National Academies Press: OpenBook

Guideline and Recommended Standard for Geofoam Applications in Highway Embankments (2004)

Chapter: Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground

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Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
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Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
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Page 54
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Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
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Page 55
Page 56
Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
×
Page 56
Page 57
Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
×
Page 57
Page 58
Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
×
Page 58
Page 59
Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
×
Page 59
Page 60
Suggested Citation:"Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground." National Academies of Sciences, Engineering, and Medicine. 2004. Guideline and Recommended Standard for Geofoam Applications in Highway Embankments. Washington, DC: The National Academies Press. doi: 10.17226/13759.
×
Page 60

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Recommended EPS-Block Geofoam Standard for Lightweight Fill in Road Embankments and Bridge Approach Fills on Soft Ground

RECOMMENDED EPS-BLOCK GEOFOAM STANDARD FOR LIGHTWEIGHT FILL IN ROAD EMBANKMENTS AND BRIDGE APPROACH FILLS ON SOFT GROUND 1 SCOPE 1.1 This document is a recommended material, product, and construction standard covering block-molded expanded polystyrene (EPS) for use as a geofoam geosynthetic product (EPS-block geofoam) in road applications involving embank- ments and related bridge approach fills on soft ground. This document is a recommended material purchasing standard, and project-specific review of its use is required. 1.2 This document is not a recommended design stan- dard, but includes technical information used in design. This document is intended to be used in conjunction with the recommended design guideline. All information concerning this report should be obtained from the Transportation Research Board (TRB). 2 REFERENCED DOCUMENTS 2.1 AASHTO Standards: none. 2.2 ASTM Standards:1 • C 578-95—Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation. • C 303-98—Standard Test Method for Dimensions and Density of Preformed Block and Board-Type Thermal Insulation. 2.3 NCHRP reports:2 • NCHRP Web Document 65: Geofoam Applications in the Design and Construction of Highway Embankments. 3 TERMINOLOGY For the purposes of this standard, the following terminol- ogy is used for the various parties involved: • Contractor: The company having the direct contractual relationship with the owner for construction of the pro- posed embankment and responsibility for its overall construction. • Designer: The organization (typically a government agency or private consulting company) having respon- sibility for the design of the portions of the project that include the proposed embankment. • Molder: The company actually manufacturing the EPS blocks used as the EPS-block geofoam for the proposed embankment. • Primary Molder: When more than one molder will sup- ply EPS blocks to a project under a given contract, this is the molder who is selected or designated as having authority to conduct business on behalf of all molders and who is ultimately responsible for the product qual- ity of all molders. • Owner: The government agency having contractual authority over the proposed embankment at the time of its construction. This may or may not be the government agency having final ownership or jurisdiction over the operation and maintenance of the proposed road. For example, a state department of transportation (DOT) may oversee construction on behalf of a local (i.e., county or town) jurisdiction. In this case, the DOT would be con- sidered the owner for the purposes of this recommended standard. • Owner’s Agent: The organization (typically a govern- ment agency or private consulting company) having re- sponsibility for inspection during construction of the pro- posed embankment. This organization may or may not be the designer. • Supplier: The company having the contractual relation- ship with the contractor for the supply of the EPS-block geofoam. This company may be the molder or primary molder directly or an intermediary company (typically a distributor of construction and/or geosynthetic products manufactured by others). 4 PRODUCT MANUFACTURING QUALITY CONTROL REQUIREMENTS 4.1 Manufacturing quality control (MQC) of the EPS- block geofoam product is the primary responsibility of the molder or primary molder. The purpose of this section is to define the parameters for use by a molder or primary molder in developing an MQC plan. These parameters will also be those measured as part of the manufacturing quality assurance (MQA) to be conducted by the owner’s agent. MQA requirements are detailed in sections 5, 6, and 8 of this standard. 4.2 All EPS-block geofoam shall consist entirely of expanded polystyrene. At the discretion of the molder or primary molder, the EPS-block geofoam may consist of some 1 Available from the American Society for Testing and Materials; 100 Barr Harbor Drive; West Conshohocken, Pennsylvania 19428-2959. 2 Available from the Transportation Research Board; 500 Fifth St., N.W.; Washington, D.C., 20001. http://gulliver.trb.org/publications/nchrp/nchrp_w65.pdf. 1 R ECO M M ENDED EPS-BLO CK G EO FO AM STANDARD

mixture of virgin raw material and recycled EPS material. However, if regrind is to be used, its use shall be clearly stated by the molder or primary molder as part of the Phase I MQA, pre-construction, pre-certification process described in Section 6. The source of the regrind (block-molded versus shape-molded EPS, in-plant versus post-consumer) shall also be stated clearly. 4.3 All EPS-block geofoam shall be adequately seasoned prior to shipment to the project site. For the purposes of this standard, seasoning is defined as storage in an area suitable for the intended purpose as subsequently defined herein for a minimum of 72 hours at normal ambient room temperature after an EPS block is released from the mold. Seasoning shall be done within a building or other structure that protects the EPS blocks from moisture as well as ultraviolet (UV) radiation. The area in which EPS blocks are stored for seasoning shall also be such that adequate space is allowed between blocks and such that positive air circulation and venting of the structure are provided so as to foster the outgassing of blowing agent and trapped condensate from within the blocks. The owner’s agent shall be allowed to inspect the structure(s) to be used for seasoning upon request and during normal business days and hours. The molder or primary molder may request a shortened seasoning period if the EPS blocks are seasoned within an appropriate heated storage space and the molder or primary molder demonstrates to the satisfaction of the owner’s agent that the alternative seasoning treatment produces blocks that equal or exceed the quality of blocks subjected to the normal 72-hour seasoning period. 4.4 All EPS-block geofoam shall satisfy the product flammability requirements specified in ASTM C 578. 4.5 Table 1 indicates the AASHTO material type designations used for the different densities/unit weights of EPS blocks that are covered by this standard. Only these material type designations shall be used in any correspondence or other communication related to this project. For a given material type, the dry density/unit weight of each EPS block (as measured for the overall block as a whole) after the period of seasoning, as defined in Section 4.3, shall equal or exceed that shown in Table 1. The dry density/unit weight shall be determined by measuring the mass/weight of the entire block by weighing the block on a scale and dividing the mass by the volume of the block. The volume shall be determined by obtaining dimensional measurements of the block in accordance with ASTM test method C 303. 4.6 Table 2 gives the minimum allowable values of various material parameters corresponding to each AASHTO material type shown in Table 1. These material parameters are to be obtained by testing specimens prepared from samples 2 taken from actual blocks produced for the project. The actual blocks should be covered by this standard for either MQC by the molder or MQA by the owner’s agent as described in Section 8 of this standard. All test specimens shall be seasoned as specified in ASTM C 578. Dry density/unit weight, compressive strength, and flexural strength shall be measured as specified in ASTM C 578. The specimens used for compressive testing shall be cubic in shape with a 50-mm (2-in.) face width. A strain rate of 10 percent per minute shall be used for the compressive strength tests. Both the elastic- limit stress and the initial tangent Young’s modulus shall be determined in the same test used to measure compressive strength. The elastic-limit stress is defined as the measured compressive normal stress at a compressive normal strain of 1 percent. The initial tangent Young’s modulus is defined as the average slope of the compressive stress versus compressive strain curve between 0-percent and 1-percent strain. 4.7 Each EPS block shall meet dimensional tolerances, as determined in three distinct areas: • Variations in linear dimensions, as defined in Section 4.8. • Deviation from perpendicularity of block faces, as defined in Section 4.9. • Overall warp of block faces, as defined in Section 4.10. 4.8 The thickness, width, and length dimensions of an EPS block are defined herein as the minimum, intermediate, and maximum overall dimensions of the block, respectively, as measured along a block face. These dimensions of each block shall not deviate from the theoretical dimensions by more than 0.5 percent. 4.9 The corner or edge formed by any two faces of an EPS block shall be perpendicular, i.e., form an angle of 90 degrees. The deviation of any face of the block from a theo- retical perpendicular plane shall not exceed 3 mm (0.12 in.) over a distance of 500 mm (20 in.). 4.10 Any one face of a block shall not deviate from planarity by more than 5 mm (0.2 in.) when measured using a straightedge with a length of 3 m (9.8 ft). 5 PRODUCT MANUFACTURING QUALITY ASSURANCE: GENERAL REQUIREMENTS 5.1 MQA of the EPS-block geofoam product will be conducted to verify the molder’s MQC procedures. The owner’s agent will have primary responsibility for all MQA unless the owner notifies the contractor otherwise. The TABLE 1 AASHTO material type designations for EPS-block geofoam Material Designation Minimum Allowable Density/Unit Weight, kg/m3 (lbf/ft3) AASHTO (proposed) ASTM C 578 Each Block as a Whole Any Test MQC/MQA Specimen EPS40 I 16 (1.0) 15 (0.90) EPS50 VIII 20 (1.25) 18 (1.15) EPS70 II 24 (1.5) 22 (1.35) EPS100 IX 32 (2.0) 29 (1.80) R EC O M M EN DE D EP S- BL O CK G EO FO AM S TA ND AR D

owner’s agent will communicate directly only with the con- tractor in matters and questions of MQA unless all parties agree otherwise. 5.2 MQA of the EPS-block geofoam will consist of two phases. Phase I MQA consists of pre-certification of the molder and shall be conducted prior to shipment of any EPS blocks to the project site. Phase I MQA is covered in Sec- tion 6 of these specifications. Phase II MQA shall be conducted as the EPS blocks are delivered to the project site and is discussed in Section 8 of these specifications. Table 3 provides a summary of the MQA procedures. 6 PRODUCT MANUFACTURING QUALITY ASSURANCE: PHASE I 6.1 No EPS blocks shall be shipped to the project site until such time as all parts of Phase I MQA have been com- pleted in the order listed and as specified in this section. 6.2 The contractor shall first indicate in writing to the owner’s agent whether the molder has a third-party certification program in force. When there are multiple molders, each 3 molder must have a program in order for third-party certifi- cation to be indicated, and the primary molder must take responsibility for coordinating the third-party certification of all molders. 6.3 If third-party certification is offered, this notification shall be accompanied by documentation that identifies the business entity providing the third-party certification and de- scribes in detail the steps to be taken by this agency to verify the molder’s compliance with the specific requirements of this specification. Acceptance of the molder’s third-party certification by the owner’s agent will waive the need for pre- construction product submittal and testing as specified in Section 6.4. When there are multiple molders, third-party certification must be acceptable for each and every molder; otherwise, it will be denied for each and every molder. 6.4 If the molder does not have third-party certification or the certification is deemed unacceptable by the owner’s agent, the contractor shall deliver a minimum of three full- size EPS blocks for each AASHTO EPS-block geofoam type to be used on the project to a location specified by the owner’s agent. When there are multiple molders, there shall be three blocks from each molder. These blocks shall in all Material Designation Dry Density/ Unit Weight, kg/m3 (lbf/ft3) Compressive Strength, kPa (lbs/in2) Flexural Strength, kPa (lbs/in2) Elastic Limit Stress, kPa (lbs/in2) Initial Tangent Young's Modulus, MPa (lbs/in2) EPS40 15 (0.90) 69 (10) 173 (25) 40 (5.8) 4 (580) EPS50 18 (1.15) 90 (13) 208 (30) 50 (7.2) 5 (725) EPS70 22 (1.35) 104 (15) 276 (40) 70 (10.1) 7 (1015) EPS100 29 (1.80) 173 (25) 345 (50) 100 (14.5) 10 (1450) TABLE 2 Minimum allowable values of MQC/MQA parameters for individual test specimens Phase Sub- phase Start of Phase Description Requirements Possible Actions I None Prior to shipment to the project site Pre- certification of the molder Approved third-party certification: Molder will • Identify the organization providing this service. • Provide detailed information as to the procedure and tests used by this organization to verify the molder’s compliance with the specific requirements of this specification. • Provide written certification that all EPS blocks supplied to the project will meet the requirements specified in the project specifications. No approved third-party certification: • Contractor shall deliver a minimum of three full-size EPS blocks for each AASHTO EPS- block geofoam type to be used on the project to a location specified by the owner's agent. • Owner's agent will weigh, measure, sample, and test a random number of blocks. Sampling and testing protocol will be the same as for Phase IIc MQA. • Molder should submit a letter stating that all EPS blocks supplied for the project are warranteed to meet specification requirements and identifying what MQC measures the molder employs. • Acceptance of the molder’s third-party certification by the owner’s agent will waive the need for pre-construction product submittal and testing. • No EPS blocks shall be shipped to the project until such time as all parts of Phase I MQA have been completed. TABLE 3 MQA procedures for EPS-block geofoam used for the function of lightweight fill in road embankments (continued on next page) R ECO M M ENDED EPS-BLO CK G EO FO AM STANDARD

4II IIa As the EPS blocks are delivered to the project site On-site visual inspection of each block delivered to the project site to check for damage as well as visually verify the labeled information on each block Approved third-party certification: • For each truckload, owner’s agent should inventory each and every block. No approved third-party certification: • For each truckload, owner’s agent should inventory each and every block. • Any blocks with significant physical damage or not meeting specifications will be (a) rejected on the spot and placed in an area separate from those blocks that are accepted or (b) marked “unacceptable” and returned to the supplier. II IIb As the EPS blocks are delivered to the project site On-site verification that the minimum block dry density, as well as the physical tolerances, meet specifications Approved third-party certification: • For each truckload, initially, only one block per load should be tested to ensure that the minimum block dry density, as well as the physical tolerances, meet specifications. No approved third-party certification: • For each truckload, each block for the first load and at least one block per load for subsequent truckloads should be tested to ensure that the minimum block dry density, as well as the physical tolerances, meet specifications. • If the selected block meets specifications with respect to its size and shape, and the mass agrees with the mass marked on the block, no further checking of the load for these parameters is required and the shipment is approved conditionally until the Phase IIc test results verify that the block meets specifications. • If the selected block does not meet specifications, then other blocks in the truckload should be checked and none used until the additional checking has determined which blocks are unsatisfactory. • At the completion of this subphase, the construction contractor should be conditionally (until the Phase IIc test results verify that the blocks meet specifications) allowed to proceed with installing blocks. Phase Sub- phase Start of Phase Description Requirements Possible Actions II IIc As the EPS blocks are delivered to the project site Confirming the EPS engineering design parameters related to stiffness as well as the quality control strength parameters Approved third-party certification: • Use the discretion of the owner’s CQA agent. For example, parameter confirmation can be omitted entirely on a small project, can be performed only at the beginning of a project, or can be done on an ongoing basis. No approved third-party certification: • Parameter confirmation should be performed on all projects throughout the entire duration of the project. • For each AASHTO EPS-block geofoam type, at least one block will be selected for sampling from the first truckload. • Additional blocks may be selected at a rate of sampling not exceeding one sample for every 250 m3 (325 yd3). • Sampling is to be performed per the locations indicated in Table 2. • Laboratory tests should be performed to check for compliance with the parameters shown in Table 2 to include the elastic- limit stress, initial tangent Young’s modulus, compressive strength, and flexural strength. • Portions of sampled blocks that are not damaged or otherwise compromised by the sampling can be used as desired by the contractor. • If unsatisfactory test results are obtained, the contractor may be directed to remove potentially defective EPS blocks and replace them with blocks of acceptable quality at no additional expense to the owner. II IId As the EPS blocks are placed As-built drawing(s) • The owner’s agent, with the cooperation of the contractor, will prepare as-built drawing(s) as well as perform additional record keeping to document the location of all EPS blocks placed for the project. Note: A truckload of EPS blocks is intended to mean either a full-length box-trailer or a flat-bed trailer of typical dimensions, i.e., approximately 12 m (40 ft) or more in length, fully loaded with EPS blocks. The volume of EPS in such a truckload would typically be on the order of 50 to 100 m (65 to 130 yd ). 3 3 TABLE 3 (Continued) R EC O M M EN DE D EP S- BL O CK G EO FO AM S TA ND AR D

respects be the same as blocks to be supplied to the project, including required seasoning as described in Section 4.3. The owner’s agent will weigh, measure, sample, and test a random number of blocks to evaluate the ability of the molder(s) to produce EPS-block geofoam of quality as spe- cified herein. The sampling and testing protocol will be the same as for Phase II MQA as discussed in Section 8. 6.5 If required by the contract documents, the contractor shall submit shop drawings indicating the proposed location and layout of all EPS blocks to be placed during the project. When there are multiple molders, the areas to be covered by each molder shall be clearly identified. These drawings shall be reviewed by the owner’s agent. The block layout shall be designed so that the following general design details are taken into account: • The plane on which a given layer of blocks is placed must be parallel to the longitudinal axis of the road alignment. • There must be a minimum of two layers of blocks at all locations. • Within a given layer of blocks, the longitudinal axes of all blocks must be parallel to each other. • Within a given layer of blocks, the vertical joints be- tween the adjacent ends of blocks within a given row of blocks must be offset to the greatest extent practicable relative to blocks in adjacent rows. • The longitudinal axes of blocks for layers above and/or below a given layer must be perpendicular to the longi- tudinal axes of blocks within that given layer. • The longitudinal axes of the uppermost layer of blocks must be perpendicular to the longitudinal axis of the road alignment. 6.6 Prior to delivery of any EPS-block geofoam to the project site, a meeting shall be held between, at a minimum, the owner’s agent and contractor. The supplier and/or molder/ primary molder of the EPS-block geofoam may also attend at the contractor’s discretion to answer any questions. The purpose of this meeting shall be to review the Phase I MQA results and discuss the Phase II MQA as well as other aspects of construction to ensure that all parties are familiar with the requirements of this standard. At the satisfactory conclusion of this meeting, the contractor shall be allowed to begin on- site receipt, storage (if desired), and placement of the EPS- block geofoam. 7 PRODUCT SHIPMENT AND STORAGE 7.1 Each EPS block shall be labeled to indicate the name of the molder (if there is more than one supplying a given project), the date the block was molded, the mass/ weight of the entire block (in kilograms or pounds) as measured after a satisfactory period of seasoning as specified in Section 4.3, the dimensions of the block in millimeters or inches, and the actual dry density/unit weight in kilograms 5 per cubic meter or pounds per cubic foot. Additional markings using alphanumeric characters, colors, and/or symbols shall be applied as necessary by the supplier to indicate the location of placement of each block relative to the shop drawing indicated in Section 6.5 of this specification, as well as the density of the block if multiple block densities are to be supplied for a given project. If multiple block densities /unit weights are to be supplied, the use of no marking shall be considered an acceptable marking for one of the densities as long as it is used for the lower (or lowest) density/unit weight EPS blocks supplied to the project. 7.2 At all stages of manufacturing, shipment, and con- struction, the EPS blocks shall be handled in a manner so as to minimize physical damage to the blocks. No method of lifting or transporting the blocks that creates dents or holes in the block surfaces or losses of portions of the block shall be allowed. 7.3 If the EPS blocks are to be stockpiled at the project site until placement, a secure storage area shall be designated for this purpose. The storage area shall be away from any heat source or construction activity that produces heat or flame. In addition, personal tobacco smoking shall not be allowed in the storage area. EPS blocks in temporary on-site storage shall be secured with sandbags and similar “soft” weights to prevent their being dislodged by wind. The blocks shall not be covered in any manner that might allow the buildup of heat beneath the cover. The blocks shall not be trafficked by any vehicle or equipment. In addition, foot traffic by persons shall be kept to a minimum. 7.4 EPS is not an inherently dangerous or toxic material, so there are no particular safety issues to be observed other than normal construction safety and protection against heat and flame, as specified in Section 7.3. However, extra caution is required during wet or cold weather. Surfaces of the EPS blocks tend to be more slippery when wet than when dry. In addition, when air temperatures approach or go below freezing, a thin layer of ice can readily develop on the exposed surfaces of EPS blocks if the dewpoint is sufficiently high. Thus, the surfaces of the EPS blocks can pose particular slip hazards in this condition. 8 PRODUCT MANUFACTURING QUALITY ASSURANCE: PHASE II 8.1 Phase II MQA will be performed by the owner’s agent as the EPS blocks are delivered to the project site. Phase II MQA will consist of four subphases (IIa through IId). The contractor shall cooperate with and assist the owner’s agent in implementing Phase II MQA. 8.2 Phase IIa MQA will consist of on-site visual in- spection of each block delivered to the project site to check for damage and to visually verify the labeled information on each block. Any blocks with damage or not meeting specifi- cations will be (a) rejected on the spot and placed in an area separate from those blocks that are accepted or (b) marked “unacceptable” and returned to the supplier. R ECO M M ENDED EPS-BLO CK G EO FO AM STANDARD

8.3 Phase IIb MQA will consist of on-site verification that the minimum block dry density/unit weight, as well as the physical tolerances specified in Sections 4.8 through 4.10, meets specifications. At least one truckload will be checked, and additional blocks will be checked if initial measurements indicate lack of compliance. A truckload of EPS blocks is defined as either a full-length box-trailer or a flat-bed trailer of typical dimensions, i.e., approximately 12 m (40 ft) or more in length, fully loaded with EPS blocks. The volume of EPS in such a truckload would typically be on the order of 50 to 100 m3 (65 to 130 yd3). The contractor shall supply a scale on site with sufficient capacity and precision for weighing of EPS blocks. This scale shall be recently calibrated, and certification of such calibration shall be made available to the owner’s agent. 8.4 Phase IIc MQA will consist of sampling the EPS blocks and laboratory testing specimens prepared from these samples. Sampling will be at the locations shown in Figure 1. The laboratory tests will check for compliance with the parameters shown in Table 2. The contractor shall cooperate with and assist the owner’s agent with obtaining the neces- sary samples. Testing will be by or under the direction of the owner’s agent. For each density/unit weight of EPS used on a project, at least one block will be selected for sampling from the first truckload of EPS blocks of that density delivered to the job site. Additional blocks may be selected for sampling during the course of the project at the discretion of the owner’s agent at a rate of sampling not to exceed one sample for every 250 m3 (325 yd3) of EPS delivered. Portions of sampled blocks that are otherwise acceptable can be used as desired by the contractor. The owner’s agent will make every reasonable effort to conduct the laboratory testing expeditiously. However, if unsatisfactory test results are obtained, the contractor may be directed to remove potentially defective EPS blocks and replace them with blocks of acceptable quality at no additional expense to the owner. 8.5 Phase IId MQA will consist of preparation of an as-built drawing or drawings, as well as additional record keeping to document the location of all EPS blocks placed 6 for the project. The contractor shall cooperate with and assist the owner’s agent with this phase. 9 CONSTRUCTION QUALITY REQUIREMENTS 9.1 The contractor shall be directly responsible for all construction quality control (CQC). Items covered by CQC include all earthwork and related activities other than manu- facturing and shipment of the EPS-block geofoam. Items of particular relevance to the placement of EPS-block geofoam are given in Sections 10 through 12. 9.2 The owner’s agent will be responsible for providing construction quality assurance (CQA) of the contractor’s construction activities. 10 SITE PREPARATION 10.1 If required by the contract drawings, the natural soil subgrade shall be cleared of vegetation and any large or sharp-edged soil particles and be reasonably planar prior to placing a geotextile and/or sand bedding layer. If no sand bedding layer is used, the natural subgrade shall be cleared such that there is no vegetation, or particles of soil or rock larger than coarse gravel, exposed at the surface. 10.2 Regardless of the subgrade material (i.e., natural soils or sand bed), the subgrade surface on which the EPS blocks will be placed shall be sufficiently planar (i.e., smooth) prior to the placement of the first block layer. The required smoothness is defined as a vertical deviation of no more than 10 mm (0.4 in.) over any 3-m (9.8-ft) distance. 10.3 There shall be no debris of any kind on the subgrade surface when EPS blocks are placed. 10.4 Unless directed otherwise by the owner’s agent, there shall be no standing water or accumulated snow or ice on the subgrade within the area where EPS blocks are placed at the time of block placement. Top of Block (If Vertical Mold) or Fill End of Block (If Horizontal Mold) Test Specimen Sample H L H C B W L 4 L 2 W 4 W 2 A Figure 1. Recommended block sampling and test specimens.R EC O M M EN DE D EP S- BL O CK G EO FO AM S TA ND AR D

10.5 EPS blocks shall not be placed on a frozen subgrade except in the case of construction over continuous or dis- continuous permafrost terrain and as directed by the owner’s agent. 11 PLACEMENT OF EPS-BLOCK GEOFOAM 11.1 EPS blocks shall be placed at the locations shown on either the contract drawings or approved shop drawings sub- mitted by the contractor. Particular care is required if EPS blocks of different density/unit weight are to be used on the project. 11.2 EPS blocks shall be placed so that all vertical and horizontal joints between blocks are tight. 11.3 The surfaces of the EPS blocks shall not be directly traversed by any vehicle or construction equipment during or after placement of the blocks. 11.4 Blocks shall not be placed above blocks in which ice has developed on the surface. 11.5 With the exception of sand bags or similar “soft” weights used to temporarily restrain EPS blocks against wind, no construction material other than that shown on the contract drawings shall be placed or stockpiled on the EPS blocks. 7 R ECO M M ENDED EPS-BLO CK G EO FO AM STANDARD 11.6 At no time shall heat or open flame be used near the EPS blocks so as to cause melting or combustion of the EPS. 11.7 The final surface of the EPS blocks shall be covered as shown on the contract drawings. Care shall be exercised during placement of the cover material so as not to cause any damage to the EPS blocks. 12 PAVEMENT CONSTRUCTION 12.1 The pavement system is defined for the purposes of this standard as all material placed above the EPS blocks within the limits of the roadway, including any shoulders. 12.2 The pavement system shall be constructed above the EPS-block geofoam as shown on the contract drawings. Specifications covering construction of the pavement system are given elsewhere in the contract documents. 12.3 No vehicles or construction equipment shall traverse directly on the EPS blocks or on any separation material placed between the EPS blocks and the pavement system. Soil or aggregate for the pavement system layers shall be pushed onto the EPS blocks or separation layer using appropriate equipment such as a bulldozer or a front-end loader. A min- imum of 300 mm (12 in.) of soil or aggregate shall cover the top of the EPS blocks or separation layer before compaction commences.

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Guideline and Recommended Standard for Geofoam Applications in Highway Embankments Get This Book
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TRB National Cooperative Highway Research Program (NCHRP) Report 529: Guideline and Recommended Standard for Geofoam Applications in Highway Embankments includes a design guideline and recommended standard for geofoam applications in the design and construction of highway embankments.

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