SECTION 203: EXCAVATION, BORROW, AND EMBANKMENT

203.1 DESCRIPTION
This Work consists of performing excavation, providing borrow, constructing
Embankment, hauling, disposing, placing, and compacting Materials.
203.2 MATERIALS
The Department will provide geotechnical investigation and pavement investigation
results (when available) in the Contract documents. Use the results for information only.
203.2.1 Material Classifications
203.2.1.1 Rock Excavation
Rock excavation is material that meets one (1) of the following field test criteria:
1. Ripping Test. Material that can not be broken down by one pass with a single
tooth ripper mounted on a crawler-type tractor in low gear with a minimum net
flywheel power rating of 255 hp;
2. Seismic Test. Material that has a seismic velocity greater than 6,000 ft/s. Submit
the qualifications of the person performing and interpreting the seismic testing for
Project Manager Approval at least 14 Days before testing. Perform the Ripping Test
to resolve differences in material classification if seismic velocities fall below
6,000 ft/s;
3. Handling Test. Rock with a volume greater than 1 yd3 that cannot be readily
broken down with excavation Equipment.
203.2.1.2 Unclassified Excavation
Unclassified excavation is material other than rock excavation.
203.2.1.3 Borrow
Material from Contractor-provided sources required for Embankment, subexcavation
replacement or other Work approved by the Department.
203.2.1.4 Subexcavation
Subexcavation is existing material that is unsuitable. Unsuitable material is that with an
R-value less than the Contract R-value, or if Deleterious Material is present. Subexcavation
shall consist of excavating unsuitable material below established Profile Grade or typical
cross-section shown on the Plans, or as designated by the Project Manager. Voids created by
subexcavation shall be backfilled with approved material meeting the R-value requirements
shown in the Contract.
203.2.1.5 Unstable Subgrade Stabilization
Unstable Subgrade is defined as Subgrade that is soft, pumping, and/or displaces with
applied loading when encountered in non-borrow sections such as cuts or existing grades, due
to no fault or neglect of the Contractor.
203.3 CONSTRUCTION REQUIREMENTS
203.3.1 General
Finish excavation and Embankment for the Roadway, intersections, and entrances to
reasonably smooth and uniform surfaces. Do not remove Materials from the Project limits
without the approval of the Project Manager. Ensure the top 2 ft of the finished Subgrade
contains material with the design R-value. Preserve the Materials below and beyond the lines
Section 203: Excavation, Borrow, and Embankment Page 97
and grades while conducting excavation operations. Before beginning excavation, grading,
and Embankment operations, perform the necessary clearing and grubbing in accordance with
Section 201, Clearing and Grubbing. Notify the Project Manager before opening excavation
or borrow areas. Take cross section elevations of the ground surface before opening
excavation or borrow areas.
Terminate operations in the immediate area of environmental or Cultural Resources not
listed in the Contract, until the Department reviews and completes appropriate mitigation
actions in accordance with Section 107.12, Environmental and Cultural Resource
Discoveries.
Place excess or unsuitable excavated material (including rock and boulders unsuitable
for Embankments) in the toe of any fills, or use to flatten slopes of nearby fills. Place at least
2 ft of cover soil over the rocks and boulders. Dispose of excess or unsuitable material in
accordance with environmental requirements and as approved by the Project Manager.
203.3.2 Excavation
Within cut sections, remove excavated material from the limits of the cut section to the
Subgrade elevation for the width of the Roadbed. Finish Roadbed cut sections to a smooth
and uniform surface. Remove unsuitable or unstable material below finished Subgrade. Take
cross-sectional measurements after the removal of unsuitable and unstable material.
203.3.3 Rock Cuts
Perform proper drilling and blasting operations in accordance with the specified practices.
When required, perform controlled blasting of rock excavation to produce a clean face on the
excavated cut. Ensure subsequent blasting and excavation operations do not affect
previously excavated faces. Do not excavate more than six (6) inches below the specified
Subgrade elevation for Roadbed cuts in rock, unless directed otherwise. Do not leave
undrained pockets on the Roadbed surface. Place and compact Base Course on the rock cut
foundation in accordance with Section 304, Base Course.
203.3.3.1 Blasting Requirements
Use controlled blasting to establish a specified backslope with minimal blast damage, and
production blasting to facilitate excavation. Before the start of blasting, notify adjacent property
owners and occupants.
203.3.3.1.1 Definitions
Blasting Operations. Activities related to blasting including, but not limited to the
following:
1. Collaring and drilling blast holes;
2. Preparing, fixing, loading, and firing explosive charges;
3. Assessing the blast after detonation; and
4. Handling misfires.
Buffer Row. The first row of production blast holes immediately adjacent and drilled in
a plane parallel to the controlled blast line. The explosive load in the buffer row
should be reduced from standard production loads to minimize damage to the
backslope of the final excavation.
Controlled Blasting. The controlled use of explosives and blasting accessories in
carefully spaced and aligned blast holes to provide a free surface or shear plane in
the rock along the specified backslope, and to limit fly rock, permanent ground
displacement, air concussion, and overbreak. Controlled blasting methods include
pre-splitting and cushion blasting.
Cushion Blasting (Trim Blasting). The simultaneous detonation of one (1) line of blast
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holes along a specified excavation backslope after the main excavation is complete.
This method is performed to trim the excavation to the final backslope.
Final Line (Controlled Blast Line). Refers to the row of controlled blast holes drilled in
the plane of a specified excavation backslope. The controlled blast holes drilled in
this plane constitute the basis for payment under the Controlled Blasting pay item.
The Department considers the blast holes drilled in front of the final line blast holes
to be production blast holes, which are Incidental to the Rock Excavation pay item.
Pre-Splitting. The simultaneous detonation of one (1) line of blast holes drilled along a
specified excavation backslope before production blast holes are fired.
Production Blasting. Fragmentation blasting in the main excavation area.
203.3.3.1.2 Submittals
203.3.3.1.2.1 Blaster in Charge
Do not begin drilling or blasting Work until the Project Manager approves of the Blaster in
Charge. Submit the name and qualifications of the proposed Blaster in Charge to the Project
Manager for approval at least 30 Days before the delivery of explosive material to the Project.
Provide the following information:
1. Proof of a license by the applicable State and/or local regulatory agencies to
possess, transport, and use explosives;
2. A list of, and references, for at least three (3) blasting Projects, of similar complexity,
successfully completed within the previous five (5) years.
The Blaster in Charge must be on site during blasting operations.
203.3.3.1.2.2 Blasting Plans
Submit a General Blasting Plan to the Project Manager for each cut that requires
blasting, at least two (2) weeks before the start of drilling and blasting operations on a
specified cut. Provide the following information in the General Blasting Plan:
1. Description of the proposed blasting operation;
2. Preliminary design criteria for production and controlled blasting, including blast hole
depths and patterns; and
3. Details regarding the proposed explosives and blasting accessories;
Submit a Detailed Blasting Plan at least 48 h before an individual blast. Provide the
following information in the Detailed Blasting Plan:
4. Station limits of the proposed location of the blast, including the bench elevation, if
applicable;
5. Date and time the blasting will occur;
6. Required removal of overburden, if applicable;
7. Plan and cross section diagrams of proposed drill pattern for controlled and
production blast holes, including buffer rows, free face, burden, blast hole spacing,
blast hole diameters, blast hole angles, lift height, and subdrill depth. Draw these
Plans and cross sections to scale;
8. Loading diagram showing the type and amount of explosives, primers, and initiators;
and the location, depth, and type of stemming;
9. Initiation sequence of controlled and production blast holes, including delay times
and the delay system;
10. Manufacturers data sheets for the explosives, primers, and initiators to be used.
Submit the blasting Plans to the Project Manager for review and approval. The Project
Manager will review and provide comments to the Contractor. Submit revisions to the blasting
Plans for final review and approval. Do not proceed with drilling and blasting operations
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related to a General Blasting Plan or loading of blast holes associated with a Detailed Blasting
Plan without written approval.
Cease blasting operations and submit revised blasting Plans if the Department
determines that the blasting operations under the employed methods are causing property
damage in and beyond the Right of Way.
203.3.3.1.2.3 Blasting Records
Prepare and submit to the Department a Blasting Record for each blast, on the Day of
the blast. Provide the following information in a Blasting Record:
1. Actual dimensions of the shot, including blast hole diameters and depths, burden,
spacing, subdrilling depths, stemming, powder loads, powder factors, and timing;
2. A drawing or sketch showing the direction of the face and the physical shot layout;
3. The location of the blast in relation to Project stationing and elevation;
4. The date and time of loading and detonation;
5. The name and signature of the person responsible for loading and firing;
6. Comments by Blaster in Charge regarding misfires, fly rock occurrences, unusual
results or effects; and damage to existing facilities, adjacent property, or completed
Work;
7. Vibration and blast monitoring results; and
8. Any complaints received due to the blasting.
203.3.3.1.3 Explosives
Transport, store, handle, and use explosives in accordance with applicable federal, State,
and local laws and regulations. Purchase explosives and accessory devices from industry
recognized Suppliers and manufactures. Use explosives and accessory devices in
accordance with manufacturer instructions. Do not use expired products.
The CFR specifies responsibility for the following federal agencies regarding the
administration of regulations involving explosive Materials:
1. Bureau of Alcohol, Tobacco, Firearms, and Explosives (ATF). Storage and
accountability of record keeping and security in accordance with 27 CFR part 555;
2. OSHA. Transportation, worker safety, and health in accordance with title 29 CFR;
storage and safe blasting practices in handling and use in accordance with 29 CFR
part 1926.900 et seq;
3. Federal Department of Transportation (USDOT). Transportation and public safety,
49 CFR.
The fire marshal, sheriff, or other local officials, may have additional regulations for
explosive Materials.
203.3.3.1.4 Safety
Follow safe practices, including the following:
1. Federal, State, and local regulations pertaining to the transportation, storage, and
use of explosives must be strictly followed;
2. When required, the Blaster in Charge must obtain a blasting permit from the local
regulatory agency before blasting;
3. Only persons authorized and qualified based on training and experience will handle
and use explosives;
4. No person will smoke; carry matches or other flame producing devices; or carry
firearms or loaded cartridges while in or near a motor vehicle that is transporting
explosives;
5. Keep track of explosives at all times. Explosives must be stored and locked in an
approved magazine facility in accordance with the applicable provisions of the
Section 203: