DUTIES OF A MATERIAL ENGINEER y Ensures that all materials comply with the schedule of minimum testing requirement.

y Advises the project engineer on the acceptance/ rejection of construction materials. y Recommends remedial measures to correct unsatisfactory condition of materials. y Prepare design mixes for concrete and bituminous materials. y Ensures the samples are properly cured by standard procedures. y Fully acquainted with standard procedures of sampling, testing and quality control of materials. y To see if the laboratory is adequately equipped. y Keep record of daily his activities. y Submit test reports & pertinent papers. y To see to it that quality of completed projects are attained as per DPWH standard. TERMINOLOGIES QUALITY CONTROL PROGRAM- prepared by Materials Quality Control Division of the Regional Office and MQC Section of the District Office to be complied by the contractor. FIELD DENSITY REPORT- if pavement is being constructed CONCRETE POURING PERMIT/ POURING SLIP- to ensure that all concreting works are done in accordance with the approved plans and specifications (Dept Order NO. 211 ser 2000). MONTHLY MATERIALS REPORT- every 25th of the month. POLICIES AND ADMINISTRATIVE ISSUANCES DO No. 206- re-guidelines on accreditation of Contractor s & Consultants Materials Engineers DO No. 14- adoption of DPWH Standard Specification 1995 Edition Volume 2 in the implementation of all Infrastructure Projects. DO No. 184- guidelines on accreditation of Contractor s & Consultants Materials Engineers DMC No. 03 Standard Spec for Chemical Admixtures Quality Control - checking for conformance to requirements to ensure the highest quality of work. Check and regulate the use of construction material to economize the cost of construction. Quality Assurance- acceptance inspection

STD SPEC FOR AGGREGATES AND SOIL AGGREGATES SUBBASE, BASE AND SURFACE COURSES COARSE AGGREGATE retain on # 10 sieves. % wear < 50 FINE AGGREGATE - passing # 10. Passing # 200 sieve ( 0.075 mm) < 2/3 of passing at # 40 sieve (0.425) SURFACE COURSE MATERIAL- minimum 8 % passing # 200 sieve. Maximum liquid limit of 35. Plasticity Index range of 2 to 9. SOIL CLASSIFICATION (AASHTO 145) GRANULAR MATERIALS- 35 % or less 0.075 mm sieve SILT CLAY MATERIALS- more than 35 % passing BINDER- passing 0.425 (#40) sieve

STONE-angular particles of rock, passes 75 mm (3 ) sieve and retained on 2 mm (#10) sieve. GRAVEL-rounded particles of rock w/c passes75 mm (3 ) sieve, retained 25.0 mm (1 ) sieve. SAND- granular materials , passes 2 mm (#10) sieve retained on 0.075 (#200) sieve. SILT FRACTION-passes #200 but larger than 0.002 mm CLAY FRACTION-smaller than 0.002 mm COLLOID-smaller than 0.001 mm

GROUP INDEX --measure of the relative supporting power of the subgrade soil. Greater depth is required for higher GI value.Empirical value from 0 to 20, Zero (0) GI indicates good material and GI of 20 indicates a very poor material. GI= (F 35) 0.2 + 0.005(LL-40) + 0.01 (F 15) (PI 10) F= percentage passing 0.075 sieve expressed in positive whole number. LL= numerical Liquid Limit, pos whole number PI= numerical Plasticity Index,pos whole number Granular material to control pumping under concrete pavement: -max size not more than 1/3 the thickness of the subbase. -passing # 200 -15% max PI= 6 max LL=25 max LIME FOR ROAD STABILIZATON- causes finely divided clay particles to agglomerate into coarser particles to improve load bearing properties Hydrated lime- retained on #30 <3%, retained on #200<25% Quicklime- shall all pass 1 sieve DRY PREPARATION OF DISTURBED SOIL AND SOIL AGGREGATE SAMPLES FOR TEST 1. Particle size analysis of soil. Hydrometer Analysis- determines the particle size distribution of soil passing No. 200. % of Hygroscopic Moisture= ( W-W1 x100 ) / W1 W- wt of air dried sample W1-wt of oven dried sample Con Mass of air dried sample for hygroscopic moisture= (air dried mass) x (100/100+% hyg moisture) % of originally dispersed soil remaining in suspension, P= (Ra/w) x 100 R- Corrected hydrometer reading. a- constant depending on density of suspension w- mass in grams of soil originally dispersed minus the hygroscopic moisture a

2. Specific Gravity. 3. Physical Test.

EXCAVATION 1. ROADWAY EXCAVATION-unclassified excavation, rock exc., common exc., muck exc.(with organic matter) 2. BORROW EXCAVATION approved materials for const embankment. Borrow Case 1- designated in plans and specs Borrow Case 2- provided by contractors.

ITEM 200, AGGREGATE SUBBASE COURSE % passing No. 200 shall not be greater than 2/3 of the fraction passing No. 40 (0. 425 mm) Fraction passing No. 40 shall have LL< 35, PI< 12.

ITEM 201, AGGREGATE BASE COURSE % passing No. 200 shall not be greater than 2/3 of the fraction passing No. 40 (0. 425 mm) FILLER- shall not contain more than 15% materials retained on the No. 4. Fraction passing No. 40 shall have LL< 25, PI< 6.

Fraction passing No. 10 shall have mass % wear<50. Fraction passing No. 10 shall have soaked CBR<80% ABRATION TEST - evaluates structural strength of coarse aggregates, resistance to impact and wear. Apparatus: Los Angeles Machine, Sieve, Abrasive Charges, Pans and Balance /Weights Abrasive Charges--- cast-iron spheres on steel spheres, approx. 48 mm diameter each weighing 390 & 455 grams. Charge depends on grading of test sample. Rotated at speed of 30-33 rpm. % wear= orig mass of sample sample retained on 1.7 mm sieve / orig mass of sample x 100

LIQUID LIMIT- lowest moisture content at which the soil will flow upon the application of a very small shearing force. - MC at 25 blows at CASAGRANDE - water content at which a soil changes from plastic to liquid behavior PLASTIC LIMIT minimum moisture content at which the soil can be readily molded w/o breaking. Plasticity Index indicates compressibility. Crumbled soil at 1/8 diameter Compressibility-- ability of a soil or rock to reduce in volume with applied pressure Permeability-- ability of a porous material to allow fluids to pass through it PI = LL - PL  high PI, low permeability, high compressibility.

SHRINKAGE LIMIT - water content where further loss of moisture will not result in any more volume reduction. Proctor Moulds- use to determine relationship b/w moisture content& density of compacted soil. Proctor Rammers- use to compact the soil in proctor moulds. Pavement Coring Machine- use to cut concrete samples, asphalt or similar materials.

BASIC CONCRETE TECHNOLOGY

2 main parts ------- paste, and aggregates

If air content of fresh concrete . Increases 1%, compressive strength decreases 5% Decreases 1%, yield (volume) decreases about 0.93 (1/4 cu. Ft/ cu yd) Decreases 1%, slump decreases about inch Decreases 1%, durability decreases about 10% CEMENT 1. Pozzolan cement- w/ volcanic earths. 2. Portland cement calcium, alumina, iron and silica Note: 30 kg of water are required to hydrate 100 kg of cement. Chemical Compounds in Portland cement 1. Tricalcium Silicate- C3S hydrates and hardens rapidly. Responsible for initial set. 2. Dicalcium Silicate-C2S contributes to strength increase at ages. Hydrates and Hardens slowly. 3. Tricalcium Aluminate- C3A liberates large amount of heat. 4. Tetracalcium Aluminoferrite-C4AF reduces clinkering temperature. Properties of Portland cement: 1. Fineness of cement- affects heat released and rate of hydration. Greater cement fineness increase hydration thus, accelerates strength development. (Blaine Permeability Test) 2. Soundness- ability to return to retain its volume after setting. 3. Consistency- mobility/ ability to grow 4. Setting Time- (Vicat Apparatus or Gilmore Needle) 5. False Set6. Compressive Strength 7. Heat of Hydration- generated when cement and water react 8. Loss of Ignition 9. Specific Gravity- Portland Cement- 3.15, Portland blast furnace slag and Portland pozzolan- 2.9 10. Weight of Cement- Water of Convenience, 10 to 50 extra kg of water for workability.( add to 30kg ) AIR VOIDS 1. Air entrapped readily visible 2. Air entrained- barely visible, beneficial. These tiny bubbles absorb pressure built up w/in concrete. ADMIXTURES 1. Air entraining Admixture- derivatives from oil, soil, fat, resin, etc.

2. Chemical Admixture a. Type A, Water reducing Admixture- reduce amount of water required to produce concrete of a given slump or consistency. b. Type B,Retarding Mixture- slows down the early hardening of concrete. Slow hydration produces denser structure. c. Type C, Accelerating Admixture-speeds up initial and final set, faster development of strength. d. Type D, Water Reducing and Retarding Mixture e. Type E, Water Reducing and Accelerating Mixture f. Type F, Water Reducing, High Range Admixture- super plasticizers or fluidizers: Do not have undesirable effect at high dosage. 3. Mineral Admixture- modifies the properties of concrete, or as a partial cement replacement to lower the cost. a. Fly Ash- from stack emission of coal combustion, fineness similar to cement. Use at a rate of 30-150 kg / m3. Class F- pozzolanic; reacts chemically with cement hydration. Class C- cementitious; can give strength by itself when mixed w/ water. b. Ground Granulated Blast Furnace Slag (GGBF Slag) mineral admixture. But it is in reality a hydraulic cement; it gains considerable strength when mixed with water. Replaces cement at a rate of 15 to 70 %. Derived from a by-product of the manufactured iron. c. Micro Silica/ Silica Fume- by-product of the production of silicon metals. An extremely fine powder, finer than cigarette smoke.it is handled as slurry mixed with water or as densified powder. (20 to 70 kg per cu m). Low permeability & high strength but is more susceptible to cracking (plastic shrinkage). Alkali-Silica Reactivity (ASR) - a gel is produced w/c increases in volume by taking up water and so exerts expansive pressure resulting to serious expansion & cracking in concrete. Sulfate Attack on ConcreteEttringite Formation- occurs in high temperature curing, above 70 degrees Celsius. - Hydrous calcium aluminum sulfate mineral, crystallizes in voids/ cracks. Soundness- volume stability of a cementitious paste The lower the water cement ratio, the higher the strength. Concrete Curing- maintaining sufficient moisture and a favorable temperature. (7 -14 days) 1. By maintaining a moist environment: spraying, steam, saturated cover materials such as earth, sawdust, hay or burlap. 2. By preventing loss of mixing water: sealing with impervious sheets or application of member forming curing compound to freshly placed concrete. DESIGN OF CONCRETE MIX 1. Choice of slump (for consistency of mixture) 2. Choice of maximum size of aggregate 3. Estimate amount of mixing water and water content 4. Select water cement ratio 5. Calculate cement content 6. Estimate quantity of fine and coarse aggregates 7. Adjust moisture content of aggregates 8. Check mixture proportion by testing trial batches

Specified Strength MPa 27.6 25.8 24.1 20.7 17.2

Water cement ratio By weight 0.44 0.48 0.51 0.58 0.65

Usual Initial Mixing time: 1 minute for cubic meters.

PLACING OF CONCRETE-It should be placed in horizontal layers not exceeding 60 cm in depth, avoiding inclined layers and cold joint. Cold Joint- when fresh concrete is poured on top or adjacent to a concrete that has already begun to set up.(that is why vibration is needed). Internal Vibration- most effective method of consolidating concrete. (8300 to 960 impulses per minute under a load at a maximum spacing of 60 cm)

PORTLAND CEMENT CONCRETE PAVEMENT

Fine Aggregate - Shall not contain more than 3% of materials passing # 200, - 1% of clay lumps or shale - When subjected to 5 cycles of sodium sulfate soundness test, the weighted loss shall not exceed 10%. Coarse Aggregate - Shall not contain more than 1% of materials passing # 200, - 0.25% of clay lumps or shale - When subjected to 5 cycles of sodium sulfate soundness test, the weighted loss shall not exceed 12%. Reinforcing Steel - Tie bars shall be deformed bars. - Dowels shall be plain round bars. - of the length of the dowel shall be painted with 1 coat of approved lead or tar paint. - Sleeves shall be metal. Joint Filler- asphalt and mineral or rubber filler. Proportioning, Consistency and Strength of Concrete -Slump between 40-75, if vibrated. -Flexural Strength of not less than 3.8 Mpa (midpoint),4.5 Mpa (third point) -Compressive Strength of 24.1 MPa when tested at 14 days. Mixing Concrete y In central Mixing Plant: Mixing Time shall not less be than 50 seconds nor more than 90 seconds. y The time elapsed the water is added to the mix until the concrete is deposited in place shall not exceed 45 minutes. y Retempering of concrete is only permitted in concrete delivered in truck mixers, provided that these shall be performed within 45 minutes after the initial mixing operation and the water cement ratio is not exceeded. y Concrete not in place within 90 minutes from the time the ingredients were charged to mixing drum or that has developed initial set shall not be use. Placing Concrete y Vibrators shall not be operated longer than 15 seconds in one location. Joints y Tie bars shall not be painted or coated with asphalt or other material or enclosed in sleeve. y Transverse expansion joint. Finished joint shall not deviate more than 6 mm from a straight line. y Transverse Contraction Joint shall consist of plane of weakness by cutting grooves in the surface of the pavement. Sawing shall commence as soon as the concrete hardened sufficiently usually within 24 hours.

No transverse joint shall be constructed within 1.5 m of the expansion joint, contraction joint or plane of weakness.

Load Transfer Device y The sleeve for the dowel shall be metal designed to cover 50 mm plus or minus 5 mm of the dowel.

Finishing y Concrete shall be screeded as soon as placed.Screed shall be 2 ft. longer than the maximum width of the slab. Surface Test y As soon as the concrete has hardened, the pavement surfaceshall be tested using the 3 meter straight edge. Areas showing high spot of more than 3 mm but not exceeding 12 mm shall be ground down with and approved grinding tool. If it exceeds 12 mm, the pavement shall be removed and replace. y Any areas so removed shall be not less than 1.5 m in length and not less than the full width of the lane involved. Removal of Forms y Forms shall be in place undisturbed for not less than 24 hours after concrete pouring. Acceptance of concrete y Strength will be considered satisfactory if the average of all sets of three consecutive test results equal or exceed the specified strength, and no individual test result is deficient by more than 15 of the specified strength. y Concrete represented by cores may be considered adequate if the average strength is equal to at least 85 % of, if no single core is less than 75 % of the specified strength. Pavement thickness and tolerance y Completed pavement shall be accepted by lot. A lot is equal to 1000 lm (single lane) or 500 lm (two lanes) .The last units in each slab can be considered as lot when its length is at least of the normal lot length.--------------Concrete Pipe 1. Non reinforced concrete sewer, storm drain and culvert pipe. 2. Reinforced concrete sewer, storm drain and culvert pipe.

3. Perforated Pipe. 4. Porous concrete pipe. Sampling and Testing: 0.5% of the number of pipes each size but not less than two and not to exceed five.

Hollow Blocks 1. Load Bearing Block-capable of carrying superimposed load, may be exposed to weather. Strength Requirement: Individual: 500 psi (5.45 MPa) min Average: 600 psi (4.14 Mpa) min 2. Non-Load Bearing- not exposed to weather. Strength Requirement: Individual: 800 psi (5.5 MPa) min Average: 1000 psi (6.9 Mpa) min Absorption: 240 kg/m max Moisture Content: 25% max Sampling and Testing: to be submitted for testing: 6 units for each lot of 10,000. 12 units for more than 10,000 units. 6 units from 50,000. REINFORCING STEEL- used primarily to control cracking. Sampling: one meter long specimen to present 10,000 kg of steel bars of each size. Testing: maximum phosphorous content of only 0.10%. Tension Test is done by subjecting the specimen with an effective gage length of200 mm tensile stress and determining the maximum load that the bar can resist before breaking. 60,000 psi (414 Mpa) - Grade 60 40,000 psi (276 Mpa) - Grade 40 Bar Diameter mm 10 12 16 20 22 25 28 32 36 Nominal weight Kg/m 0.560 0.994 1.552 2.535 3.042 3.973 4.96 6.403 7.906

GALVANIZED IRON SHEETS, STEEL SHEETS AND COILS Test shall be made from one sheet in each 2500 sheets. Coating of Zinc- protection against corrosion.

1. Triple Spot Test 2. Single Spot Test 3. Coating Bend Test- shall stand bending through 180 at room temperature without bending.

PAINTS Prime Pigment low refractive index, classified as extenders. Aluminum Paint- primer for woods Zinc Oxide- readily wetted by oil, tends to thicken the paint and retards the setting of the pigment. White Lead- ability to impart to the paint all the properties necessary to a successful paint performance. Colored Pigments- iron oxide and red lead. Linseed oil- drying oil. Sampling- 4 L or 20 L cans for every lot of 100cans of paint

ASPHALT TECHNOLOGY
Cracks 13 mm (1/2 in) is usually sealed with asphalt mix. If the slab is broken to the point where it cannot be undersealed, it should be further broken into pieces less than 0. 3 m (12 in) in diameter, rolled and sealed. 1. Pavement Condition Survey- 10 to 20 slabs. Identify type, extent and severity of pavement distress. 2. Nondestructive Testing- Deflection measurement shall be taken at joints and cracks to determine loss of support exist. Performed using NDT devise that delivers 8000 to 10000 lb (356 to 445 kN) load to the pavement. Reflection Cracking- fractures in an overlay or surface that reflects the crack or joint pattern. Methods to minimize cracking: 1. Design a thicker asphalt overlay.- may be used if cracking is less than 9 inches (229 mm). 2. Crack and Seal.- break and seal . Cracking PCC into small segments with heavy rollers to eliminate underlying voids and overlaying with asphalt. The segment is usually 4 to 6 ft2 (0.37-0.56 m2). 3. Crack Relief Layer in Overlays.- It is placed as the first course of an overlay system, 3.5 in (90 mm) layer of course open graded asphalt containing 25 to 35 interconnecting voids and is made up of 100% crushed material. 4. INLAYING- for extensive cracking. The work consists of removing the damaged pavement and replacing of sub base courses and subgrade if necessary. TYPICAL CROSS SECTION OF OVERLAY WITH CRACK RELIEF LAYER 1. Existing Pavement 2. Tack Coat- to ensure sufficient bond. 3. Open Graded Hot Mix Asphalt- 3.5 in (88.9 mm) 4. Dense graded intermediate Binder or leveling course for smooth foundation,2 to 4 in (51 -102 mm) thick. 5. Dense Graded Surface / Wearing Course - 1.5 in (38 mm) Open graded aggregate- aggregate with no mineral filler, compacted with relatively large voids. Materials used for producing Asphalt: a. Aggregates constituting mineral Skeleton .

b. Bituminous Binder. Fines/ Fillers- minerals from sound rock, may contain cement or lime. It increases stability and quality of mixture. Mineral Powder- filler for hot asphalt mixture. It is produced by crushing limestone or igneous rock and shall contain 1% water and free of agglomerators. Agglomerates are coarse accumulations of large blocks of volcanic material with mass of molten rock(no grain, w/c make it extrusive).

Different Types of Plant Mixes 1. Bitumenous Mortars.- fillers, sand, binders 2. Bitumenous Macadams-comprise in addition, one or more sizes of chippings. 3. Bitumenous Concrete.-excellent quality. Binder Content Mortar- 6-10% Bitumen Macadam- 4-7% (dense), 4-5% (open) Bituminous Concrete-5-8% P= (Weight of Bitumen/ Total Weight of Mix)x 100 A. SUBBASE COURSE y CBR not less than 25% y PI (passing 0.425 ) < 12 , max size under 50 mm B. BASE COURSE y Max size of aggregate for Grade A and B are 50 mm and 37.5 mm respectively. y PI<6 PLACING- 150mm thickness or less (one layer). Where the required thickness is more than 150 mm, the sub base/base course shall be spread and compacted in two or more layers of approximately equal layers and the compacted thickness of any one layer shall not exceed 150 mm.

y y y y

MARSHALL MIX DESIGN- The main idea of the Marshall Mix Design method involves the selection of the asphalt binder content with a suitable density which satisfies minimum stability and range of flow values. Optimum Binder Content- aggregates are fully coated with bitumen and the voids are sealed up. Marshall Stability is the resistance to plastic flow of cylindrical specimens of a bituminous mixture loaded on the lateral surface. Blue smoke indicates overheated asphalt. Hard Blown Asphalt is also known as Oxidized Bitumen produced by passing air through soft bitumen under controlled temperature conditions which gives the bitumen more rubbery properties.

ITEM 301- BITUMENOUS PRIME COAT- (initial treatment on base before surfacing with granular material) treatment of an aggregate base course in preparation for bituminous surface course. 1. RAPID CURING (RC) CUTBACK ASPHALT- asphalt cement with low boiling point petroleum distillate such as gasoline and naphtha.

2. MEDIUM CURING (MC) CUTBACK ASPHALT-with light petroleum distillate such as kerosene. y y y y y y Do not apply on foggy or rainy weather. Sprayed by pressure distributor of not less than 1000 liters capacity mounted on pneumatic tires w/c produces load of not more than 1N (100kgf) per cm width of tire. Rate of application shall be 1-2 liters / square meter. Prime coat should not be disturbed for at least 24 hours. Areas not accessible shall be sprayed manually. Rate of application shall be 0.2 to 0.7 liters per square meters (for manual application)

ITEM 302-BITUMENOUS TACK COAT-preparation and treatment of bituminous or concrete surface with bituminous material in preparation for the construction of bituminous surface course. 1. 2. y y RAPID CURING (RC) CUTBACK ASPHALT EMULSIFIED ASPHALT-asphalt cement and water with a small quantity of an emulsifying agent. (same above) Pressure distributor should have heating device.

ITEM 310-BITUMENOUS CONCRETE SURFACE COURSE, HOT LAID- laid on a prepared base. Tolerances for the job mix formula: y y y y y Passing No. 4 and large sieves Passing No. 8 to No. 100 sieves Passing No. 200 sieve Bituminous Material Temperature of mixture +-7% +-4% +-2% +-0.4% +-10 degrees Celsius

New job mix formula shall comply with the ff. requirements y y y Minimum dry compressive strength -1.4 MPa (200 psi) Mass % Voids 5-7% Index of Retained Strength- not less than 70.

Accepting, Sampling and Testing y y y y Core drill, 150 x150 100 mm diameter full depth. At least one but not more than 3 samples taken each day or operation. 90% or greater of the Laboratory Specimen --Density of the compacted pavement. Variation of the pavement surface (from the contract) shall not exceed 6 mm. (measured using 3 m straight edge after the initial compaction). Placing temperature for the mixture should not be less than 107 degrees Celsius (225 deg F)

PHASES OF ROLLING 1. Breakdown Rolling- carried out by steel wheeled rollers and mix should be 200-225 F. 2. Intermediate Rolling- Carried out by Pneumatic Roller. 3. Final Rolling- to remove marks made by other rollers.