS samples for maximum specific gravity provided the IAS inspector observes the sampling. The sample is to be split and the IAS test performed on one-half the sample. Project personnel test the other half of the sample for acceptance purposes (FAST). The IAS inspector may perform the IAS test at the project using project equipment. Both inspectors may use scales that have been calibrated within the past 12 months. However, the IAS inspector is to review calibration records for the maximum specific gravity testing equipment being used. The report is to state that the calibration records were reviewed and found current and satisfactory, or not. The frequency of IAS is shown in the established guidelines.

Volumetrics (specific gravity of gyratory compacted specimens) should be determined on a set of specimens (pills) compacted by the FAST inspector using a gyratory compactor. The IAS inspector may use the same specimens that were produced when reviewing the FAST inspector operating the gyratory compactor.

IAS tests of compacted superpave asphaltic concrete pavement, plant mix bituminous pavement or plant mix bituminous base are to be performed on the same samples taken by the project inspector at the frequency shown in the established guidelines.

IAS tests may be performed in the district laboratory or the Central Laboratory. When tests are performed in the district laboratory, the test report is to show the location by roadway, station, distance and direction from centerline, and the lift designation of the course. If submitted to the Central Laboratory for testing, the identification sheet is to also show this information.

When performing IAS on bituminous mixes using RAP, the combined gradation will be calculated using the RAP gradation being determined daily by the project personnel and the aggregate gradation determined from the cold feeds or the hot bins. At some batch plants, the RAP may be added prior to the hot bins. In that case, the combined gradation will be determined from the hot bins only. Project personnel should be consulted, prior to testing, to find out where the RAP is being added.

If the contractor elects to use the binder ignition method to determine the combined gradation for job control, the IAS inspector shall witness the testing process to ensure proper testing procedures are being used. Tests shall be performed at the frequencies shown in the established guidelines.

123.3.1.2.5 Portland Cement Concrete Pavement and Base

IAS of aggregates are to be obtained at the batching plant from the belt or the bin discharge as they are proportioned for use and are to be taken by one of the methods earlier described. The place of sampling and the approximate roadway station number where the aggregate is used is to be shown on the report. For coarse aggregate produced in more than one fraction, the gradation of each fraction, percent of each used and the combined gradation shall be shown.

The concrete sample for IAS for air and slump is to be from the same concrete sample taken by the project inspector for the FAST test.

Quantities of pavement and base are not to be combined for determination of the number of samples to be taken. IAS of PCC Pavement may not be used to fulfill the sampling requirements of PCC Base.

Independent Assurance Samples for pavement repair concrete are not required.

When a compression-testing machine is used for normal job control, the IAS inspector is not required to perform any of those tests. However, observing the sample preparation, testing, and reporting are required. When a compression-testing machine is used, the IAS inspector is to review the calibration records for the compression-testing machine being used. The report is to state that the calibration records were reviewed and found current and satisfactory, or not. The frequency of IAS is shown in the established guidelines.

When a thickness-measuring device is used for normal job control, the IAS inspector is not required to perform any of those tests. However, observing the sample preparation, testing, and reporting are required. The frequency of IAS is shown in the established guidelines.

Not required to perform IAS on the QA inspector when QA tests involving compressive strength or pavement thickness are being performed at the Central Laboratory. All IAS testing will be performed on the QC inspector when QA testing is being performed at the Central Laboratory.

123.3.1.2.6 Concrete Masonry

IAS of aggregates are to be obtained at the batching plant from belt or bin discharge as they are proportioned for use and are to be taken by one of the methods earlier described. The place of sampling, class of concrete, structure and structure elements are to be shown on the report.

The concrete sample for IAS for air, slump, and cylinders is to be from the same concrete sample taken by the project inspector for the FAST test.

IAS for miscellaneous items of concrete are not required. Examples of miscellaneous items are bearing pile, curb, barrier curbs, paved ditch, sidewalk and post bases. IAS are required for items paid for under Specification Sections 701, Drilled Shafts and 703, Concrete Masonry Construction, except barrier curb. IAS of miscellaneous concrete will not compensate for a deficiency of IAS of concrete used in culverts, retaining walls, etc.

IAS are not required for precast units.

A compressive strength test shall consist of molding two cylinders and the testing of each cylinder. The testing of IAS cylinders is to be performed in the Central Laboratory at 28 days. IAS cylinders are to represent routine compressive strength tests, not tests made for a specific operational control such as form removal, heat removal, etc.

123.3.1.3 Comparison of Test Results

All IAS test results, including those not meeting specifications and those IAS samples submitted to the laboratory for testing, are to be compared with the companion FAST results by the inspector as soon as possible and the results reported. The IAS test result and the FAST test result should compare within the limits shown in the established guidelines. If the two tests do not compare within those limits, test procedures are to be reviewed, equipment checked, and if necessary, the test repeated to determine the reason(s).

123.3.1.4 Sample Record

Results of IAS are to be reported on the appropriate form in SiteManager with complete information shown. The reports should be submitted promptly after tests are completed, within ten working days at the latest.

IAS tests are not to be reported as "accepted" or "rejected". The IAS test result is not to be used for purposes of acceptance or rejection of material. When IAS testing compares with FAST testing or when IAS confirms equipment calibrations are current and proper testing procedures were utilized, the SiteManager report will show the status as “Compared Favorably/Compliant (FAST/IAS)”. When IAS testing does not compare with FAST testing or when IAS finds equipment calibrations are not current or proper testing procedures were not utilized, the SiteManager report will show the status as “Not Compared Favorably/Not Comply (FAST/IAS)”.

The following information is also to be on the IAS report:

• The report shall state that the calculations were checked and are on file in the district office. It will not be necessary for intermediate calculations to be shown on the report, since only the final result for the particular test is required; however, all calculations shall be carefully checked for accuracy and maintained on file in the district office.

• The report shall state that test results of the IAS were compared with the FAST results. The Identification No. (when used), date performed, and test results of the FAST are to be shown on the report. In addition, the comparison difference between the IAS and FAST is to be shown for each test result obtained. The report shall state whether the comparison was favorable or not favorable. If the comparison was not favorable, the probable reason(s) and any corrective action taken shall be shown on the report. If the FAST does not have an Identification No., other information shall be shown to identify the comparison FAST.

• If the IAS inspector witnessed a test, state what parts of the tests were observed and include the statement "location designated, procedure and computations checked by the IAS inspector." The name of the project inspector performing the test is to be shown.

• The report shall state where the tests were performed (field, district laboratory, or Central Laboratory) and what equipment was used (Construction and Materials or field personnel), e.g. "The test was performed in the district laboratory using construction and materials Equipment".

Each report is to be signed by the IAS inspector and the district construction and materials engineer. The use of a rubber signature stamp by the district construction and materials engineer will be permitted provided the stamped signature is personally initialed. In case of absence of the district construction and materials engineer, a designated representative may sign these reports using their own name and title below the district construction and materials engineer’s name and title.

When using SiteManager and in lieu of a paper report, it is also acceptable for the district construction and materials engineer or designated representative to authorize the Sample ID through SiteManager. The district construction and materials engineer may designate a representative by submitting the name or names, to the State Construction and Materials Engineer by letter. Designation shall remain in effect until cancelled by the district construction and materials engineer. The IAS Inspector must be the creator of the sample record and may not authorize their own sample.

Copies should be prepared for project and district construction and materials files. No letter of transmittal should accompany IAS reports.

The State Construction and Materials Engineer does not require a paper copy of the report, if it is properly created and authorized by the district construction and materials engineer in SiteManager.

123.3.1.5 Summary of Independent Assurance Samples

Upon completion of a project, all IAS tests are to be listed on a Summary of Independent Assurance Samples, using Impromptu report Summary of IAS.imr. Comments are necessary only when explanatory information is needed to supplement IAS reports.

Any deficiency in the minimum number of IAS for any material is to be acknowledged with an appropriate explanation.

If a portion of the project is constructed without Federal-Aid participation resulting in no IAS being taken on that portion, a blank Summary of IAS.imr can be printed to denote this.

A separate summary is required for each project even though it may have been awarded in combination with other projects. The summary is to be signed by the district construction and materials engineer and submitted to the State Construction and Materials Engineer. In case of absence of the district construction and materials engineer, designated representatives may sign the summary using their own name and title below the district construction and materials engineer's name and title. No letter of transmittal is required.

If the quantities in a project covered by these instructions are such that Independent Assurance Samples are not required, or if the type of construction for the project does not require Independent Assurance Samples, a letter is to be initiated by the district to the State Construction and Materials Engineer stating that condition.

123.3.2 Federal-Aid Acceptance Sampling and Testing (FAST)

The following information establishes procedures for Federal-Aid Acceptance Sampling and Testing (FAST) of aggregates for all Federal-Aid projects awarded and administered by the Missouri Department of Transportation. They apply to aggregates on Federal-Aid projects on which the Department performs the acceptance sampling and testing. The acceptance sampling and testing procedures for other materials and construction processes are to be as shown in other articles in this Guide. These procedures do not change the sampling and testing requirements for aggregates at the production source.

123.3.2.1 General Procedures

An inspector who takes Independent Assurance Samples (IAS) for these materials on a project is not to perform the FAST for the same material on the same project. The inspector may take a sample and furnish one-half the sample to the FAST inspector who will then perform the required tests and report the results as a FAST. Whenever possible, the IAS inspector and the FAST inspector of a particular sample should not report to the same immediate supervisor.

An inspector performing Process Control Tests (at quarry, source, etc.) may also perform FAST on the same aggregates. An IAS inspector may take FAST samples of aggregates on projects other than those on which he is taking IAS.

The frequency at which FAST is to be performed should generally conform to the guide schedule.

FAST of aggregates are to be obtained at the last point of handling prior to mixing with other materials or incorporation into the work. The district construction and materials engineer will determine if samples are taken from the pugmill or loaded truck at the pugmill, from the belt or bin discharge at the batch plant, from the roadway, or at other points.

The FAST is to be performed as soon as practicable after sampling. The district may determine the frequency at which gradations will be performed as washed tests except that if a FAST is performed on one-half of an IAS, it is to be washed. The size of sample and method of sieve analysis of fine and coarse aggregate is to be in accordance with 1002 Aggregate for Asphaltic Concrete.

For coarse aggregate, the nominal maximum size of particle is to be considered as the largest sieve size on which material is retained. The sample size of fine aggregate may have to be adjusted in order to comply with the requirement in 1002 Aggregate for Asphaltic Concrete, i.e., the fraction retained on any sieve at the completion of the sieving operation shall not exceed 4 grams per square inch [6 kg/m2] of sieving surface. As a guide only, it is suggested approximately 400 grams be used as a sample size for fine aggregate for portland cement concrete (Specification 1005.3) and approximately 100-150 grams for all other fine aggregate gradations.

Test results are to be rounded according to information contained in Reporting Test Results.

123.3.2.2 Report

Results of FAST are to be reported using SiteManager and are to provide complete information. The sample record should be created and reports submitted promptly after tests are completed, within ten working days at the latest.

The sample record should be created with the following information provided as clarification of specific issues.

The Status, when the sample record is complete will be set to FAST Compliant or FAST Deviant. Any other status is incorrect.

The Sample Type will be set to PJ (Proj. F.A.S.T.).

The Acceptance Method will be SATE (Sample and Test).

The Producer/Supplier shall be the original producer of the material. For example, the quarry, not the ready-mix plant, would be shown.

Smpld From shall show the location of sampling, i.e., "stockpile, bin discharge or roadway".

Smpl Origin shall show the origin of the sample, i.e., “project, Anytown Ready Mix”.

The quantity may be shown on the contract tab when the FAST inspector knows the appropriate quantity to report and is able to confirm that the material complies with all appropriate specifications, not just those part of the FAST inspection process. Care must be taken to avoid duplicate reporting of quantity. This option is provided to allow more efficient use of SiteManager, and the quantity data reported in this manner is not considered to have a direct relationship to the FAST process.

When a FAST is one-half of an IAS, the report is to identify the IAS either by complete information as to project number, date sampled, and complete location of sampling including station number, all included in the Remarks or by an identification number. For example, the FAST report could carry an identifying note such as "Test performed on one-half of IAS 1-93-20" as part of the test template.

The report shall state either the "Fast Compliant" which means the material complies with the specifications or ”FAST Deviant” which means material deviates from specifications. If a specification deviation occurs, retests should be made as soon as possible. Any corrective action to be taken will be determined by the district. Reports showing specification deviations are to include full information including results of retests, if made, cause of deviation, if known, what corrective action was taken, and the amount and disposition of this material.

Where material is being used on more than one Federal-Aid project, such as at a ready mix concrete plant, the frequency of performing FAST may be determined by combining the tons of that type aggregate being used. An example of this would be a ready mix plant producing concrete for three Federal-Aid projects; FAST of coarse aggregate would be obtained when 1,000 tons (megagrams) of coarse aggregate had been used on all projects combined. A report of this test would then be issued for each of these projects. When FAST is performed on one-half of an IAS, only the test report issued to the project for which the IAS was taken is to contain remarks identifying the IAS.

Distribution of the report shall be as is normally appropriate for the material tested.